Burner Management

System

Eng. Ahmed El Sayed Youssef

Burner Management
Systems..
What is a BMS?
A Burner Management System
is defined as the following:
A Control System that is
dedicated to burner 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
Why Have a Burner Management
?System
Burner Management Objectives
Sequence burner through safe start-up
Insure a complete pre-purge of burner
Supervise safety limits during operation
Supervise the flame presence during operation
Sequence a safe shutdown at end of cycle or at
trip
Integrate with combustion control system for
proper fuel and air flows

Conclusion
To Protect Personnel
To ensure safe operation of combustion in
heaters , furnaces , boilers, etc.
To maintain safe operation during start up,
 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

Magnitude and intensity of

explosion depends on relative
quantity of combustibles and the
proportion of air at the time of
 Furnace Explosions can occur
with any or a combination of the
following:
Momentary loss of flame followed by
delayed re-ignition
Fuel leakage into an idle furnace ignited
by source of ignition
Repeated Light-off attempts without
proper purging
Loss of Flame on one Burner while
others are in operation
Complete Furnace Flame-out followed
Components of BMS
Local control panel
Ignition push buttons , lamp indications
Ignition devices
Pilot and main flame detectors
Solenoids operated shutdown valves
with proximity switches for open &
close indications
Pressure, Temperature, flow
transmitters and switches
BMS & ESD PLC
Standards followed
NFPA 85 Boiler & combustion
Control Systems Hazards Code
API 556 Instrumentation & Controls
for Fired Heaters and Steam
Generators
ANSI/ISA S84.01 Application of Safety
Instrumented Systems for the
Process Industries
IEC 61508
History
For many years BMS systems
were constructed from
nonprogrammable, hardwired
electro-mechanical relays.

These relay systems were

relatively simple and their failure
characteristics were well known.
A properly designed relay system
was considered by most to be
 Cont. History
The drawback of relay systems becomes
quickly apparent when the number of I/O
(inputs and outputs) increases much beyond
20. The wiring is cumbersome, the logic is
difficult to change, documentation must be
done manually, there is no form of automatic
diagnostics, no digital communications, etc.

Relay systems have a low initial price, but

the overall cost of ownership can be
relatively high.
 PLC
The introduction of the PLC
(programmable logic controller) in 1969
brought about many changes. PLCs
were specifically designed to replace
hardwired relay control systems.

They offered many potential

advantages (e.g., software flexibility,
self-documentation, smaller size, lower
life cycle costs, etc.).
Layer of protection
Process Control
Process as used in the terms
process control and process
industry, refers to the methods of
changing or refining raw
materials to create end products.
This is the physical system we
wish to monitor and control.
Process control refers to the
methods that are used to control
process variables when
1. Introduction to Process
Control
Manufacturers control the
production process for three
reasons:

Reduce Variability.
Increase Efficiency.
Ensure Safety.
Some definitions to review;

Process variable is a condition of the

process fluid (a liquid or gas) that can
change the manufacturing process in
some way.

Setpoint is a value for a process variable

that is desired to be maintained.

MEASURED VARIABLES, PROCESS

VARIABLES, AND MANIPULATED
VARIABLES.
 Error is the difference between the measured
variable and the setpoint and can be either
positive or negative.

Offset is a sustained deviation of the process

variable from the setpoint.

LOAD DISTURBANCE.
A load in a controlled process is any variable
subject to change which has an impact on the
variable being controlled (the process variable),
but is not subject to correction by the controller.

CLOSED AND OPEN CONTROL LOOPS.

