Beruflich Dokumente
Kultur Dokumente
A fully automated burner management system operating as a SIS for burner control
can meet minimum safety targets, improve system availability and lower costs
NIKKI BISHOP and DAVID SHEPPARD
Emerson Process Management
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PC
Stack
TI
temperature
Total charge
flow
CO
FC
AC
AC
FC
Draught
pressure
Firebox
temperature
Oxygen
TI
TC
TI
Pass 1
FC
TI
TI
Coil outlet
temperature
TC
Pass 2
FC
TI
TI
Pass 3
TI
FC
TI
Pass 4
Fuel
gas
PI
Fuel gas
PI
Pilot gas
FI
Combustion
air flow
PTQ Q3 2013 35
Analysis
Hazard and risk
assessment
Allocation of safety
functions to protection
layers
Safety requirements
Specifications for
the SIS
Implementation
Management
of functional
safety, and
Safety
functional
lifecycle
safety
structure
assessment and planning
and auditing
Design and
engineering of
safety
instrumenated
system
Design and
development of
other means of risk
reduction
Verification
Installation,
commissioning and
validation
Operation
Operation and
maintenance
Modification
Decommissioning
Source: IEC 61511-1 ed. 1.0 Copyright 2003 Geneva, Switzerland. www.iec.ch
36 PTQ Q3 2013
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Logic solver
Sensor
38 PTQ Q3 2013
A common trend in all of the standards is the use of SIS for protective
actions. By definition, a SIS is a set
of components such as sensors,
logic solvers and final control
elements arranged for the purpose
of taking the process to a safe state.
Figure 3 shows the components of
a SIS. These are separate from all
other control systems such that, in
the event of a failure of the control
system, the SIS is not prevented
from performing the SIF. Certified
SIS systems follow a stringent certification process and are designed,
maintained, inspected and tested
per applicable standards and
recommended practices. Safety
rated hardware is more robust and
experiences fewer device failures
than traditional hardware. SIS offer
the benefits of improved safety,
increased system availability and
compliance with standards and
practices. The benefits can be
extended to operational benefits by
taking advantage of safety systems
that go beyond meeting minimum
safety requirements and can actually improve operational efficiency.
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Pre-purge
in progress
Shutdown
and ready
Shutdown,
not ready
S03
Purge
complete
S04
S02
Ignite
pilot
S01
S05
Start-up failure
Pilot only
running
S06
S13
Waste gas
only
S08
S10
S09
Mixed gas
Ignite main
with pilot
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PTQ Q3 2013 39
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Conclusion
Sample cost savings for a fully automated BMS to reduce startup time
Unit
Heater
Margin $/bbl
Crude distillation
Crude heater
$2
Preflash heater
$2
Vacuum distillation
Vacuum heater
$1
FCC
Feed heater
$6
Alkylation
lsostripper reboiler
Heater
$4
Hydrotreating
Reactor feed heater
$1
Stripper reboiler heater
$1
Reforming
Reactor feed heaters
$8
Stabiliser reboiler heater
$8
Hydrogen plant PSA Reformer reactor furnace $8
Hydrocracking
Feed heater
$6
Fractionator heater
$6
Stabiliser reboiler heater
$6
Coking/thermal cracking Feed heater
$8
Two-hour value
$33 334
$33 334
$16 666
$100 000
Unit total
$66 666
$8334
$8334
$133 334
$133 334
$133 334
$100 000
$100 000
$100 000
$133 334
$66 668
$66 668
$16 666
$100 000
$16 668
$266 668
$133 334
$300 000
$133 334
Example savings calculation associated with two-hour reduction in unit startup time for a 200 000 bpd refinery
with typical downstream processing capacities.
Table 1
PTQ Q3 2013 41