elements of a successful burner management project
DESCRIPTION
BP's Kirk Adams and Emerson's David Shepard present at the 2011 Emerson Exchange in Nashville. A refinery SRU project replaced the BMS/combustion controls on two SCOT units, four Claus units, and two incinerators. The BMS platform was DeltaV SIS and the combustion controls was done in DeltaV. Many different factors led to a successful project. During the engineering phase, a standard state based approach simplified design for multiple types of equipment and made it easy to coordinate combustion controls with the BMS. Having an engineered approach to test the trips was also important. Special Bypass Functionality and AMS Quickcheck helped reduce startup time.TRANSCRIPT
Elements of a Successful Burner
Management Project
Elements of a Successful Burner
Management Project
PresentersPresenters
Kirk Adams
David Sheppard
IntroductionIntroduction
– Details of the SRU BMS Project– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing– Considerations for system requirements when the
unit is not running– Summary / Questions?
Successful Project Considerations
Design
Yearly Testing
Down Time
BP SRU ProjectBP SRU Project
Over 600 SIS IO Majority of the safety related scope centered on
replacement of the burner management systems on the eight fired equipment 4 Claus, 2 SCOT, and 2 incinerators
DeltaV System used as Process Controls System including Combustion Controls
New Remote Instrument Enclosure Asset Management System SRU Unit never goes into full Turnaround
– Details of the SRU BMS Project– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing– Considerations for system requirements when the unit is not
running– Summary / Questions?
Presentation:Presentation:
DeltaV SIS advanced function blocks simplify configurationDeltaV 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 StatesExample BMS States
S01
S02
S03S04
S06
Shutdown,
Not Ready
Shutdown,
& Ready
Pre-Purge In
progress
Purge Complete Ignite Pilot
Pilot only
Running
Ignite Main with
Pilot
Cold Start, Set Low
fire positionS09S10
S12
Main without pilot, not at TempMixed Gas
Mixed firing, set low
fire position
Waste Gas Only
Trips from States
5, 6, 7, 8, 9, 10, 12
Startup failure
S05
S07
S08
S13
3 Main Logic Part to a BMS System3 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 Burner-
Multi Fuel
with 13 states:
Outputs – Defined per StateOutputs – Defined per State Once the States are defined, the position of each Output (Valve,
igniter, etc) is defined in each state in a simple table
State Output Control
Output
Description
Description
Main natur
al gas
upstream block valve
Main natur
al gas
downstrea
m 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
downstrea
m block valve
Waste gas contr
ol valve solenoid 1
Waste gas contr
ol valve
solenoid 2
Oxygen to contr
ol valve
Oxygen to contr
ol valve
Oxygen to block valve
Nitrogen to
block valve (FO)
Pilot combustion air valve
Sour Water Gas Contr
ol Valve Solenoid
Pilot Ignite
r
Burner
Switch #1 Tunin
g Comman
d
Burner
Switch #2 Tunin
g Comman
d
Tag
XYXXX1-
1
XYXXX2-
2
FYXXXX-
3
FYXXXY-
3
FYXXXY-
4
FYXXXX-
4
XYXXX1-
5
XYXXX2-
6
FYXXXX-
7
FYXXXY-
7PXXXX-8
FYXXXX-
9
XXXXX-10
XYXXXX-
11
XYXXXX-
12
FYXXXX-
13
BYXXXX-
14
BXXXXX1-15
BXXXXX2-15
Notes 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
State Name StateD=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 S12 D D E E E E D D E E D D D D D D D D D Waste gas Only S13 D D E E E E D D E E E E E D D E D E E
StatesStates
OutputsOutputs
Outputs – Defined per StateOutputs – Defined per State
State Output Control
Output Description
Description
Main
natural gas upstream
block
valve
Main
natural gas downstream bloc
k valv
e
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 bloc
k valv
e
Waste
gas control
valve
solenoid
1
Waste
gas control
valve
solenoid
2
Oxygen to
control
valve
Oxygen to
control
valve
Oxygen to
block
valve
Nitrogen to bloc
k valv
e (FO)
Pilot combustion air
valve
Sour
Water
Gas Control Valv
e Solenoid
Pilot Igniter
Burner Switch #1
Tuning Command
Burner Switch #2
Tuning Command
Tag
XYXXXX1-1
XY206C2-2
FY2XXXX-3
FY205CY-3
FY212CY-4
FY212CX-4
XY202C1-5
XY202C2-6
FY215CX-7
FY215CY-7
PY237C-8
FY240C-9
XY250C-10
XY224C-11
XY203C-12
FY216C-13
BY217C-14
BX201C1-15
BX201C2-15
Notes 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
State Name StateD=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 S12 D D E E E E D D E E D D D D D D D D D
Waste gas Only S13 D D E E E E D D E E E E E D D E D E E
StatesStates
OutputsOutputs
OutputsOutputs
StatesStates
Trip Matrix / Appropriate MaskingTrip Matrix / Appropriate Masking Different Trip conditions are be masked in different states. Trips
Trip Input
Description
Description
1 - Loss of main flame signal
2 - Low Natural
Gas Pressur
e
3 - Hi Hi combustion air
pressure
4 - Low Total
Combustion Air Flow
5 - Hi Hi level in Waste gas KO drum
6 - Hi Hi thermal reactor tempera
ture
7 - Manual
ESD Button,
RIE
8 - Manual
ESD Button, Local
9 - Hi Hi level in hydroca
rbon drum 1
10 - Low level in
high pressure stream
drum
11 - Hi Hi level
in hydroca
rbon drum 2
12 - Hi Hi level
in hydroca
rbon drum 3
13 - Hi Hi level
in hydroca
rbon drum 4
14 - Loss of
pilot flame signal
15 - Trip on
Software
Shutdown
TagBSLXXX
1/2PT7XXX
/Y/ZPTXXX1
/2/3
FTXXX1/2/3
FTXXX1/2/3
LTXXXX/Y/Z
TTXXX TTXXXX
HS2XXX2
HSXXX3
LTXXX1/2/3
LTXXX1/2/3
LTXXX1/2/3
LTXXX1/2/3
LTXXX1/2/3 BSLXXX
HSXXXX
Notes
State "T" = Trip, "M"=Mask (no trip)S01 M T T M T T T T T T T T T M TS02 M M T M T T T T T T T T T M TS03 M M T M T T T T T T T T T M TS04 M M T M T T T T T T T T T M TS05 M M T M T T T T T T T T T M TS06 M T T M T T T T T T T T T T TS07 M T T M T T T T T T T T T T TS08 T T T T T T T T T T T T T T TS09 T T T T T T T T T T T T T M TS10 T T T T T T T T T T T T T M TS11 S12 T M T T T T T T T T T T T M TS13 T M T T T T T T T T T T T M T
This cause needs to be “masked” in this
state!
