Burner Management and Combustion Control
Rev 5058-CO900E
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Industrial Combustion Team Overview
Background and Industry Experience
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RA’s IC&PG Team Expertise
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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
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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.
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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
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Rockwell Automation IC&PG SIL
Certification
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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
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
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Safety Codes and Application Highlights
Survey of Applicable Codes for Fired Equipment
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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”
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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…..”
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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
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Burner Management System Value
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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
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Questions?
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