Preferred Utilities Manufacturing Corp.

Burner
Management Systems
A Technical Discussion
 Preferred Utilities Manufacturing Corp.

 Introduction
 Burner
Management System Objectives
 BMS Design Standards and Definitions
 BMS Logic
 BMS Strategies and Hardware
 Types of Burner Management Systems
 BMS Interface to SCADA Systems
 Summary
 Introduction

Burner Management
Systems..

..a starting point.

 Introduction
What is a BMS?
 A Burner Management System 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
burning equipment. 1
1. From NFPA 8501 “Standard for Single Burner Boiler Operation”
 Burner Management Objectives

 Sequence burner through safe start-up

 Insure a complete pre-purge of boiler
 Supervise safety limits during operation
 Supervise the flame presence during
operation
 Sequence a safe shutdown at end of cycle
 Integrate with combustion control system
for proper fuel and air flows
 BMS Design Standards
 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 8501
/8502 or others)
 Industrial Risk Insurers (IRI)
 Factory Mutual loss prevention guidelines
 Each burner management system should be
designed to accomplish a safety shutdown in the
event of an unsafe condition. (FAIL SAFE)
 BMS Design Standards
 U.S.
National Fire Protection Association
(NFPA)
 Governs safety system design on virtually all 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.
 NFPA 8501

 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 / No.2 Oil / No. 6 Oil)
 Simultaneous Firing
 NFPA 8502

 NFPA 8502 Standard for Prevention of

Furnace Explosions / 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)
 BMS Definitions

 Furnace Explosions
 “Ignition of accumulated combustible mixture within
the confined space of a furnace or associated boiler
passes, ducts, and fans that convey gases of combustion
to the stack”1
 Magnitude and intensity of explosion depends on
relative quantity of combustibles and the proportion of
air at the time of ignition
1. From NFPA 8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers”
 BMS Definitions

 Furnace
Explosions can occur with any or a
combination of the following:1
 Momentary loss of flame followed by delayed re-
ignition
 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 Burner while others are in
operation
 Complete Furnace Flame-out followed by an attempt to
light a burner
1. From NFPA 8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers”
 BMS Definitions

 Furnace Implosions
 More common in large Utility Boilers
 Caused by any of the following:
» Malfunction of equipment regulating boiler gas flow
resulting in furnace exposure to excessive induced
draft fan head capability
» Rapid decay for furnace gas temperature and
pressure due to furnace trip
1. From NFPA 8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers”
 BMS Basic Definitions

 Common Terminology
 Supervised Manual
» Manual Burner Lightoff with 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 Manual
command to start.
 Types of Flame Scanners
 Infrared (IR) Detectors
 Single Burner Applications
 More Suitable with Oil Burning Flames
 Ultra-Violet (UV) Detectors
 Multiple Burner Applications
 More Suitable for Gas Burners and
Combination Gas / Oil Burners
 Self Check Scanners
 Flame Signal is interrupted at set intervals to
verify proper operation of scanner
 Single Burner BMS Inputs

Low Low Drum Lev el (D)

High Steam Pressure (D)
(D)
Purge Purge Air Flow
Minimum Air Flow (D)

Li mi t s Made
Flame / No Flame (D)
Hol d t o Purge

S CR L RES E T M O DE

BURNER FUEL SELECT FD FAN

O FF O N G AS O IL HAND O FF AUTO

Fuel Oil Temp Low (D)

Fuel Oil Temp High (D)

Fuel Oil Press Low (D)
Fuel Oil Flow (A)
(D)
Atomizing Medium Flow > Min
Atomizing AE TE
(D) Medium
Common Alarm Output
Press Low (D)

Remote Annunciator
(By Others) FEEDWATER
PSH

PSL STEAM
PT PSH
FT

IGNITER
Saf ety Shut Of f
GAS LSLL
& Vent Valv es

LSLL

Fuel Fuel
Gas Gas FT PSL TSH TSL FS
Press Press
Low High
(D) (D) PSL PSL
OIL Saf ety Shut Of f Control
Valv es Valv e
ATOMIZING Control Valv e &
MEDIUM Shut Of f Valv e (D) - Descrete Signal Used By Flame Saf eguard Sy stem

FT PSL PSH

GAS Saf ety Shut Of f & Control

Vent Valv es Valv e
 BMS Logic

 Burner Management Systems can be broken

down into “Interlock Groups”
 Typical BMS Interlock Groups:
 Boiler Purge
 Igniter Header Valve Management
 Main Fuel Header Valve Management
 MFT (Master Fuel Trip) Logic
 Purge Interlocks
BOILER TRIPPED

AND PURGE / RESET PB

START-UP
TIMER

START FD FAN

PERMISSIVES SATISFIED:
- MAIN FUEL VALVES CLOSED
- NO FLAME PRESENT
- FD FAN RUNNING AND
- MINIMUM AIR FLOW SWITCH MADE
- WATER LEVEL SATISFACTORY
- ATOMIZING MEDIUM ON
- FUEL SUPPLY PRESSURE NOT LOW

