Post on 28-Jun-2018
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E
T10 - Standards Review - Burner Management and Combustion Control
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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
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Definitions
3
TSSA - Technical Standards and Safety Authority
NFPA – National Fire Protection Association
FM Factory Mutual – Insurance Underwriter
SIS – Safety Instrumented System
SIL – Safety Integrity Level
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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
4
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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
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Safety Codes and Application Highlights
Survey of Applicable Codes for Fired Equipment
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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
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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
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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
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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
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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.
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Application: Typical Boiler –Combustion Control related devices
4
22(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Copyright © 2012 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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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
BMS Safety IO to/from devices
Combustion Control IO
to/from devices
Combustion
Control / Burner Management
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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
BMS Safety IO to/from devices
Combustion Control IO
to/from devices
Combustion Control / Burner Management
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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 Safety IO to/from devices
BMS - Burner Management
SIL 2 rating1715 IO
SIL 2 rating
Combustion Control IO
to/from devices
BPCS
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Advanced Solution – SIL 2 Fault Tolerant
Ethernet/IP with
CIP Safety
BMS Safety IO to/from devices
BMS - Burner Management
SIL 2 rating1715 IO
SIL 2 rating (Jan ’13)
Combustion Control IO
to/from devices
BPCS
PlantPAx BMS:
INDEPENDENT BMS and CCS
ControlLogix, in SIL 2 Configuration, for BMS Control.
ControlLogix for BPCS (Combustion Control System)
Safety IO using 1715
Fault Tolerant BMS Configuration
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AADvance Controller – SIL 2 Fail Safe
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CPU Base with one
CPU populated
I/O Base with one
input and one
output fail safe
BMS Safety IO to/from devices
Combustion Control IO
to/from devices
BPCS
PlantPAx AAdvanced BMS:
INDEPENDENT BMS and CCS
AAdvance, in SIL 2 Configuration, for BMS Control.
ControlLogix for BPCS (Combustion Control System)
Fail Safe BMS Configuration
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AADvance Controller – SIL 3
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Redundant
CPUs
BMS Safety IO to/from devices
Combustion Control IO
to/from devices
BPCS
PlantPAx AAdvanced BMS:
INDEPENDENT BMS and CCS
AAdvance, in SIL 3 Configuration, for BMS Control.
ControlLogix for BPCS (Combustion Control System)
SIL 3 Fail Safe BMS Configuration
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 30
AADvance Controller – SIL 3 Fault Tolerant
30
Redundant
CPUs
BMS Safety IO to/from devices
Combustion Control IO
to/from devices
BPCS
PlantPAx AAdvanced BMS:
INDEPENDENT BMS and CCS
AAdvance, in SIL 3 Configuration, for BMS Control.
ControlLogix for BPCS (Combustion Control System)
SIL 3 Fault Tolerant BMS Configuration
Redundant
Inputs
Redundant
Outputs
Redundant
Terminations
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