t10 - standards review - burner management and...

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

T10 - Standards Review - Burner Management and Combustion Control

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

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

- Plant Master, demineralizer control, feedwater control, coal/ash

handling, scrubber control, soot blower control, etc.

Combustion Control & Burner Management


Definitions

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TSSA - Technical Standards and Safety Authority

NFPA – National Fire Protection Association

FM Factory Mutual – Insurance Underwriter

SIS – Safety Instrumented System

SIL – Safety Integrity Level


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 heat is used

in the manufacturing process

Burner Management & Combustion

(Temperature) Control Systems

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

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TSSA Standards

TSSA FIELD APPROVAL

CODE, TSSA-FA-2012

December 2012

(2015 draft version)

This document adopts either in whole or in part:

The CSA B149.3-10 Code for the Field Approval of Fuel-Related Components on

Appliances and Equipment published in 2010 with amendments;

the National Fire Protection Association NFPA 85-2011 Boiler and Combustion

Systems Hazards Code with amendments;

the National Fire Protection Association NFPA 86-2011 Standard for Ovens and

Furnaces with amendments.


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TSSA Key Highlights

This document establishes the requirements for approval of appliances

that are custom made, built on site or produced in limited numbers.

Approval under this code is for code compliance and safety. It does not

include performance of the appliance or equipment.

If the appliance approved under this Code is modified, the approval is

void and the modified appliance shall be re-approved.

Note: For further details, refer to the TSSA Advisory Maintenance vs.

Modification and Upgrading, Ref. No. FS-133-08.


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NFPA Standards

NFPA 85 – Boiler and Combustion Systems Hazards Code

(2015 Edition)

NFPA 86 – Standards for Ovens and Furnaces (2015 Edition)


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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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IEC Safety Standards

PROCESS SECTOR SAFETY INSTRUMENTED SYSTEM

STANDARDS

Safety Instrumented Systems Designers, Integrators & Users

IEC 61511

Manufacturers & Suppliers of Devices

IEC 61508


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IEC 61508

This is a Basic International Standard that defines the requirement

that Electric/Electronic/Programmable Electronic devices must meet

when used in Safety applications.

Performance based Standard

Includes all activities related to the Safety Life Cycle

Covers possible hazards caused by Failure of the Safety Functions

Does not cover SIS with SIL requirements less than 1


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IEC 61511

A Process Sector Specific International Standard covering

Functional Safety for Safety Instrumented Systems

It defines the requirements that users must meet when designing,

implementing and maintaining a Safety Instrumented System in

Process Plants.

Performance based Standard

The document differentiates between Safety certified devices and

off the shelf general purpose devices.


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ISA/ANSI S84.01

The Americanized version of IEC 61511.


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IEC - Safety Integrity Levels (SIL) forSafety Instrumented Systems (SIS) Safety integrity is the probability that an SIS will perform its safety function(s) when the

process demands it.

Safety Integrity is specified as a discrete level, from 1 to 4 or Safety Integrity Level (SIL).

DEMAND MODE OF OPERATION

Safety IntegrityLevel (SIL)

Target AverageProbability of Failure on Demand

Target Risk Reduction

4 10-5

to <10-4

>10,000 to 100,000

3 10-4

to <10-3

>1000 to 10,000

2 10-3

to <10-2

>100 to 1000

1 10-2

to <10-1

>10 to 100

CONTINUOUS MODE OF OPERATION

Safety IntegrityLevel (SIL)

Target Frequency ofDangerous Failures to perform thesafety instrumented function (per

hour)

4 10-9

to <10-8

3 10-8

to <10-7

2 10-7

to <10-6

1 10-6

to <10-5


Burner Management System (BMS)

Description: Burner Management System

A BMS is a SAFETY SYSTEM

A BMS is only for the safe start-up, monitoring and shutdown of a

combustion system.

