Preferred Utilities Manufacturing Corp.

Burner
Management Systems
A Technical Discussion
 Prefened Utilities Manufacturing Corp.

o Introduction
D Burner Management System Objectives
D BMS Design Standards and Definitions
D BMS Logic
D BMS Strategies and Hardware
• Types of Burner Management Systems
D BMS Interface to SCAD A Systems
D Smnmary

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 Introduction

Burner Management
Systems ..

. .a starting point.

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 Introduction
What is a BMS?
o A Bmner Management £'stem is defined as
the following:
• A Control System that is dedicated to boiler
safety, operator assistance in the starting and
stopping of fuel preparation and burning
equipment, and the prevention of mis-operation
of and damage to fuel preparation and fuel
buming equipment. 1
I. from NFPA 850 I ''Swndard for Single Burnco·lloiler Operaoion··

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 Burner Manage1nent Objectives

D Sequence burner through safe start-up

D Insure a complete pre-purge of boiler
D Supervise safety limits during operation
D Supervise the flame presence during
operation
D Sequence a safe shutdown at end of cycle
o Integrate with combustion control system
for proper fuel and air flows

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 BMS Design Standards
o Each Burner Management System should be
designed in accordance with the below listed
guidelines to control and monitor all sequences of
the start-up and shutdown of the burner
• National Fire Protection Association (NFPA 850 l
/8502 or others)
• Industrial Risk Insurers (IRI)
• Factory Mutual loss prevention guidelines
o Each burner management system should be
designed to accomplish a safety shutdown in the
event of an unsafe condition. (FAIL SAFE)

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 BMS Design Standards
o U.S. National Fire Protection Association
(NFPA)
• Governs safety system design on virtually aU boilers
(regardless of the process to be used to combust the
fuel)
• Requires the separation of the Burner Management
System from any other control system
• Requires the use of a hardwired backup tripping scheme
for microprocessor based systems
• Requires that a single failure NOT prevent an
appropriate shutdown
• Factory Mutual loss prevention guidelines.

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 NFPA8501

o NFPA 8501 Standard for Single Burner

Boiler Operation
• Single Burner Boilers with fuel input greater than 12.5
mBTU/Hr (Approx. 250 BHP)
• Single Fuel or Combination of Fuels (Common being
Natural Gas I No.2 Oil I No. 6 Oil)
• Simultaneous Firing

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 NFPA8502

o NFPA 8502 Standard for Prevention of

Furnace Explosions I Implosions in Multiple
Burner Boilers
• Multiple Burner Boilers with fuel input greater than
12.5 mBTU/Hr
• Single Fuel or Combination of Fuels including
Pulverized Coal
• Emphasis on implosion protection (larger boilers with
induced draft systems)

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 BMS Definitions

o Furnace Explosions
• "Ignition of accumulated combustible mjxture withjn
the confined space of a furnace or associated boiler
passes, ducts, and fans that convey gases of combustion
to tbe stack"l
• Magilltude and intensity of explosion depends on
relative quantity of combustibles and the propo1tion of
air at the time of ignjtion
I. From NFPA 8502 ..Prevcnlion of Furnace Ext>losions/ lmplosions in Multipl\! Burner Boilers"

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 BMS Definitions

o Furnace Explosions can occur with any or a

combination of the following: 1
• Momentary loss of flame followed by delayed re-
ignit ion
• Fuel leakage into an idle furnace ignited by source of
ignition (such as a welding spark)
• Repeated Light-off attempts without proper purging
• Loss of Flame on one Bw-ner while others are in
operation
• Complete Fmnace Flame-out followed by an attempt to
light a burner
I. From NFPA 8502 ''Prevention of Furnace Explosions / Implosions in Multiple llu m~: r Ooilcrs''

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 BMS Definitions

o Furnace Implosions
• More common in large Utility Boilers
• Caused by any oftbe folJowing:
» Malfunction of equipment regulating boiler gas flow
resulting in fhrnace exposw·e to excessive induced
draft fan bead capability
» Rapid decay for furnace gas temperature and
pressure due to furnace trip
I. from NFPA 8502 "l,.rcvcnlion of Furnace E.'iplosions / lmplosions in Multiple Burner Boilers"

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 BMS Basic Definitions

o Common Terminology
• Supervised Manual
» Manual Burner Lightoffwith Interlocks
• Automatic Recycling (Single Burner Only)
» Automatic Burner Start and Stop based on preset
operating range (ie .. Drum pressure)
• Automatic Non Recycling (Single Burner Only)
» Automatic Burner Start and Stop based on MrulUal
command to start.

