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Introduction to Burner
Management Systems
On-line Lesson
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Stack
HRA
Fuel
Furnace
ID Fan
Windbox
FD Fan
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Stack
HRA
Fuel
Furnace
ID Fan
WindBox
FD Fan
Heat is released from combustion inside the Furnace. Much of that heat is
transferred into boiler tubes contained inside the furnace.
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HRA
Fuel
Furnace
ID Fan
WindBox
FD Fan
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Fans are used to maintain proper draft. The FD fan provides combustion air
into the boiler. The ID fan pulls flue gas from the boiler. The pressure inside
the boiler is controlled with this fan.
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Economizer
Fuel
Air Heater
Furnace
ID Fan
WindBox
FD Fan
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Superheated
Steam
Steam Drum
Stack
Feedwater to boiler
Steam to headers
HRA
Drum
Economizer
Fuel
Air Heater
Furnace
ID Fan
WindBox
FD Fan
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Superheated
Steam
Stack
HRA
Drum
Economizer
Fuel
Air Heater
Furnace
ID Fan
WindBox
FD Fan
The control systems used include control of the firing demand based on the
need for steam. This is done by controlling fuel flow and air flow. The
firebox pressure is controlled with the ID fan speed. The water level in the
drum is also controlled.
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Common hazards are involved in the combustion of solid, liquid and gaseous
fuels. Each of these fuels have special hazards related to its physical
characteristics. The following items must be considered in the design of
the firing systems for oil fuels
(a) Fuel oils have high volumetric heats of combustion; therefore, even small
leaks can create potential fire hazards.
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Proper pumping and atomization of fuel oils are dependent upon control of
viscosity. Changes in viscosity in relation to temperature vary for different
oils and blends of oils. Very close attention shall be given to the design
and operation of viscosity control systems for each fuel where the source
or properties are variable.
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Clear distillate fuels have low conductivities and generate static electrical
charges in the fuel stream that can be dangerous unless flowing
velocities are limited.
NOTE: See NFPA 77, Recommended Practice on Static Electricity, and API
RP 2003, Recommended Practice for Protection Against Ignition arising
out of static, lightning, stray currents.
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The incompressibility of fuel oil can create very rapid transients in oil flow
through operating burners under the following conditions:
1. The rapid operation of an oil supply valve;
2. The rapid operation of individual burner shutoff valves;
3. The rapid operation of a regulating valve in the return oil line from the
burner header (on systems using this type of control).
The equipment must be designed to withstand this transient pressure without
creating leaks or other equipment failures.
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The following items must be considered in the design of the firing systems
for gas fuels
Gas is colorless; therefore, a leak usually cannot be detected visually. In
addition, detection of a gas leak by means of odor is unreliable.
Potentially hazardous conditions are most likely to occur within buildings,
particularly where the gas piping is routed through confined areas. In the
latter situation, adequate ventilation shall be provided.
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Natural gas can have many impurities. These cause plugging or fouling of
smaller lines. Natural gas can be either "wet" or "dry." A wet gas usually
implies the presence of distillate, which can be characteristic of a particular
source. In the case of such a wet gas, the carryover of distillate into the
burners could result in a momentary flameout and possible re-ignition. Reignition could result in a furnace explosion. Therefore, special precautions
shall be taken with wet gas supply systems.
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Natural gas can discharge from relief valves or vents. If ignited, this can be
the cause of explosions.
The maintenance and repair of piping is more hazardous with natural gas as
gas must be purged from lines for safe maintenance.
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There are also a number of special issues to be considered when coal is the
fuel. The key point is that different hazards may be present depending on
fuel type. All such hazards must be identified and addressed with sufficient
protection. The safety lifecycle is becoming the most commonly used
method process to address the necessary protection.
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At around noon a crew on the east side of the boiler inserted a blanking
piece into the natural gas supply line to seal off the flow. It is believed that
the blanking plate was not fully inserted.
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Pilot burner valves were opened to purge any remaining gas from supply
lines through the boiler.
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However, it is believed that gas flowed from the east side supply line into the
furnace and slowly built up.
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State inspectors state that a double block and bleed valve probably would
have prevented the gas buildup that led to the explosion.
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Deaths
1058
Accidents
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PURPOSE
To protect against start-up when unsafe conditions exist.
To protect against the unsafe operating conditions and admission
of improper quantities of fuel to the furnace.
Provide the operator with status information
Initiate a safe operating condition or shut-down procedure if
unsafe condition exists.
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This is an excerpt from the 1995 NFPA 8502 Standard for the prevention of
Furnace Explosions/Implosions in Multiple Burner Boilers. It explicitly covers
the entire safety of the boiler and does not just look at the burners.
This is consistent with newer standards that ask for a comprehensive review
of possible hazards and risk reduction methods.
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NFPA
FM - Factory Mutual
UL Underwriters Lab
ISA 84.01
IEC 61508/61511
CGA Canadian Gas
Association
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NFPA Standards
8501 - Single Burner
8502 - Multiple Burner
(Previously 85C)
8503 - Pulverized Fuel
8504 - Fluidized Bed
Boilers
8506 - Ovens & Furnaces
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NFPA
NFPA85C
85C
Prevention
Preventionof
ofFurnace
Furnace
Explosions/Implosions
Explosions/Implosions
in
inMultiple
MultipleBurner
Burner
Boiler-Furnaces
Boiler-Furnaces
1991
Edition
1991Edition
National Fire Protection Association 1 Batterymarch Park, POBox 9101, Quincy, MA 02269-9101
National Fire Protection Association 1 Batterymarch Park, POBox 9101, Quincy, MA 02269-9101
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NFPA 85
General Requirements
The logic system for burner management
shall be designed specifically so that a
single failure in that system does not
prevent an appropriate shutdown.