Cont. Introduction

ProcessInstrument Types
Transducer
Transmitter
Indicator
Controller
Final control element
Cont. Introduction
CLOSED CONTROL LOOP.
Open Loop Control Like
sprinkler system
Manual control
2. Basic feedback control
principles
Cont. Basic feedback control
principles
3. Cascade control
4. Feedforward control
5. Ratio control
6. Limit, Selector, and
Override controls
Limit controls
Selector controls
Valves and Actuators
Valve failure selection
Dampers and louvers
Pinion and rack
Self-operated valves
Limit Switches
Proximity Switches
Limit switch Box
Solenoid Valves
2-way solenoid valves
way solenoid valves-3
Two Way
Three Way
Four Way
Five Port / Four Way
Distributer
Distributer 5/2
3/2
 P&ID OVERVEIW

-All definitions and symbols will be according to

ISA-5.1 standard

- P&ID is a controlled document: any changes to

the drawings are identified and clearly
documented
Definition of Instrument and Control System:

Instrument
A device for measuring, indicating, or controlling

Process control
All first-level control process or discrete consists of three
parts:
Sensing
Comparing
Correcting
The Control Loop
In automatic control, the three devices the
transmitter that senses, the controller that
compares, and the control valve that corrects.
 The Control Loop
Line Symbols
Pneumatic Transmission :
Electronic Transmission :
Symbols
Pipe Lines:
This additional information might include
materials of construction, pressure ratings,
connection methods and service.
P&IDs and Symbols

Instrument Numbering

Many different numbering systems are used:

Parallel
method: starting a new number
sequence for each first letter. Therefore, there
may be an FRC-101, a PIC-101, and a TI-101.
 P&IDs and Symbols

Instrument Numbering

Series method: using a single numerical

sequence for all devices. Therefore, there may
be an FRC-101, a LR-102, a PIC-103, and a TI-
104.
P&IDs and Symbols

Instrument Numbering

Use Basic Number if project is small and there

are no area, unit, or plant numbers:
Basic Number: FT-2 or FT-02 or FT-002
P&IDs and Symbols

Instrument Numbering

If project has a few areas, units, or plants (9 or

less), use the first digit of the plant number as
the tag number:
FT-102 (1 = area, unit, or plant number)
P&IDs and Symbols

Instrument Numbering

If project is divided into area, units, or plants:

1-FT002
01-FT002
001-FT002
 P&IDs and Symbols

Instrument Numbering

A block of numbers is sometimes used to

designate certain types of devices. For
example, all safety valves might use the 900
series: PSV-900, PSV-901, PSV-902, etc.
 P&IDs and Symbols
Instrument Function/Location
Steam Boiler
A Boiler is an important unit
operation, widely used in oil
refinery, petrochemical and
power industries.

Itutilizes the combustion

energy of fuel to generate
steam, which used in various
equipment in the plant.

The boiler feed water (BFW) is

Steam Boiler
The energy required for the
steam generation is obtained
by burning fuel oil or fuel gas
with air.
The hot combustion gases also
known as flue gas transfer heat
by radiation and convection to
the water to generate steam.
The cold flue gas leaves the
boiler through the stack and
Steam Boiler
The steam produced in a boiler
is used in various equipment in
a plant and hence the boiler
operation directly affects the
overall plant performance.

Ifa boiler shuts down a

significant portion of the plant
may have to be shut down
Applications of Boilers
Stripping steam for distillation
columns
Motive steam for turbine
drivers
Heating fluid for heat
exchangers

HPS , MPS and LPS

Types of Boilers
There are several types of boilers
and their structure varies widely
depending on their capacity.

Boilers can be classified on

Mode of the water flow

Mode of air and flue gas flow

Classification based on upon
water flow
1. Once-through boiler
2. Fire tube boiler
3. Drum-type boiler
Classification based on upon
air flow and flue gas flow
1. Forced-draft boiler
2. Induced-draft boiler
3. Balanced-draft boiler
 Draft System

Hot air
rises
because
it is less
dense
than cool
air
Boiler Feed Water
Treatment
The successful operation of boilers requires
accurate analysis of the water that is used,
proper treatment to remove corrosive
minerals and gases, and careful attention to
the controls and procedures for the taking of
water samples, their testing, and all
required inspections.

Thekey player is the boiler Operator and, of

course, assigned Supervisors.

