Burner Management and Combustion Control Primer

Burner Management &
Combustion Control:
How not to go BOOM!
Presented by:
Jerry Wenzel
Principal, Chief Knowledge Officer
TA_ADMIN\Marketing\Presentations\2017\TEAM M3 BMS Combustion Control

PROVIDING SUPPORT FOR
Siemens PCS7 DCS
Rockwell PlantPAx DCS & PLC’s
APACS+
Siemens APACS OS
InSight and InVision APACS HMI Frameworks
Wonderware Intouch, ActiveFactory and Information Server
Foxboro DCS
Honeywell
Profibus DP, Profibus PA, AS-interface and HART Fieldbuses
OUR SERVICES
DCS Migrations
Secure remote DCS network connections
Process tuning and optimization
Loop checkout/commissioning and start-up assistance
New and on-going control system support
Web and excel-based plant data reporting
Wireless tablet PC’s for equipment operation or data entry
Integration of APC schemes
Foreign device interfacing: OPC, Modbus, 4-20mA, etc.
Process tuning and optimization
WHY TRIDENT AUTOMATION?
24/7 support
Customized process control solutions for manufacturers
Experienced engineers in integrating control platforms in existing systems or creating

advanced solutions
Robust & Reliable solutions ranging from single components to complete system solutions
Transparent work in a collaborative environment with an open system design.
Markets served: pulp & paper, biofuels & renewable energy, ethanol, chemical, power
generation, hydrocarbon and other specialized projects.
PRODUCTIVITY
Uptime is good, downtime is bad. It’s that simple if you work with experts who have
first-hand knowledge of all aspects of manufacturing – because that’s all we do!
Burner Management Systems
(BMS) aka Flame Safety
• The BMS is responsible for purging, light-off,
and continuous monitoring of safety devices.
• It is a separate system from the DCS.
• Typical systems consist of two options:

– A dedicated flame controller (FireEye).
– A safety PLC.
Dedicated flame controller
advantages
• An example of a typical dedicated
flame controller is the FireEye
E110.
• The FireEye E110 is less

expensive than a safety PLC.
• Built in flame scanner interface.

Dedicated flame controller
disadvantages
• All trips in series wired to 1 input.
• Lack of visibility of which safety device caused the trip.
• Lack of ability to track trip history.
• Lack of ability to interface to the DCS.
• Lack of software to diagnose external and internal faults.
• More complex wiring.
• Trip devices 120VAC.

Safety PLC
• More expensive than a flame controller.
• Typically requires a external flame

amplifier.
Safety PLC advantages:
• Every trip is a dedicated 24VDC input.
• Accurate and easy to understand first outs.
• The state of each interlock is continuously displayed.
• Each trip device has a trip counter for trip analysis and identification.
• Can leak check the gas shut off valves prior to each light off.
• Ability to sense abnormal conditions beyond code requirements.
• Maintenance only reset when faults are sensed in field instruments.

Upgrading your BMS
Options
OPTION 1: FlamePAC™:
• Replaces the majority of devices and wiring in your existing
BMS panels.
• It is based on a Rockwell or Siemens safety rated PLC.
• It provides all of the advantages of the Safety PLC.
• Typical cost is $24,000 per zone installed in groups of 3 zones.

Upgrading your BMS
Options
OPTION 2: FlamePAC FO™:
• Accurate and easy to understand first out indications.
• Continuous display of all interlocks.
• Trip counters for identifying the most problematic trips.
• FlamePAC FO costs approximately $17,000 per zone installed in groups of 3

zones.
• It uses the same controller as the full BMS solution providing an easy upgrade
path to a full BMS.
Example BMS by Trident
Example FO display by Trident
Trident’s FlamePAC and
FlamePAC FO:
• Meet NFPA 8501 & NPFA 8601 flame safety
standards.
• Utilize SIL 2 & 3 safety rated components.
• Are built in our UL rated panel shop.
• Tested on an actual burner at our facility.

