Boiler Interlocks and Burner Management System - Upload
Boiler Interlocks and Burner Management System - Upload
Boiler Interlocks and Burner Management System - Upload
Management system
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Basics
Interlock means to fit or fasten together
Developed using electrical contacts
Contacts are wired to accomplish logical tasks
Nomenclature :
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Basics
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Discrete Input Devices
Hand Switches :
Symbol
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Discrete Input Devices
Proximity Switches :
Non contact sensor that senses closeness of the object
Uses Magnetic, Electric or Optical means
Inductive proximity switches sense the presence of
metallic objects using a high-frequency magnetic field.
Capacitive proximity switches sense the presence of
non-metallic objects using a high-frequency electric
field.
Optical switches detect the interruption of a light beam
by an object.
Similar to Limit switch
except the switch symbol
is enclosed by a diamond
shape, indicating a
powered (active) device
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Proximity Probe
Contacts
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Discrete Input Devices
Temperature Switch:
Uses Metal bulb filled with fluid
Expansion of fluid due to temperature actuates
switch as in case of pressure switch
Electronic switches employ RTD or Thermocouple
sensors
Symbol :
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Discrete Input Devices
Flow Switch :
Uses Paddles as the flow sensing
element
Symbol
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Discrete Output Devices
The Discrete Output Device has only two states :
ON and OFF or
OPEN and CLOSE or
ENERGISED and DE- ENERGISED etc.
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Discrete Output Devices
Fluid Powered Systems :
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Discrete Output Devices
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Discrete Output Devices
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Discrete Output Devices
Solenoid Valve Actuators :
It is a coil of wire that produces a magnetic force
when electrically energised.
Movable iron called Armature moves under
influence of magnetic field.
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Discrete Output Devices
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Discrete Output Devices
Control Relays :
It is Electrical Switch actuated by an electromagnet coil.
It switches electrical contacts when coil is energised or
de-energised.
Types of Relays :
SPST : Single Pole Single Throw - 1 NO or 1 NC
SPDT : Single Pole Double Throw - 1 NO , 1 NC
DPDT : Double Pole Double Throw - 2 NO, 2 NC
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Discrete Output Devices
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Ladder Diagram
Ladder diagrams (also called "ladder logic") are a type of
electrical notation and symbology used to illustrate how
electromechanical switches and relays are interconnected.
The two vertical lines are called "rails" and attach to
opposite poles of a power supply, usually 120 volts AC.
L1 designates the "hot" AC wire and L2 the "neutral" (may
be grounded) conductor.
Horizontal lines in a ladder diagram are called "rungs,"
each one representing a unique parallel circuit branch
between the poles of the power supply.
Typically, wires in control systems are marked with
numbers and/or letters for identification.
The rule is, all permanently connected (electrically
common) points must bear the same label.
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Ladder Diagram Symbols
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Ladder Diagram
Rails
Rung
Rung Number
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Ladder Diagram
Lamp comes ON if
either contact A or B
is actuated .
This is OR Logic
function
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Ladder Diagram
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Ladder Diagram
NOT Logical Function :
Use of NC contact instead of NO contact in ladder
results in logical inversion.
Now, the lamp energizes if the contact is not
actuated, and de-energizes when the contact is
actuated.
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Ladder Diagram
NAND Logical Function : (NOT + AND)
When OR function receives inverted input , the
resultant output will be NAND function as per
DeMorgans Theorem.
The lamp will be energized if either contact is
unactuated. It will go out only if both contacts are
actuated simultaneously.
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Ladder Diagram
NOR Logical Function : ( NOT + OR)
When AND function receives inverted input
through NC contacts, resultant output is NOR
function.
Lamp is ON if both inputs are NOT actuated. Lamp
goes OFF if any of the input is actuated
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Ladder Diagram
Exclusive OR logic Function :
2 PARALLEL
RUNGS FORM
OR GATE
BOTTOM NOT/AND
GATE
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Ladder Diagram
OUTPUT INVERSION :
We have seen INPUT is inversed by using NC
contact in place of NO contact.
For OUTPUT INVERSION a Relay having NC contact
is required.
Control Relay
STOP
CR1 RUN
3
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Ladder Diagram v/s Logic Function
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Permissive and Interlock
The practical example of foregoing is given below
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Basic Boiler Interlocks
PURGE INTERLOCK
Prevents fuel from being admitted to an unfired furnace
until the furnace has been thoroughly air purged.
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Boiler Burner Management
What is a BMS?