This cause needs to be “masked” in this
state!
This cause has to be able to trip in this
state.
This cause has to be able to trip in this
state.
Trips –Including Masking Based on StateTrips –Including Masking Based on State
Trips
Trip Input
Description
Description
1 - Loss of main flame signal
2 - Low Natural
Gas Pressur
e
3 - Hi Hi combusti
on air pressure
4 - Low Total
Combustion Air Flow
5 - Hi Hi level in Waste gas KO drum
6 - Hi Hi thermal reactor
temperature
7 - Manual
ESD Button,
RIE
8 - Manual
ESD Button, Local
9 - Hi Hi level in
hydrocarbon
drum 1
10 - Low level in
high pressure stream drum
11 - Hi Hi level
in hydrocar
bon drum 2
12 - Hi Hi level
in hydrocar
bon drum 3
13 - Hi Hi level
in hydrocar
bon drum 4
14 - Loss of
pilot flame signal
15 - Trip on
Software Shutdow
n
TagBSL201C1/C2
PT729X/Y/Z
PT217C1/2/3
FT205C1/2/3
FT212C1/2/3
LT211X/Y/Z
TT222C TT229C
HS210C2
HS210C3
LT105C1/2/3
LT203C1/2/3
LT625C1/2/3
LT625D1/2/3
LT105D1/2/3
BSL202C
HSXXXX
Notes
State "T" = Trip, "M"=Mask (no trip)S01 M T T M T T T T T T T T T M TS02 M M T M T T T T T T T T T M TS03 M M T M T T T T T T T T T M TS04 M M T M T T T T T T T T T M TS05 M M T M T T T T T T T T T M TS06 M T T M T T T T T T T T T T TS07 M T T M T T T T T T T T T T TS08 T T T T T T T T T T T T T T TS09 T T T T T T T T T T T T T M TS10 T T T T T T T T T T T T T M TS11 S12 T M T T T T T T T T T T T M TS13 T M T T T T T T T T T T T M T
StatesStates OutputsOutputs
This Cause is
“masked” in this
State!
This Cause is
“masked” in this
State!
– Details of the SRU BMS Project– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing– Considerations for system requirements when the unit is not
running– Summary / Questions?
Presentation:Presentation:
Interface with Combustion ControlsInterface with Combustion Controls Typical Systems use many flags or Bits.
1. Go To Min Fire 2. Open Valves for Purge
3. Set Valves to Ignite Pilot4. Set Valves to Ignite Main Burner5. Main Light, Release to Modulate
These items have to be Set / Reset / tested
Only One Parameter
was Required.
The State.
It Resets Itself.
– Details of the SRU BMS Project– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing– Considerations for system requirements when the unit is not
running– Summary / Questions?
Presentation:Presentation:
Projects Remember Customer NeedsProjects Remember Customer Needs
Project teams consider start-up time, but sometimes forget the yearly testing.
Operations is the final customer! Successful projects consider entire Life Cycle!
Used existing tools effectively to deliver a better result.
AMS and QuickcheckAMS and Quickcheck
Consistent / Complete / Repeatable TestingConsistent / Complete / Repeatable Testing
Ensure Each Step is Tested Ensure Each Step is Tested
Step 1 – Sets All Transmitters to Normal
Step 2 – FT101 Vote to Trip
Step 3 – FT101 & FT102 Vote to Trip
Step 4 – Resets All Transmitters to Normal
Step 5-7 – Tests FT102 & FT103
Step 8 – Tests FT101 Over-range
Step 9 – Tests FT101 Under-range
Step 10-16 – Tests other Transmitters
Testing Considerations – Loss of FlameTesting Considerations – Loss of Flame
SIF Test Button
Bypasses every Trip
Test team simulates good
condition on transmitters using
AMS
Skips Purge and Ignite Steps
Bypass is removed on Test
Transmitters
Trips GraphicTrips Graphic
Bypass ConsiderationsBypass Considerations
– Details of the SRU BMS Project– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing– Considerations for system requirements when the unit is not
running– Summary / Questions?
Presentation:Presentation:
Allow Stroking of any BMS Valve during Down TimeAllow Stroking of any BMS Valve during Down Time
– Details of the SRU BMS Project– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing– Considerations for system requirements when the unit is not
running– Summary / Questions?
Presentation:Presentation:
Summary / ResultsSummary / Results
Utilized Advance Function Blocks in a State Transition Diagram approach
Simplified Interface with Combustion Controls
Consideration for Yearly Testing using AMS and Quickcheck
Consideration for stroking Valves during Turn-around
The approach can also be used for other applications in Safety Logic Solvers or DeltaV Controllers
Successful Startup Testing of all Trips was done very
quickly and systematically