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 Types of Flame Scanners
o Infrared (IR) Detectors
• Single Burner Applications
• More Suitable with Oil Burning F lames
o Ultra-Violet (UV) Detectors
• Multiple Burner Applications
• More Suitable for Gas Burners and
Combination Gas I Oil Burners
o Self Check Scanners
• Flame Signal is interrupted at set intervals to
verify proper operation of scanner

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 Single Burner BMS Inputs

---
laool....t>-~

....""'~""""-.-
--·
•

owoo:....~ •
.... 01-.....
... o.-""' -

·--
---....·-·-·
...o. ..... ..

..
--
--·
--~eo-~, -~ ·

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 BMS Logic

o Burner Management Systems can be broken

down into "Interlock Groups"
o Typical BMS Interlock Groups:
• Boiler Purge
• Igniter Header Va lve Management
• Main Fuel Header Valve Management
• MFT (Master Fuel Trip) Logic

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 Purge Interlocks
.OI..Ek TJ't..Pf_O

~ PUIItOE l llfH't ,.B

'~ I
$TNP FD Fo\H

pt.U.SSNQ $A111StiCO:
· -II.U.WAI.YUQOHO
• 1110 kHIIIt fOIIIUOil
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.'W.ollJIIU:YU ,.._,,tCCIII!'f
-"'"*""0 tCOUIIOC.
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"LLAGE SOW. TO C:CS

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II JO~RNI

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 Igniter Interlocks
PURGE COWPLElE

AROAMPERNlOWF'Rf FUELVALVENLOWFR.
AND
POS""" POSillON

ENERGIZE GHO'ERANO
13NITER MEAtiER VAlVES

FLAME
PROVEN NOT

L-- - - - - - - - < AND

SYSTEM TRIP
PERMIT FOR MAN
FLAME

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 Main Flame Interlocks
t:)Nrre.R lt.1ER
COMPLETE

FlAME
I>ROVEN I--- <AND
ENERGIZE MAH
FUEL VALVES

10 SEC MAN FLAME

TRIAL

TMER COMPLETe

NOT

L------< AND

DE-ENERGIZE
IGHT10N
COMPONENTS

RELEASE TO
MODUlATE TO CCS SYSTEM TRIP
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 Single Burner Main Fuel Trip
FOR OIL: FOR GAS:
• LONRS. FfiESSI.R; • LONR.e.G\SPRESS.JE
. """""f<RAJ1.RE (t£AJB>OI.S) • HCH GAS F'Rf.S9..RE
·tCSSO:CO.QJSTICN~ .l())SCFCO.QJSOCN~
·lQ;SQ!RJM:CRFit.. TOEST/ftJSH ·t.CSSCPR./MECRF/<1. 10EST/8JSH
. LOSSO' <XMRCl. S'oSTEME>ER:>Y ·l.CSSfF(X)fflQ. S'ISffM~
• PC>.\eA Fl<l.l.fle • F'I.'A•.ER Flt.l.R:
·I.OM'A$ LE\EI. (AJXLE\EI.<Xl'ITI>CT) • I.OM'AlS' LE\EI. (lt.OCLE\EI.<Xl'ITI>CT)
. LCSSO:AJCMZN3~EDLM ·E>CESSr.ES'TI%•0Rl.fwl.m:sst.AE
·El(:E$\E"""'~
·HG<Cl.'la.I'ERAI\J'E!IEATlDOI.S)

0~
OR
y

TRIP BOILER

t t t t
TRIP IGNITER, TRIP MAIN FUEL FUEL CONTROL
lGNITER VALVES, VALVES, OPEN VALVE TO
TRIP MFT RELAY
OPEN IGNJTER VENTVALVE CLOSED
VENT (GAS ONLY) POSrTION

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 BMS System Types

o Early Burner Management Systems

• Hardwired Systems
• Solid State Systems
o Microprocessor Based Systems
• Fireye EllO / Honeywell 7800 series witb fixed
Logic.
o PLC Based Systems
• Programmable Logic Controller (PLC) Based
• Powerful, versatile, expandable, more reliable.

