Burner Management –
A Straightforward
Approach Using DeltaV
SIS for Typical Systems
David Sheppard, CFSE
Presentation:
– SIS, BMS, Why Implement BMS in a SIS
– State Transition Approach to BMS Design
– Review Example Design of a typical BMS System
–
–
–
–
Show Function Blocks used in the Configuration
Show An Example Operator Interface
Startup and Trip a Simulated BMS System
Summary / Questions?
Emerson Confidential
June 30, 2009 – Slide 2
Emerson’s vision
By extending the Emerson digital PlantWeb
architecture to safety systems, Smart SIS will
provide unprecedented
customer value by:
–
–
–
–
enabling safer plants
increasing availability
lowering lifecycle cost
simplifying regulatory compliance
Emerson Confidential
June 30, 2009 – Slide 3
DEFINITION: SIS
(Safety Instrumented System)
A SIS
– Takes a process to a safe state when predetermined
(dangerous) conditions are violated (e.g. ESD)
– Permits a process to move forward in a safe manner
when specified conditions allow (e.g. BMS)
– Takes action to mitigate the consequences of an
industrial hazard (e.g. FGS)
Related Definitions
logic
solver
• ESD - Emergency Shutdown
• ESS - Emergency Shutdown System
• SSD - Safety Shutdown Systems
transmitter
shutdown
valve
Emerson Confidential
June 30, 2009 – Slide 4
• BMS - Burner Management System
• FGS – Fire & Gas System
What is the purpose of a BMS?
To inhibit startup when unsafe conditions exist.
To protect against the unsafe operating conditions and
admission of improper quantities of fuel to the furnace.
To provide the operator with status information – operator
assistance
To initiate a safe operating condition or shutdown
interlock if unsafe condition exists.
As per NFPA 85, “the BMS is a control system dedicated
to boiler furnace safety and operator assistance……”
Emerson Confidential
June 30, 2009 – Slide 5
Why implement BMS in an SIS?
Increased safety
Increased system availability
Regulatory compliance
Emerson Confidential
June 30, 2009 – Slide 6
Is BMS a SIS?
Burners, furnaces and boilers are very critical and complex systems.
There is evidence that OEMs and end users who wish to comply with
standards (IEC/NFPA), or to meet certain insurance requirements, will
have to classify burner management systems as safetyinstrumented systems, to achieve certification by a third-party agency.
In the process industry, a BMS is included in the IEC 61511 definition,
although not by direct reference. There is also no exclusionary
clause.
Burner Management Systems (BMS) are defined as Safety Instrumented
Systems (SIS) if they contain sensors, a logic solver and a final
control element according to IEC 61511.
All safety critical processes must be analyzed and their potential risk
determined.
By considering a BMS as a SIS, companies can ensure that these
systems are designed, maintained, inspected and tested per both the
applicable prescriptive standards (API, NFPA, etc.) as well as the
latest SIS performance-based standards (ANSI/ISA, and IEC).
Emerson Confidential
June 30, 2009 – Slide 7
Is a BMS a SIS?
Six (6) different codes, standards and / or recommended practices have been, or are currently
being developed, that mandate a BMS is a SIS until proven otherwise.
– The Black Liquor Recovery Boiler Advisory Committee (BLRBAC) has developed several
guideline documents regarding design and operation of Recovery Boilers in the Pulp and
Paper Industry. These documents invoke SIS requirements on the Recovery Boiler BMS.
– FM 7605 – Factory Mutual requires that any PLC listed for use in combustion safeguard
service meet the SIS requirements contained in IEC 61508.
– TR84 – The ISA S84 committee has formed a BMS sub-committee to develop a document that
clarifies how SIS concepts apply to a BMS. Examples being included in the document for each
code or standard are:
• NFPA 85 – Single burner boiler
• NFPA 86 – Thermal oxidizer
• API 14C – Process heater with multiple burners
• API 556 – Glycol Reboilers
The goal of the S84 committee is for industrial users to properly follow the safety
lifecycle to define the risk of every BMS to determine if it is a SIS.
– NFPA 86 Committee is planning to update this standard to reflect their agreement that
an industrial BMS is a SIS and that a safety PLC should be used. It also will refer to
ANSI/ISA 84.00.01-2004 as acceptable methodology.
– EN 50156-1 is a European standard covering electrical equipment for furnaces which invokes
SIS requirements for a BMS.
– API 556 document governs design of BMS’s in the petroleum industry. It invokes SIS
requirements on BMS’s.
Emerson Confidential
June 30, 2009 – Slide 8
Burners and boilers are very critical
and complex systems
Distance of boiler displacement = 50m
Emerson Confidential
June 30, 2009 – Slide 9
DeltaV SIS advanced function blocks
simplify configuration
IEC 61508 certified modules
and functionality for BMS
– Cause and Effect Matrix (CEM)
– Step Sequencer
– State Transition
Provides very efficient
configuration and powerful
application software.
