af15 burner management and combustion control · pdf filetitle: microsoft powerpoint -...

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E

Burner Management and Combustion Control

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION

Industrial Combustion Team Overview

Background and Industry Experience


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RA’s IC&PG Team Expertise

� 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


Industrial Combustion and Power Generation

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.

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.

Combustion Control & Burner Management


Definitions

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� 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


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

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� 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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Industrial & Process Heating


Safety Codes and Application Highlights

Survey of Applicable Codes for Fired Equipment

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri

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”

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 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…..”

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION � 12

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

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

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Questions?

af15 burner management and combustion control · pdf filetitle: microsoft powerpoint -...

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