ENERGIZE FUEL RELAY

NOT AND

PURGE SIGNAL TO CCS

PURGE AIR FD DAMPER IN

FLOW SWITCH AND FULL OPEN
MADE POSITION

PURGE TIMER SET

PURGE COMPLETE
NO
YES

REMOVE PURGE TO CCS SYSTEM TRIP

 Igniter Interlocks
PURGE COMPLETE

AIR DAMPER IN LOW FIRE FUEL VALVE IN LOW FIRE

AND
POSITION POSITION

ENERGIZE IGNITER AND

IGNITER HEADER VALVES

10 SECOND DELAY

10 SEC PILOT TRIAL

FOR IGNITION

TIMER COMPLETE
FLAME
PROVEN NOT

AND

SYSTEM TRIP
PERMIT FOR MAIN
FLAME
 Main Flame Interlocks
IGNITER TIMER
COMPLETE

FLAME
AND
PROVEN
ENERGIZE MAIN
FUEL VALVES

10 SEC MAIN FLAME

TRIAL

TIMER COMPLETE

NOT

AND

DE-ENERGIZE
IGNITION
COMPONENTS

RELEASE TO
MODULATE TO CCS SYSTEM TRIP
 Single Burner Main Fuel Trip
FOR OIL: FOR GAS:
- LOWFUEL PRESSURE - LOW FUEL GAS PRESSURE
- LOW TEMPERATURE (HEATED OILS) - HIGH GAS PRESSURE
- LOSS OF COMBUSTION AIR - LOSS OF COMBUSTION AIR
- LOSS OF FLAME OR FAIL TO ESTABLISH - LOSS OF FLAME OR FAIL TO ESTABLISH
- LOSS OF CONTROL SYSTEMENERGY - LOSS OF CONTROL SYSTEMENERGY
- POWER FAILURE - POWER FAILURE
- LOWWATER LEVEL (AUXLEVEL CONTACT) - LOWWATER LEVEL (AUXLEVEL CONTACT)
- LOSS OF ATOMIZING MEDIUM - EXCESSIVE STEAMDRUMPRESSURE
- EXCESSIVE STEAMDRUMPRESSURE
- HIGH OIL TEMPERATURE (HEATED OILS)
OR

OR

TRIP BOILER

TRIP IGNITER, TRIP MAIN FUEL FUEL CONTROL

IGNITER VALVES, VALVES, OPEN VALVE TO
TRIP MFT RELAY
OPEN IGNITER VENT VALVE CLOSED
VENT (GAS ONLY) POSITION
 BMS System Types

 Early Burner Management Systems

 Hardwired Systems
 Solid State Systems
 Microprocessor Based Systems
 Fireye E110 / Honeywell 7800 series with fixed
Logic.
 PLC Based Systems
 Programmable Logic Controller (PLC) Based
 Powerful, versatile, expandable, more reliable.
 Early Burner Management Systems

 Hardwired Systems
 Relay and Timer Driven. Found on older
installations
 Typical of Late 50’s, 60’s
 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.
 MicroProcessor Based Systems

 Microprocessor Based System providing:

 Burner Sequencing
 Ignition
 Flame Monitoring
 FixedProgram with Limited Configuration
Changes
 Components Selected Based on Requirements
 Programmers, Flame Amplifiers, Message Displays
 Fireye™ BMS Layout

AMPLIFIER
EP PROGRAMMER

AUTOMATIC PRIMARY SAFETY CONTROL

FIELD WIRING
FIELD WIRING

FLAME
SCANNER
 MicroProcessor Capabilities

 Simple, Cost Effective

 Features
 Selectable Flame Amplifiers / 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

 “Simple” Boiler Installations

 Packaged Firetube / Watertube Boilers (Steam /
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

 PLC Based Features

 NFPA 8501, 8502
 Watchdog timer
 UL 508 Certification
 Redundant Scanners
 Logic+ Message Center
 Shows program status
 Displays alarms
 Prompts operator
 PLC System Basic Design Features

 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

 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
 Redundant Scanners, change scanner with fuel
 Single or Multiple Burner Applications
 Integration of BMS with SCADA
 PLC Based Operator Interfaces

 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 / Alarm Messages
» Status Messages / Prompts Operator
 PLC System Layout (Typical)
Door Mounted Lights / Pushbuttons

Logic+ Message
SW ITCH SILENCE LIGHT

Display

PLC CPU I/O I/O I/O I/O

COMBUSTION
CONTROL SYSTEM

FLAME AMPLIFIER
(SINGLE /
REDUNDANT)

I/O EXPANSION I/O

FIELD DEVICES
 Benefits of PLC Based Systems

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

 “Complex” Boiler Installations

 Larger Packaged Units / Field Erected Units
 Multiple Burners
 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
 BMSSystems 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 for fault
evaluation
 Burner Operation can be trended over time
 BMS SCADA Interface
 Interface Methods:
SCADA PC

MODBUS
COMMUNICATION
PROTOCOL

MODBUS
COMMUNICATION
Communication
PROTOCOL
Interface
(If Necessary)

PLC CPU I/O I/O I/O I/O

BMS LOGIC+ SYSTEM

FIREYE E110 SYSTEM
BMS SCADA Interface
 Summary

 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

 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
Preferred Utilities Manufacturing Corp

For further information, contact...

Preferred Utilities Manufacturing Corporation
31-35 South St. • Danbury • CT
T: (203) 743-6741 • F: (203) 798-7313
www.preferred-mfg.com