Available dynamos and
faceplates make the application
very transparent for the
operator.
Example BMS States
S03
Shutdown,
Not Ready
S01
S04
S02
Shutdown,
& Ready
Pre-Purge
In progress
Purge
Complete
Ignite Pilot
Startup failure
S05
Pilot only
Running
Trips from States
5, 6, 7, 8, 9, 10, 12
S12
Mixed firing,
set low fire
position
S06
S07
S13
Waste Gas
Only
S08
S10
Mixed Gas
S09
Main without
pilot, not at Temp
Ignite Main
with Pilot
Cold Start,
Set Low fire
position
3 Main Logic Part to a BMS System
In order to define a BMS you must know 3 fundamental items.
1. States & Transitions – When to move from one to another
2. Outputs – Valve Positions defined for each State
3. Trips – Including which is active during each State
Once these are defined, the DeltaV SIS logic can be programmed in
An easy to follow manner.
The following
Example is a
Single BurnerMulti Fuel
with 13 states:
BMS State Transition Diagram
1) No Trip
condition exists
and all trips
have been reset
1) Operator initiates Purge hand switch.
S03
S04
S02
S01
Ignite Pilot
Pre-Purge In
progress
Shutdown,
& Ready
Purge Complete
1) Total volume flow
of nitrogen is
confirmed at 200
SCFM for 5 min
Shutdown,
Not Ready
1) Operator
initiates pilot
ignition with hand
switch.
S05
Pilot only
Running
1) Pilot flame detected
within 15 sec
Startup failure
Trips from States
5, 6, 7, 8, 9, 10, 12
1) Operator
initiates
“Mixed Gas“
hand switch
1) Flame
detectors
confirm flame
within 15 sec
2) Additional 15
sec for flame
stabilization
1) Low fire
positions
confirmed
S12
S13
Mixed firing, set
low fire position
Waste Gas Only
Mixed Gas
1) Reached min temp
2) Operator initiates hand
switch to “Mixed Gas"
Cold Start, Set
Low fire position
S09
Main without
pilot, not at Temp
S06
S07
S08
S10
1) Operator initiates
"Waste Gas Only“
hand switch
1) At least 15 seconds elapsed
2) At least 6 hours of cold restart
time is elapsed OR Operator
over-rides this timer.
3) Operator initiates "Light Main
Burner" hand switch.
Ignite Main with
Pilot
1) Low fire
positions
confirmed
State Transitions – Defines What Allows the Logic to
move from one State to Another
For Example:
To move from
State 2 – Shutdown and Ready to
State 3 – Pre Purge in Progress
The Operator Selects Cold
Restart
The Built in DeltaV SIS Function
Block - State Transition Block - is
used to Easily Define the
Transition Logic.
State Name
State
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Tag
Oxygen to control valve
Oxygen to control valve
Pilot Igniter
Burner Switch #1 Tuning
BXXXXX1-15
BXXXXX1
Command
Burner Switch #2 Tuning
BXXXXX2-15
BXXXXX2
Command
BYXXXX-14
BYXXXX
Oxygen to block valve
Nitrogen to block valve
(FO)
XYXXXX
XYXXXX-11
Pilot combustion air
valve
XYXXXX-12
XYXXXX
Sour Water Gas Control
FYXXXX-13
FYXXXX
Valve Solenoid
XXXXX-10
XXXXX
FYXXXX-9
FYXXXX
PXXXX-8
PXXXX
FYXXXY-7
FYXXXY
FYXXXX-7
FYXXXX
XYXXX2-6
XYXXX2
XYXXX1-5
XYXXX1
FYXXXX-4
FYXXXX
FYXXXY-4
FYXXXY
FYXXXY-3
FYXXXY
FYXXXX-3
FYXXXX
XYXXX2-2
XYXXX2
Description
Main natural gas
upstream block valve
Main natural gas
downstream block valve
Main combustion air
valve solenoid #1
Main combustion air
valve solenoid #2
Trim combustion air
solenoid #1
Trim combustion air
solenoid #2
Pilot gas upstream block
valve
Pilot gas downstream
block valve
Waste gas control valve