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Burner Management Objectives
Sequence burner through safe start-up
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BMS Design Standards
Each Burner Management System should be designed
in accordance with the below listed guidelines to control
and monitor all sequences of the start-up and shutdown
of the burner
n National Fire Protection Association (NFPA 8501
/8502 or others)
n Industrial Risk Insurers (IRI)
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BMS Design Standards
National standards - typical requirements
Governs safety system design on virtually all boilers
(regardless of the process to be used to combust the
fuel)
Requires the separation of the Burner Management
System from any other control system
Requires the use of a hardwired backup tripping
scheme for microprocessor based systems
Requires that a single failure NOT prevent an
appropriate shutdown
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BMS Definitions
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 stack1
Magnitude and intensity of explosion depends on
relative quantity of combustibles and the proportion
of air at the time of ignition
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BMS Definitions
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 (such as a welding spark)
Repeated Light-off attempts without proper purging
Loss of Flame on one Burner while others are in
operation
Complete Furnace Flame-out followed by an
attempt to light a burner
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BMS Definitions
Furnace Implosions
More common in large Utility Boilers
Caused by any of the following:
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BMS Basic Definitions
Common Terminology
Supervised Manual
Manual Burner Lightoff with Interlocks
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BMS Functions
The BMS is typically designed to perform the following
functions:
Prevent firing unless a satisfactory furnace purge has
first been completed.
Prohibit start-up of the equipment unless certain
permissive interlocks have first been completed.
Monitor and control the correct component sequencing
during start-up and shut-down of the equipment.
Conditionally allow the continued operation of the
equipment only while certain safety interlocks remaining
satisfied.
Provide component condition feedback to the operator
and, if so equipped, to the plant control systems and/or
data loggers.
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BMS Functions
Provide automatic supervision when the equipment
is in service and provide means to make a Master
Fuel Trip (MFT) should certain unacceptable firing
conditions occur.
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BMS
Furnace Purge :
Before Fuel Firing is Permitted, following purge
requirement must be satisfied
1. Drum level within operating range (not high, not
low)
3. Fan is in service
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BMS Furnace Purge sequence
PURGE COMPLETE light remains for 10 minutes within
which Operator has to RESET MFT else PURGE
COMPLETE goes off and entire purge cycle has to be
repeated.
START-UP
TIMER
START FD FAN
PERMISSIVES SATISFIED:
- MAIN FUEL VALVES CLOSED
- NO FLAME PRESENT
- FD FAN RUNNING AND
- MINIMUM AIR FLOW SWITCH MADE
- WATER LEVEL SATISFACTORY
- ATOMIZING MEDIUM ON
- FUEL SUPPLY PRESSURE NOT LOW
NOT AND
PURGE COMPLETE
NO
YES
SYSTEM TRIP
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REMOVE PURGE TO CCS
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BMS Main Flame Start up sequence
Lighting off of Pilot flame to Main Flame typically follows
automated sequence.
The sequence starts when START BOILER button is
pressed. ( can be terminated by STOP BOILER button).
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BMS Main Flame Start up sequence
For Fuel Oil
All of the above mentioned for the pilot igniter
Oil gun is in place in the burner
Oil pressure is normal
Fuel oil atomizing interlocks are satisfied
Fuel oil atomizing medium is provided to the burner
Oil control valve is in light-off position
Other Conditions:
No MFT condition after purge
All flame scanners report no flame
All natural gas, or all fuel oil, block valves shown
closed
All air dampers are in light-off position
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BMS Main Flame Start up sequence
Pilot Flame Sequence :
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Igniter Interlocks
PURGE COMPLETE
10 SECOND DELAY
TIMER COMPLETE
FLAME
PROVEN NOT
AND
SYSTEM TRIP
PERMIT FOR MAIN 55
FLAME
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BMS Main Flame Start up sequence
Main Flame Light off :
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Main Flame Interlocks
IGNITER TIMER
COMPLETE
FLAME
AND
PROVEN
ENERGIZE MAIN
FUEL VALVES
TIMER COMPLETE
NOT
AND
DE-ENERGIZE
IGNITION
COMPONENTS
RELEASE TO
MODULATE TO CCS SYSTEM TRIP
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Boiler Master Fuel Trip
Following is list of Conditions causing Boiler trip.
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Boiler Master Fuel Trip
For natural gas:
Excessive steam pressure or water temperature.
Low water level.
High or low gas pressure.
Loss of combustion air supply.
Loss of flame.
Loss of control system power.
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Timing diagram for typical multifuel burner light-
off sequence.
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Ignitors
The gas fired igniter is a device whose flame is designed
to ignite a main burner.
A high voltage is generated from an input voltage
(mains voltage), which generates an ignition spark at
the gas nozzle.
The resulting flame generates a flame signal via the
flame rod. This flame signal is amplified in the ionization
flame monitor and enables the main burner.
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Ignitors
An ion is a charged atom that has either gained an
electron to become negatively charged (anion) or has
lost an electron to become positively charged (cation).
The energy released during a combustion process will
cause electrons to be knocked loose from an atom,
resulting in a positively charged particle and a free
electron.
This ionization, if monitored properly, can be used to
generate a safe and reliable indication of a flame.