Abasic knowledge of boiler mechanics and

water chemistry is an absolute requirement.
Water and Steam System
DEAERATOR
Economizer
Boiler Assembly
SUPERHEATER
Flame in the Furnace
For Gas Burner
For Oil Burner
Boiler BMS
A boiler system incorporates a number
of unique control strategies. The basic
objectives of the control strategy are;

to supply a continuous supply of steam

at the desired condition,
to perform normal and emergency
operations safely at all times,
to continuously operate the boiler with
the maximum possible efficiency,
to maintain a high level of safety and
sustain full boiler design life.
Boiler Control System
FeedWater Control Loop & Three
element Control.
Steam Temperature Control
Steam Pressure control Master
Pressure Control
Combustion Control loop
Refinery gas minimum pressure
Control loop
Feed Water Control Loop & Three
element Control
In a conventional two-element control
strategy the output of a level controller
cascades into a flow controller.
As the drum level increases the
controller reduces the feed water
supply.
And similarly, if the drum level
decreases the controller increases the
feed water supply.
Let us assume that the steam
consumption increases suddenly ?
Feed Water Control Loop & Three
element Control
Due to the swelling effect the steam
drum level will rise initially and then
decrease. The controller will initially
reduce the feed water supply.
This will in effect reduce the water
inventory and after the swell effect the
water drum level will drum significantly.
In order to handle this situation the
steam flow rate should also be
considered for drum level control.
Steam Temperature Control
The temperature of the steam leaving the
boiler continuously varies with the boiler load.
The main objective of the main steam
temperature controller is to maintain a
constant steam temperature at all boiler loads.
As we know, the steam leaving the steam
drum initially enters the primary super heater,
then a de-super heater and finally leaves the
boiler through a secondary super heater.
The boiler feed water is sprayed into the de-
super heater for controlling the main steam
temperature.
The main steam temperature controller
manipulates the amount of boiler feed water
Steam Pressure control Master
Pressure Control
The steam pressure is subjected to continuous
changes due to continuous variations in the
boiler load.
As the steam demand increases the steam
pressure decreases and when the steam
demand decreases the steam pressure
increases. Hence, the main objective of the
boiler control strategy is to maintain the steam
pressure at various steam demands. The steam
pressure is controlled by manipulating the
amount of fuel burnt.
As the steam pressure increases the fuel flow is
reduced to produce less steam and the steam
pressure is brought back to the desired value.
Steam Pressure control Master
Pressure Control
Normally, the control of the steam pressure is
sluggish. This is because the size of the boiler
is huge and it takes time to transfer heat from
fuel firing to make steam.

Moreover, the steam headers in the boiler

provide stability from minor steam pressure
changes. However, they provide additional lag
to pressure dynamics.

Toovercome the sluggish behavior the steam

flow is added as a compensation signal to the
output of the main steam pressure controller.
Boiler Trips and
Interlocks
The interlocks and trips are
necessary to prevent dangerous
situations which may arise during
boiler operations.

Typically,the boiler unit is provided

with an interlock mechanism which
when activated cuts the fuel flows
to the burners and stops
combustion.
Trip Logic
Trip Logic is implemented in all
modern boilers with the objective
of providing safety.
Emergency trip valves are placed
in the main fuel lines and in the
pilot gas line.
Whenever a trip condition is
detected these trip valves are
closed automatically.
 Cont. Trip Logic
Some typical causes for a boiler trip
are:
- Low Steam Drum Level,
- Low Air Flow and
Low Fuel Pressure.

Please note that the emergency trip

switch can also be used to perform
manual shutdown. In order to open
the trip valves manually certain
 Purge Logic
After a shutdown or interlock trip there is a
possibility of accumulation of unburnt fuel
in the firebox. This unburnt fuel can
possibly catch fire and damage the boiler.
certain conditions have to be met before
purging can commence. For example,
- Steam Drum Level is normal and
Combustion Air Flow is normal.
These conditions should hold true during
the entire purging operation which is
usually through a period of 5-30 minutes.
Basic Operations
Pre-Startup,

Start-up,

Shutdown and

Post-Shutdown operations.
Flame Detectors
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
General BMS Over View
Chapter 2

Heater shutdown logic in

ESD PLC
Case
Study