13 July 2014 PMI Revision 00 1

Dear Participants
WELCOME
To a discussion on
FSSS/ Boiler Protection System
Basic Concepts
and
Standards
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CONTENT
Basic concept
Function of BMS
Furnace purge procedure
STANDARDS / NFPA




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Main Functions



Furnace purge before boiler light-up
Oil firing: Permissives, Sequences and Protections
Coal firing: Permissives, Sequences and Protections
Master Fuel Trip (MFT) or Boiler Trip
Post-Trip Purge Fans Trip
Runback: Graded Mill Tripping
Runback: Graded Mill Tripping
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SG (Steam Generator)
CONTROLS
BACK
BURNER
MANAGEMENT
SYSTEM

BOILER
PROTECTIONS

MILLING
SYSTEM

FUEL OIL
SYSTEM

UNIT PURGE
SEC. AIR DAMPER
CONTROL


SOOT BLOWER
CONTROL


AUX. PRDS
CONTROL


HP-BYPASS
CONTROL


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Some Definitions



Boiler Control System:
Deals with Regulating Control
Burner Management System (BMS):
Deals with Furnace Safety and Start/Stop of Fuel
Preparation and Burning Equipment
BMS Logic:
Deals with Control System which would give
output based on external inputs and internal logic
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Burner management system
Burner management system is
designed to ensure the execution
of a safe ,orderly operating
sequence in the startup and
shutdown of fuel firing
equipments and to prevent errors
of omission safe operating
procedure.
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Function of BMS
TO PROVIDE SAFETY TO BOILER.
TO PROVIDE ORDERLY SEQUENCE IN
THE S/U & S/D OF FUEL FIRING EQUIPMENTS.
PREVENT S/U OF FUEL FIRING EQUIPMENTS
UNLESS CERTAIN PERMISSIVE INTERLOCKS
HAVE BEEN SATISFIED.
CONTINUOUS FLAME MONITORING.
FAULT DETECTION AND ASSOCIATE S/D.
INITIATE MFT UNDER CERTAIN CONDITION OF
LOAD COMBINATION.
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Basic Concepts of BMS
BMS is an independent and discreet logic system
specially designed for safety and protection during
starting , shutdown, low load and emergency
conditions.
BMS system has been designed to provide increased
safety, reliability, flexibility and over all performance of
the boiler.
The system is intended to protect against malfunction
of fuel firing equipment and associated systems.
In some phases of operation, the BMS shall provide
permissive interlocks only to ensure safe startup of
equipment.
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The Burner Management system monitors the presence
or absence of the forced draft fan running and verifies air
flow is being produced, ensures the water level in the
boiler drum is satisfactory, and verifies that there is at
least one flame in the furnace.
The Burner Management alarm system provides for a
first out cause of trip allowing operators to readily
identify the reason for an unexpected boiler trip
condition.
The Burner Management System controls the air
registers, igniters and fuel oil valves for each burner, as
well as monitoring of the flame signals for each burner in
service.


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If the flame quality degrades to 60% of maximum signal
strength a poor flame alarm is issued to the alarm
system. When a flame quality signal is below 40% for 4
seconds the burner will trip.
The Burner Management System lights off the initial
burner and cuts out burners automatically based on an
operator selected sequence.
It determines when burners need to be cutout based on
the steam pressure signal from the ACC (Automatic
Combustion Control) system.
It also provides an interface to the ACC system to tell it
when there is a state of change that can affect how the
ACC will respond or perform.
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Function of BMS
Controls boiler purge, fuel headers, and burner field devices,
allowing sequential control of the start-up and shutdown of any
burners.
Continuous monitoring of supervisory interlocks, fuel valve positions,
flame status and field devices.
The control strategy normally utilize de energize to trip method.
Smart alarms provide fail to open, fail to start, fail to close, and
fail to stop information.
Flame monitoring equipment provides the logic controller with flame
status of burners and/or igniters.
Prevent firing unless a satisfactory furnace purge has first been
completed.