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The standard has a general requirement that the logic system be designed
specifically so that a single failure does not prevent an appropriate
shutdown. This is equivalent to the IEC61508 and IEC 61511 requirement
for a hardware fault tolerance of 1.
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NFPA 85
Failure Effects
The logic system designer shall evaluate the failure modes of
components where considering the design application of the system. As
a minimum, the following failures shall be evaluated and addressed:
The standard requires that the designer evaluate the failure modes of
components used in the system to insure the general requirement that no
single failure will prevent a safety function.
A checklist of possible failure modes is given. The BMS system should
continue proper operation or fail-safe.
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NFPA 85
Failure Effects (cont.)
The logic system designer shall evaluate the failure modes of
components where considering the design application of the
system. As a minimum, the following failures shall be evaluated
and addressed:
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Trip
WD WD Relay
H
L
TR
WD
Power Supply
Input Module
Output Module
H
TR
Fuse
Input Module
H
Trip
Alarm
Load
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Fuse
Output
Module
Watchdog
Circuit(s)
Diagnostic
Cut-Off
Relay
Relay
Control
Microprocessor
Relay
Monitor
Typical for 1 of
8 channels
Output
Readback
Output
Command
Output
Switch
Monitor
Output
Protection
Circuit
Solid-State
Switch
I/O
Fuse
Load
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Many BMS designers choose safety certified equipment that has been
designed to meet many functional safety standards including BMS
standards. This type of equipment meets failure effect requirements
without external components or special design effort.
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NFPA 85
Design
Logic shall not be changed while the associated
equipment is in operation.
Diagnostics shall be included in the design to monitor
processor logic function.
Logic system failure shall not preclude proper operator
intervention.
Logic shall be protected from unauthorized changes.
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NFPA 85
Design (cont.)
System response time (throughput) shall be sufficiently
short to prevent negative effects on the application.
Protection from the effects of noise shall be adequate to
prevent false operation.
The operator shall be provided with a dedicated manual
switch(es) that shall actuate the master fuel trip relay
independently and directly.
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The designer must be careful about equipment response time and electrical
noise. Systems must include a dedicated manual switch to directly stop the
fuel source.
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NFPA 8502
Requirements for Independence
Shall not be combined with any other logic system
The logic system shall be limited to one boiler
Independent logic, I/O systems, Power supplies,
functionally and physically separated from other
systems
The same Hardware type can be used for other logic
systems
Data Highway communications, but not for trip signals
A trip will require operator action prior to restarting
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NFPA 8502
Maintenance and Inspection
An inspection and maintenance schedule shall be
established and followed
Operation, set points, and adjustments shall be verified
by periodic testing (and documented)
Defects shall be reported and corrected
System configuration (system, not just logic solver)
shall not be changed without evaluation and approval
Inspections, adjustments and repairs shall be
performed by trained personnel according to mfg.
recommendations and applicable standards
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Maintenance activities are also specified so that the entire lifecycle of the
equipment be considered.
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FM 7610
BMS Standard written for relay
based systems
Allen Bradley Burner Master (PLC5
based) FM approved per 7610 for
single burner applications.
Replaced by FM7605, December 1999
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Factory Mutual also writes standards for BMS equipment. The early
standard was created for relays based equipment but was used to approve a
programmable logic controller based on a microprocessor. This standard
was replaced in December 1999.
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The ISA 84.01 standard was not written specifically for BMS. It covers
functional safety of programmable equipment used in the process industries.
Since this standard was endorsed by OSHA in the United States it is
required on many BMS projects as well. This standard describes a lifecycle
approach to risk assessment and management using safety instrument
systems (SIS) as a risk reduction mechanism. A BMS is classified as a SIS.
The standard requires that risk reduction for specific hazards be classified
according to order of magnitude levels called safety integrity levels (SIL).
During risk analysis, a SIL target is assigned to each hazard and a safety
function is designed to prevent the hazard.
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Yes
Yes
Yes
Five-minute
time delay
Yes
Reset master
fuel trip relay(s)
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2.
3.
See Note
Loss of ID fan
6.
Loss of ID fan
8.
9.
10a.
10b.
11.
12.
A
N
D
4. Loss of FD fan
7. Loss of FD fan
13.
14.
15.
Master
Fuel Trip
Logic
Master
Fuel Trip
Relay(s)
Close main safety shutoff
and individual burner safety
valves
Typical Cause of
Trip Indication
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Other trip safety functions in a BMS look for dangerous conditions and stop
the fuel flow, shutting down the combustion.
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Interlocks/Safety Functions
Light off Sequences
Trips vs. Permissives
Master Fuel Trip and Purge Sequence
Gas-Fired Systems
Oil-Fired Systems
Pulverized coal-fired systems
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A typical BMS includes safety functions for ignition (light off) sequences,
permissives and trips. The safety functions are different depending on fuel
type and BMS systems designed for multiple fuels and by necessity more
complicated.
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Questions
Questions: please send any questions to
info@exida.com We will respond as soon as possible.
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are available from the exida on-line store. A product
listing is available at http://www.exida.com/products2/
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If have any questions, they may sent via email to info@exida.com. Please
refer to this particular lessonIntroduction to Burner Management Systems.
exida.com is a knowledge company focused on system reliability and safety.
We provide training, tools, coaching, and consulting. For general information
about exida, please view our detailed website at www.exida.com.
Thank you for your interest. Please consider other lessons in the on-line
training series from exida.com.
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