solenoid 1
Waste gas control valve
solenoid 2
Outputs
XYXXX1-1
XYXXX1
States
Notes
State Output Control
Output Description
Outputs – Defined Per State
Once the States are defined, the position of each Output (Valve,
ignitor, etc) is defined in each state in a simple table
D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation, XX=Set the output %
open
Shutdown, Not Ready
S01
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Shutdown & Ready
S02
D
D
D
D
D
D
D
D
D
D
D
D
D
E
D
D
D
D
D
Pre Purge in Progress
S03
D
D
D
D
D
D
D
D
D
D
D
D
D
E
D
D
D
D
D
Purge Complete
S04
D
D
D
D
D
D
D
D
D
D
D
D
D
E
D
D
D
D
D
Ignite Pilot
S05
D
D
D
D
D
D
E
E
D
D
D
D
D
E
E
D
E
D
D
Pilot Only Running
S06
D
D
D
D
D
D
E
E
D
D
D
D
D
E
E
D
D
D
D
Cold start, set low fire positions
S07
D
D
D
D
E
E
E
E
D
D
D
D
D
E
E
D
D
D
D
Ignite main with pilot
S08
E
E
D
D
E
E
E
E
D
D
D
D
D
E
E
D
D
D
D
Main NG w/o Pilot, not at temp
S09
E
E
D
D
E
E
D
D
D
D
D
D
D
D
D
D
D
D
D
Mixed Gas
S10
E
E
E
E
E
E
D
D
E
E
D
D
D
D
D
D
D
D
D
Not Used
S11
Mixed firing, set low fire positions
Waste gas Only
S12
S13
D
D
D
D
E
E
E
E
E
E
E
E
D
D
D
D
E
E
E
E
D
E
D
E
D
E
D
D
D
D
D
E
D
D
D
E
D
E
State Name
1
BX201C2-15
1
BX201C1-15
Pilot Igniter
Burner Switch #1
Tuning Command
Burner Switch #2
Tuning Command
BY217C-14
1
1
1
1
XY250C-10 Oxygen to block valve
Nitrogen to block valve
XY224C-11
(FO)
Pilot combustion air
XY203C-12
valve
Sour Water Gas
FY216C-13 Control Valve Solenoid
1
1
1
1
1
1
1
1
1
1
1
1
1
Notes
States
Tag
State Output Control
Output Description
Outputs
Description
Main natural gas
Main natural
XYXXXX1-1 upstream
blockgas
valve
downstream block
XY206C2-2
Main combustion air
FY2XXXX-3
valve solenoid #1
Main combustion air
valve solenoid #2
FY205CY-3
Trim combustion air
FY212CY-4
solenoid #1
Trim combustion air
solenoid #2
FY212CX-4
Pilot gas upstream
block valve
XY202C1-5
Pilot gas downstream
XY202C2-6
block valve
Waste gas control
FY215CX-7
valve solenoid 1
Waste gas control
valve solenoid 2
FY215CY-7
Oxygen to control
PY237C-8
valve
Oxygen to control
FY240C-9
valve
Outputs - Defined per state
D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation,
State XX=Set the output % open
Shutdown, Not Ready
S01
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Shutdown & Ready
S02
D
D
D
D
D
D
D
D
D
D
D
D
D
E
D
D
D
D
D
Pre Purge in Progress
S03
D
D
D
D
D
D
D
D
D
D
D
D
D
E
D
D
D
D
D
Purge Complete
S04
D
D
D
D
D
D
D
D
D
D
D
D
D
E
D
D
D
D
D
Ignite Pilot
S05
D
D
D
D
D
D
E
E
D
D
D
D
D
E
E
D
E
D
D
Pilot Only Running
S06
D
D
D
D
D
D
E
E
D
D
D
D
D
E
E
D
D
D
D
Cold start, set low fire positions
S07
D
D
D
D
E
E
E
E
D
D
D
D
D
E
E
D
D
D
D
Ignite main with pilot
S08
E
E
D
D
E
E
E
E
D
D
D
D
D
E
E
D
D
D
D
Main NG w/o Pilot, not at temp
S09
E
E
D
D
E
E
D
D
D
D
D
D
D
D
D
D
D
D
D
Mixed Gas
S10
E
E
E
E
E
E
D
D
E
E
D
D
D
D
D
D
D
D
D
Not Used
S11
Mixed firing, set low fire positions
Waste gas Only
S12
S13
D
D
D
D
E
E
E
E
E
E
E
E
D
D
D
D
E
E
E
E
D
E
D
E
D
E
D
D
D
D
D
E
D
D
D
E
D
E
States
The DeltaV SIS logic has a simple matrix that mirrors the
table. It drives the outputs blocks
Outputs
Notes
State
S01
S02
S03
S04
S05
S06
S07
S08
S09
S10
S11
S12
S13
M
M
M
M
M
M
M
T
T
T
T
M
M
M
M
T
T
T
T
T
T
T
M
M
T
M
T
T
M
T
T
M
T
T
M
T
T
M
T
T
M
T
T
M
T
T
T
T
T
T
T
This
cause
T
T
T
“masked” in this state!