Special Requirements:

Monitoring and testing of inputs and outputs

Boilers - NFPA 85 Standard

Ovens, Dryers, Furnaces, etc. - NFPA 86 Standard

Fluid Heaters – NFPA 87 Recommend Practices

Recovery Boilers - BLRBAC

Safety response – Fail-Safe Control of purge, ignition, shutdown

Factory Mutual Approval Standard (FM 7605) for PLC Based Burner Management Systems

ANSI/ISA S84.00.01/IEC 61511 - provides procedure for how to implement the SIL standards

Customer specific standards


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


Design Documents (Non-SIL)

TSSA-FA-2012

NFPA 85 for Boilers

NFPA 86 for Ovens and Furnaces

Factory Mutual (FM)

IEC 7605 Approval Standard for Programmable Logic Control (PLC)

Based Burner Management Systems

BLRBAC (Recovery Boilers Only)

Customer Standards and Specifications


Design Documents for SIL

All of the applicable non SIL documents

IEC 61511 Functional Safety Instrument Systems

IEC 61508 Functional Safety of Electrical / Electronic / Programmable

Electronic Safety Related Systems

1756-RM001 Applying ControlLogix in SIL 2 Applications

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Application: Typical Boiler –Burner Management System related devices

4

21(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved.


Application: Typical Boiler –Combustion Control related devices

4

22(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved.


Simple Solution - SIL 3 Fail Safe

PlantPAx Micro BMS:

INDEPENDENT BMS & CCS

SmartGuard 600 & PointGuard for BMS

CompactLogix with Point IO for Combustion Control

Ethernet/IP DeviceNet

BMS Safety IO to/from devices

Combustion Control IO

to/from devices

Combustion

Control SystemBurner Management System


Midrange Solution – SIL 3 Fail Safe

PlantPAx Mini BMS:

COMBINED BMS and COMBUSION

CONTROL

GuardLogix Compact for BMS and Combustion

Control, combined into one unit.

Safety IO using PointGuard

Ethernet/IP with

CIP Safety



to/from devices

Combustion

Control / Burner Management


Advanced Solution – SIL 3 Fail Safe

PlantPAx Combined BMS:

COMBINED BMS and COMBUSION

CONTROL

GuardLogix for BMS and Combustion control,

combined in one controller

Safety IO using PointGuard

Ethernet/IP with

CIP Safety



to/from devices

Combustion Control / Burner Management


Advanced Solution – SIL 2 Fail Safe

PlantPAx independent BMS:

INDEPENDENT BMS and CCS

ControlLogix, in SIL 2 Configuration, for BMS Control.

ControlLogix for BPCS (Combustion Control System)

Safety IO using 1715

Fail Safe Configuration

Ethernet/IP with

CIP Safety


BMS - Burner Management

SIL 2 rating1715 IO

SIL 2 rating


to/from devices

BPCS


Advanced Solution – SIL 2 Fault Tolerant

Ethernet/IP with

CIP Safety


BMS - Burner Management

SIL 2 rating1715 IO

SIL 2 rating (Jan ’13)


to/from devices

BPCS

PlantPAx BMS:


ControlLogix, in SIL 2 Configuration, for BMS Control.


Safety IO using 1715

Fault Tolerant BMS Configuration

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 28

AADvance Controller – SIL 2 Fail Safe

28

CPU Base with one

CPU populated

I/O Base with one

input and one

output fail safe



to/from devices

BPCS

PlantPAx AAdvanced BMS:


AAdvance, in SIL 2 Configuration, for BMS Control.


Fail Safe BMS Configuration


AADvance Controller – SIL 3

29

Redundant

CPUs



to/from devices

BPCS





SIL 3 Fail Safe BMS Configuration


AADvance Controller – SIL 3 Fault Tolerant

30

Redundant

CPUs



to/from devices

BPCS





SIL 3 Fault Tolerant BMS Configuration

Redundant

Inputs

Redundant

Outputs

Redundant

Terminations


Rockwell Automation

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