Burner Management and Combustion Control Rev 5058-CO900E
Industrial Combustion Team Overview Background and Industry Experience
RA s IC&PG Team Expertise 3 Extensive experience working with Factory Mutual Extensive Knowledge of Safety Standards and Guidelines NFPA 85 Boiler & Combustion Code NFPA 86 Furnace & Ovens NFPA 87 Fluid Heaters (Chem. Plant Oil Heaters, vessels, etc.) FM (7605) Approval Standard for PLC based BMS CSA B149.3 (Canada) BLRBAC Recommended Good Practices ANSI/ISA S84.00.011/IEC 61511 SIL Ratings for Systems IEC 61508 SIL Ratings for Hardware
Combustion Control & Burner Management Burner Management (BMS): - Combustion SAFETY and operator assistance in safely starting, monitoring and stopping the fuel fired burners - Used in conjunction with a combustion control system in any fossil fuel fired industrial combustion application. Industrial Combustion and Power Generation Combustion Control (CCS): - Regulates air/fuel ratio for stable flame and energy optimization - Used in conjunction with a burner management system in any fossil fuel fired industrial combustion application. Balance of Plant (BOP): - A catch-all for common activities in a powerhouse that excludes, burner management and combustion control - ESP, Plant Master, demineralizer control, feedwater control, coal/ash handling, scrubber control, soot blower control, etc.
Definitions NFPA National Fire Protection Association FM Factory Mutual Insurance Underwriter SIL Safety Integrity Level Critical Input Any Input that if lost will cause a trip Critical Output Any Outputs that drive fuel delivery devices Fail Safe System Inputs & Outputs - High is Normal / Low is Trip 5
Rockwell Automation IC&PG SIL Certification
Industrial Steam Generation Large Central Power House (i.e. Paper Mill or Large Industrial Complex) Boiler Steam Generation Burner Management Systems Combustion Control Systems Balance of Plant Systems Multiple Burners / Fuels including: Natural Gas Oil Black Liquor Bark/Wood Chips/Sawdust Coal Others 7
Industrial & Process Heating Any Industrial facility where steam or heat is used in the manufacturing process Burner Management & Combustion (Temperature) Control Systems Industrial Boilers Non-Boiler Applications including: - Furnaces - Ovens - Dryers - Kilns - Heaters - Oxidizers 8
Safety Codes and Application Highlights Survey of Applicable Codes for Fired Equipment
NFPA 85 Key Highlights The burner management system (BMS) shall be provided with independent logic, independent logic solving hardware, independent input/output systems, and independent power supplies and shall be functionally and physically separate device from other logic systems. The BMS safety functions shall include, but shall not be limited to, purge interlocks and timing, mandatory safety shutdowns, trial timing for ignition, and flame monitoring. Diagnostics shall be included in the BMS design to monitor processor logic function. Logic shall be protected from unauthorized changes. Logic shall not be changed while the associated equipment is in operation. No single component failure within the logic system shall prevent a mandatory master fuel trip Copyri
NFPA 86 Key Highlights Programmable logic controller-based systems listed for combustion safety service shall be used.. Safety devices shall not be bypassed electrically or mechanically. Output checking shall be provided for PLC outputs controlling fuel safety shutoff valves and oxygen safety shutoff valves. Only isolated PLC contacts shall be used in the required safety circuits. Flow and pressure transmitters can be used in place of pressure switches if the transmitter is dedicated to safety service. Access to the PLC and it s logic shall be restricted to authorized personnel. An excess temperature limit controller shall be provided and interlocked into the combustion safety circuitry.. Copyri
Burner Management Design Features A system watchdog, completely independent of the programmable controller, continually verifies the controller s timing function, as well as its ability to execute logic and control outputs Input channels on each l/o module are periodically tested to verify their ability to detect field device state changes to the fail-safe position. Critical outputs are monitored by feeding back the status of the output as a separate input signal and comparing it to the state demanded by system logic. The use of software interlocks help guard against unauthorized modification of the controller s program. A hardware trip circuit which allows the operator or the system watchdog to initiate a main fuel trip Start-up, first out, and system alarm/diagnostic messages. Communication with other Rockwell programmable automation controllers or operator terminals Adaptable to any fossil fuel combustion applications with single or multiple burners 12
Burner Management System Value 13 A new burner management system can Improve availability by increasing the operator s trouble-shooting capability and accessibility of system information through enhance diagnostics Reduce normal startup time Protects your combustion product equipment against damage Uses standard Rockwell Automation hardware thus reducing or eliminating the need for additional spare parts for existing RA Clients. Potential increase in overall safety
Rockwell Automation Questions? 14