Combustion Controls
(CCS)
• The CCS is responsible for controlling the heat
rate after the BMS has safety lit the main burner.
• The safety priority for a CCS is to prevent a fuel

rich air to fuel ratio.
• Most dryer explosions have been caused

problems with the CCS not the BMS.
CCS via valve
positioning
• Many dryers and TOs control the fuel air ratio
by controlling the position of the gas valve
and air valve with a ratio table.
• This method works but it has no way of

detecting changes in gas or air flows due to
equipment problems and can lead to a
dangerous fuel rich condition.
CCS with fuel/air cross
limiting
• Most modern combustion controls utilize a cross
limiting control scheme.
• Instead of merely positioning the gas valve and

air damper, this method measures gas & air flow
rates to prevent fuel rich mixtures.
• This results in a significant improvement in

combustion safety.
CCS with fuel/air cross
limiting
Cross limiting
challenges
• By far the most challenging part of implementing cross limiting
on an existing system is reliable air flow measurement.
• The combustion air blowers are often closely ducted to the

burner which severely reduces straight duct runs that are
optimal for accurate air flow measurement.
• Trident can provide suggestions and resources for air flow

measurement in less than optimal duct configurations.
Cross limiting additions
• The safety and efficiency of cross limiting can be enhanced
with:
– O2 trim that monitors exhaust oxygen and fine tunes the air fuel
ratio accordingly. This can allow you to run with lower excess O2
and realize energy savings. O2 sensors can also act as an
additional check to alarm in fuel rich conditions.
– Trident also adds additional features not typically found in cross

limiting schemes. Such as, valve output to flow characterization.
By telling the control system the position a valve should be at for
the other flow, failures in flow metering can be safely dealt with.
Cross limiting
installation
• Requires gas flow, air flow & O2 meters to be installed
and accurate prior to implementation.
• Can generally be implemented while the plant is

running. Flow to output characterization can generally
be calculated from history during start-up.
• Contact Trident for a quote for cross limiting

configuration for your plant.
Summary
• A full BMS upgrade (FlamePAC) or the first out only
solution(FlamePAC-FO) provides valuable tools to quickly
diagnose trips and minimize the time it takes to get your
combustion system up and running again.
• A full BMS upgrade offers additional reliability, simplicity, leak

testing, DCS interface and troubleshooting benefits.
• Fuel/Air cross limiting adds another significant layer of safety

in preventing dangerous fuel rich conditions.
Please stop by booth #94 to see simulations of these
systems on actual control hardware.
We would be happy to answer any

questions you might have.
THANK
YOU
Email
[email protected]
Phone 920.759.7477
Website
tridentautomation.com
Find us on
Facebook and LinkedIn

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What are some of the advantages and disadvantages of using a dedicated flame controller vs a safety PLC for burner management?

What are some of the advantages and disadvantages of using a dedicated flame controller vs a safety PLC for burner management?

What is fuel/air cross limiting and how does it improve combustion safety?

What is fuel/air cross limiting and how does it improve combustion safety?

Burner Management &

TA_ADMIN\Marketing\Presentations\2017\TEAM M3 BMS Combustion Control

Customized process control solutions for manufacturers

Experienced engineers in integrating control platforms in existing systems or creating

Transparent work in a collaborative environment with an open system design.

• It is a separate system from the DCS.

• Typical systems consist of two options:

• The FireEye E110 is less

• Built in flame scanner interface.

• Lack of visibility of which safety device caused the trip.

• Lack of ability to track trip history.

• Lack of ability to interface to the DCS.

• Lack of software to diagnose external and internal faults.

• More complex wiring.

• Trip devices 120VAC.

• Typically requires a external flame

• Accurate and easy to understand first outs.

• The state of each interlock is continuously displayed.

• Ability to sense abnormal conditions beyond code requirements.

• Maintenance only reset when faults are sensed in field instruments.

• It is based on a Rockwell or Siemens safety rated PLC.

• It provides all of the advantages of the Safety PLC.

• Typical cost is $24,000 per zone installed in groups of 3 zones.

• Continuous display of all interlocks.

• Trip counters for identifying the most problematic trips.

• FlamePAC FO costs approximately $17,000 per zone installed in groups of 3

• Utilize SIL 2 & 3 safety rated components.

• Are built in our UL rated panel shop.

• Tested on an actual burner at our facility.

• The safety priority for a CCS is to prevent a fuel

• Most dryer explosions have been caused

• This method works but it has no way of

• Instead of merely positioning the gas valve and

• This results in a significant improvement in

• The combustion air blowers are often closely ducted to the

• Trident can provide suggestions and resources for air flow

– Trident also adds additional features not typically found in cross

• Can generally be implemented while the plant is

• Contact Trident for a quote for cross limiting

• A full BMS upgrade offers additional reliability, simplicity, leak

• Fuel/Air cross limiting adds another significant layer of safety

We would be happy to answer any

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