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
"T" = Trip, "M"=Mask (no trip)
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
needs
to
be
This
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
cause
T
T
to trip in this state.
T
T
T
T
T
T
T
T
T
T
T
T
T
has
T
T
T
M
M
M
M
M
T
T
T
M
to Mbe
M
M
BSLXXX
HSXXXX
14 - Loss of pilot
flame signal
LTXXX1/2/3
15 - Trip on
Software
Shutdown
13 - Hi Hi level in
hydrocarbon
drum 4
LTXXX1/2/3
LTXXX1/2/3
10 - Low level in
high pressure
stream drum
LTXXX1/2/3
12 - Hi Hi level in
hydrocarbon
drum 3
9 - Hi Hi level in
hydrocarbon
drum 1
LTXXX1/2/3
8 - Manual ESD
Button, Local
HSXXX3
11 - Hi Hi level in
hydrocarbon
drum 2
7 - Manual ESD
Button, RIE
HS2XXX2
LTXXXX/Y/Z
6 - Hi Hi thermal
reactor
temperature
5 - Hi Hi level in
Waste gas KO
drum
FTXXX1/2/3
FTXXX1/2/3
TTXXX
TTXXXX
4 - Low Total
Combustion Air
Flow
PTXXX1/2/3
2 - Low Natural
Gas Pressure
1 - Loss of main
flame signal
Description
3 - Hi Hi
combustion air
pressure
PT7XXX/Y/Z
BSLXXX1/2
Tag
Trip Input Description
Trip Matrix / Appropriate Masking
Different Trip conditions should be masked during different states. For
example, seeing Flame is Required when running, but it must be masked
when not running
Trips
T
T
T
T
T
T
T
T
T
able
T
T
T
Notes
State
S01
S02
S03
S04
S05
S06
S07
S08
S09
S10
S11
S12
S13
M
M
M
M
M
M
M
T
T
T
T
M
M
M
M
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
M
M
M
M
M
M
M
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
M
M
T
T
T
T
T
T
9 - Hi Hi level in
hydrocarbon
drum 1
LT105C1/2/3
LT211X/Y/Z
8 - Manual ESD
Button, Local
5 - Hi Hi level in
Waste gas KO
drum
FT205C1/2/3
FT212C1/2/3
HS210C3
4 - Low Total
Combustion Air
Flow
PT217C1/2/3
7 - Manual ESD
Button, RIE
3 - Hi Hi
combustion air
pressure
HS210C2
2 - Low Natural
Gas Pressure
PT729X/Y/Z
6 - Hi Hi thermal
reactor
temperature
1 - Loss of main
flame signal
BSL201C1/C2
TT222C
TT229C
Description
Tag
Trip Input Description
T
T
T
T
T
T
This Cause
is “masked”
in this State!
States
T
T
"T" = Trip, "M"=Mask (no trip)
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
Outputs
T
T
M
M
M
M
M
T
T
T
M
M
M
M
HSXXXX
BSL202C
15 - Trip on
Software
Shutdown
14 - Loss of pilot
flame signal
13 - Hi Hi level in
hydrocarbon
LT105D1/2/3
drum 4
12 - Hi Hi level in
hydrocarbon
LT625D1/2/3
drum 3
11 - Hi Hi level in
hydrocarbon
LT625C1/2/3
drum 2
10 - Low level in
high pressure
LT203C1/2/3
stream drum
Trips – Including Masking Defined per State
Trips
T
T
T
T
T
T
T
T
T
T
T
T
The DeltaV SIS logic has a simple matrix that mirrors the table above that
masks conditions based on the state the burner is in
Simple Documentation
State
Transition
Diagram
Outputs
Transitions
Trips
Traditional Graphic
BMS Trips Graphics – Normal State
BMS Trips Graphics – Trip State
BMS Ring of Fire – Step S02
BMS Ring of Fire – Step S06
Summary
The State Transition Diagram
approach is a very clear and
systematic development process:
1.
Define the states and transitions.
2.
Define the outputs in each state.
3.
Define the required trip signals.
4.
Define per state if a trip is active or
masked.
Very good for developing functional
requirements in an interdisciplinary
team.
The approach can also be used for
other applications.
Emerson Confidential
June 30, 2009 – Slide 25
Safety lifecycle benefits:
Reduced cost and improved safety
Analysis – a well defined approach
and easily understandable.
Implementation – can be easily
implemented using standard
function blocks and dynamos
Operation – because failures can
easily be located and removed.
Verification – each state has
clearly defined output signals and
trip causes which can easily be
tested and verified.
Modification – the solution is
unambiguous and can easily be
modified.
Emerson Confidential
June 30, 2009 – Slide 26
Thank you…
…any Questions?