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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 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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SIMPLIFIED BLOCK DIAGRAM OF
BURNER MANAGEMENT SYSTEM.
LOCAL
CONTROL
BOX AIR
DAMPER
B
M
S
FUEL
V/V
FLAME
DETECTOR
IGNITER
ABC
DAS
MILL
CONTROL
C.C.R
BOILER
PLANT
IGNITION
CONTROL
PANEL

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BURNER GROUP-EACH STEAM GENERATOR HAS FOUR BURNER
GROUPS.EACH GROUP COMPRISES FOUR OIL BURNER WITH
ASSOCIATE PF BURNER LOCATED ABOVE AND BELOW.

MILL GROUP- THERE ARE EIGHT MILL GROUPS PER STEAM
GENERATOR EACH GROUP COMPRISES A MILL ,ITS ASSOCIATED
COAL FEEDER AND A SEAL AIR FAN.

AIR DAMPER-
AIR DAMPER ARE DIVIDED AS FOLLOWS-
1-FIVE ELEVATION OF FOUR SECONDARY AIR.
2- 4 ELEVATION OF 4 AIR TO OIL/S.A.D
3-8 ELEVATION OF 4 AIR TO P.F. BURNER.
4-TWO ELEVATION OF FOUR OVERFIRE AIR.


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RELATIONSHIP OF MILL GROUP,
ELEVATION NUMBERS & GROUP
NUMBERS.
BURNER NOZZLE NOZZLE MILL GROUP
GROUP ELEVATION TYPE GROUP
NUMBER NUMBER
4 13---------------------------SECONDARY AIR
12---------------------------COAL--------------------------- -F
11---------------------------OIL AND S/A
3 10 --------------------------COAL-----------------------------E
9 --------------------------SECONDARY AIR
8---------------------------COAL------------------------------D
2 7-------------------------- OIL AND S/A
6---------------------------COAL------------------------------C
5---------------------------SECONDARY AIR
4---------------------------COAL------------------------------B
1 3---------------------------OIL AND S/A
2---------------------------COAL------------------------------A
1-------------------------- SECONDARY AIR
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STANDARDS AND CODES

Prescriptive standards such as NFPA have done well at
identifying what interlocks should be implemented based
upon lessons learned from previous incidents and near
misses.
In todays microprocessor-based world, it is more important
to know how to properly implement the prescriptive based
interlocks.
The logic solver was comprised of relays with simple and
well-defined failure modes, it was very easy to understand
what level of risk reduction the BMS provided.

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NFPA
Burner Management Systems (BMS) associated with fired
devices in the power boilers are defined as Safety
Instrumented Systems (SIS) if they contain sensors, a logic
solver and a final control element according to NFPA.
By actively embracing the concept that a BMS may in fact
be a SIS, companies can ensure that these systems are
designed, maintained, inspected and tested per both the
applicable prescriptive standards (API, NFPA, etc.).
A BMS can be designed that meets all requirements of the
prescriptive standards such as NFPA.
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Standard Followed
National Fire Protection Authority (NFPA) of USA

Code 85 of 2001

This code is an amalgamation of earlier codes 8501 to
8506 applicable for various types of boilers and
combustion
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IBR Requirements
Fuel supply should be shut off when:
Flame failure occurs
Failure to ignite fuel within a pre-determined
time
Abnormal drum level
Trip of Draft fans
Increase in Boiler Pressure

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BMS Logic Hardware
No specific stipulation regarding type of
hardware
NFPA stipulations are not retroactive
Existing system if giving trouble free operation
can continue to work even if not PLC/DCS
based
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Some Requirements of
NFPA
Burner Management System (BMS) Logic shall:
be such that single failure does not prevent shutdown
evaluate and address failure of components
diagnose improper logic functions
have a direct operable device for MFT which would work
irrespective of BMS logic
be protected from unauthorised logic changes
be provided with independent logic, I/O, power supply
and hardware etc for each boiler separately
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Interesting Insights to
NFPA
NFPA recognises that:
It is not possible to encompass all specific
hardware applications
The code should not be considered a cook
book
No standard can guarantee elimination of
Furnace explosion or implosion
Basic cause of Furnace Explosion is ignition of
accumulated combustibles in the furnace
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