Normal combustion:
CH4 + 2O2----->CO2 + 2H2O
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Ignitors
There is sometimes an intermediate step in which a uniform
proportion of the molecules in this reaction do the following
Since the electrons are so much lighter than the ions, the
electrons travel much faster and move away from the
burner mouth toward the tip of the flame much more
quickly than the heavier ions.
This leaves a greater concentration of positively charged
ions in the area near the burner mouth than free electrons.
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Types of Flame Scanners
Infrared (IR) Detectors
Single Burner Applications
More Suitable with Oil Burning Flames
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Flame Scanners
Flame scanners are a crucial part of a boiler's safety
system. Their primary responsibility is to identify
potential dangerous "flame out" conditions where
ignition has ceased and continued addition of fuel
could cause an explosion.
Because of the flame scanners importance, they must
be extremely reliable and rugged
The monitoring can be performed by the combination
of a flame sensor (also flame scanner) that
transforms characteristic properties of the flame into
an electrical signal, with a control unit that provides
the flame signal and ensures error free operation.
Alternatively these two parts are combined in one
compact flame monitor
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Flame Scanners
Flame detection is the technology for detecting flames,
using a flame detector.
Flame detectors are optical equipment for the detection
of flame phenomena of a fire.
There are two types :
Flame detector for the detection of a fire in a fire alarm
system.
Flame scanner for monitoring the condition of a flame
in a burner
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Flame Scanners
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Flame Scanners
ULTRAVIOLET
An ultraviolet (UV) sensor is often sensitive for radiation
in the 185 to 260 nm range. This frequency range is the
least sensitive for natural background radiation sources
like cosmic radiation and especially sunlight.
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Flame Scanners
NEAR INFRARED :
A near Infrared(IR) sensor (0.7 to 1.1 m) is
especially able to monitor flame phenomena, without
too much hindrance from water and water vapor.
Pyro electric sensors operating at this wavelength can
be relatively cheap.
Multiple channel or pixel array sensors monitoring
flames in the near IR band are arguably the most
reliable technologies available for detection of fires.
Digital image processing can be utilized to recognize
flames through analysis of the video created from the
near IR images react to radiation having a wavelength
of 800 nm or higher.
It is only the flickering of the flame which is analyzed.
Constant radiation sources, such as the glowing of the
furnace walls, are not detected as a flame.
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Flame Scanners
Flames radiating in the UV range, but whose UV
component is absorbed by dust, steam or other
substances, can often also be monitored using infra-
red detectors.
The detection element of the Infrared Flame Detector
consists of two pyroelectric sensors (sensor 1 and 2)
and a silicon photo diode (sensor 3).
Flame most useful for its detection, is the
electromagnetic radiation produced by it. This
radiation covers the spectral range from infrared to
far ultraviolet. Infrared and visible radiations, are
functions of flame temperature and emissivity.
Since furnace and burner parts become heated by the
flame, they become potential secondary sources of
infrared and visible radiation, which must be
discriminated against.
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Flame Scanners
A UV/IR detector consists of an UV and single
frequency IR sensor paired to form one unit.
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Flame Scanners
Strengths of the UV/IR detector are;
Virtually immune to false alarms
High speed response under 500 milliseconds
Solar, welding, lightning, X-rays, sparks, arcs, and
corona insensitive
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Flame Scanners
Since the UV/IR detector pairs two sensor types, it will
typically only detect fires that emit both UV and
flickering IR radiation. UV detectors will respond to
virtually all fires including hydrocarbon (liquids, gases,
and solids), metals (magnesium), sulfur, hydrogen,
hydrazine and ammonia. IR detectors typically only
respond to hydrocarbon fires.
Since the IR detector is not sensitive to burning metals,
ammonia, hydrogen and sulfur the combined unit will
not respond to these fires.
The detector is suitable for applications where
hydrocarbon fires are likely and other sources of
radiation may be present (X-rays, hot surfaces, arc
welding). They maintain constant protection while arc
welding takes place. The UV/IR detectors are highly
reliable with fast response times and low propensity to
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Logic Diagram
BMS OPERATE
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Logic Diagram
MFT RESET
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Logic Diagram
LDO MAIN VLV / LDO RECIRC. VLV
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Logic Diagram
FO MAIN VLV/ FO RECIRC. VLV
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Logic Diagram
LDO BURNER VALVE OPEN AND LDO TIME OVER
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Logic Diagram
NO.1 BNR (FG) SEQUENCE
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Logic Diagram
IGNITOR VLV / IGNITOR VENT VALVE
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Simplified BMS Interlock narration
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Exercise - Interlocks
Explain how this interlock functions and name
L1 the input / output in logic diagram L2
OHL 1
OHH 2
CR2
CR2 CR3
3
CR3
4 4
UGH
CR2
OHL
CR3
OHH
CR4
CR5.1
CR2.1
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Logic Diagram
DURING PURGE & PURGE COMPLETE
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Logic Diagram
DURING PURGE & PURGE COMPLETE
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H.G.DHOLAKIA
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