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 Early Burner Management Systems

o Hardwired Systems
• Relay and Timer Driven. Found on older
instaUations
• Typical of Late 50's, 60's
o Solid State Systems
• Solid State Processors and Relays
• Found on Systems provided in the 70's and 80 's
• Proprietary Hardware (ie .. Forney and Peabody)
• Spare Parts are extremely hard to find.

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 MicroProcessor Based Systems

o Microprocessor Based System providing:

• Burner Sequencing
• Ignition
• Flame Monitoring
o Fixed Program with Limited Configuration
Changes
o Components Selected Based on Requirements
• Programmers, Flame Amplifiers , Message Displays
 Fireye,.l\1 BMS Layout

FIELD WIRING FIELD WIRING

 MicroProcessor Capabilities

o Simple, Cost Effective

o Features
• Selectable Flame Amplifiers I Scanners
• Remote Display
• Remote Data Communications via Modbus Port
• Modernization kits are available to integrate with older
systems
• Spare Parts Normally Readily Available
 When These Systems are Used

o "Simple" Boiler Installations

• Packaged Firetube I Wate1tube Boilers (Steam I
Hot Water)
• Single Burner
• One Fuel at a Time
• No Flue Gas Re-Circulation
• Upgrades from Previous MicroProcessor Based
Systems
 PLC Based Burner Management Systems

o PLC Based Features

• NFPA8501, 8502
• Watchdog timer
__•••- ..
• UL 508 Certification
D Redundant Scanners
o Logic+ Message Center
• Shows program status
••
• Displays alarms
• Prompts operator
 PLC System Basic Design Features

o Each PLC based burner management system should

incorporate a number of design techniques which
help detect and act upon unsafe failure modes which
can occur in any microprocessor based system.
These design features include the following:
• Critical Input Checking
• Critical output channel monitoring
• Electro-mechanical Master Fuel Trip (MFT) Relay
• Redundant Watchdog Timers
• Low Water Cut-out Monitoring During Blow Down
 PLC Based System Capabilities

o Provision for Multiple Fuel Firing

• Capped gas input during curtailment
• Changeover from gas to oil at any load
• Simultaneous firing of waste and fossil fuels
o Redundant Scanners, change scanner with fuel
o Single or Multiple Burner Applications
o Integration of BMS with SCADA
 PLC Based Operator Interfaces

o Features
• Clear Written Messages to indicate status, required
operator interaction, trip/alarm indication
• High Visibility through two lines of display
• Messages reduce time consuming troubleshooting
• Prioritizes Messages
» First Out Alarms
» Warning I Alrum Messages
» Status Messages I Prompts Operator
 PLC System Layout (Typical)

Logic+ Message
Display

COMBUSTION
CONTROL SYSTEM

FLAME AMPLIFIER
(SINGLE I
REDUNDANT)

FIELD DEVICES
 Benefits of PLC Based Systems

D Flexibility I Reliability
• Programming Software allows changes to
system
D Choice ofPLCs
• GE I Modicon I Allen Bradley I Koyo
D Choice of Flame Scanners
• PPC I Fireye I Honeywell I Iris I Coen
D Application Specific
D Quantity of Burners I Fuels is not restricted
 When to Use PLC Based Systems

o "Complex" Boiler Installations

• Larger Packaged Units I Field Erected Units
• Multiple Bumers
• Multiple Fuels, On-line Fuel Changeovers
• Flue Gas Re-Circulation
• Replace Existing Relay Logic Systems
• Requirement to maintain consistent control
platform (spare parts, etc..)
 BMS SCADA Interface
o BMS Systems can be integrated into a
SCADA System
• Allows Remote Monitoring of Flame Status
• Allows Remote Control of BMS
• Events (ie .. Burner trip) can be routed to
Historical Portion of SCADA fo r fault
evaluation
• Bumer Operation can be trended over time
 BMS SCADA Interface
o Interface Methods:
SCADAPC

M008US
COMMONICAllON
PROlOCOL

MOOBUS
COMMUNICATION
PflOTOCOl

fiREYE E110 SYSTEM

 BMS SCAD A Interface

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P-'t
Steam Header
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J
 Suminary

o Benefits Associated with New Burner

Management Systems
• Help Improve plant safety
• Help qualify for reduced insurance cost
• Reduce Startup and Down Time with
comprehensive alarming and diagnostics
 Summary

o Review of Topics Discussed

• Objectives of Burner Management Systems
• BMS Design Considerations
• Basic BMS Logic
• Types of Burner Management Systems
• How BMS Systems can be integrated with
Plant Wide SCADA Systems