Your SlideShare is downloading. ×
Elements of a Successful Burner Management Project
Upcoming SlideShare
Loading in...5
×

Thanks for flagging this SlideShare!

Oops! An error has occurred.

×

Introducing the official SlideShare app

Stunning, full-screen experience for iPhone and Android

Text the download link to your phone

Standard text messaging rates apply

Elements of a Successful Burner Management Project

497
views

Published on

BP's Kirk Adams and Emerson's David Shepard present at the 2011 Emerson Exchange in Nashville. …

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.

Published in: Education, Business, Technology

0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total Views
497
On Slideshare
0
From Embeds
0
Number of Embeds
1
Actions
Shares
0
Downloads
51
Comments
0
Likes
0
Embeds 0
No embeds

Report content
Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
No notes for slide

Transcript

  • 1. Elements of a Successful BurnerManagement Project
  • 2. Presenters  Kirk Adams  David Sheppard
  • 3. Introduction – 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?
  • 4. Successful Project Considerations Design Yearly Testing Down Time
  • 5. BP 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
  • 6. Presentation: – 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?
  • 7. DeltaV SIS advanced function blockssimplify 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.
  • 8. Example BMS States S03Shutdown, S04 S02Not Ready Pre-Purge In Ignite Pilot Shutdown, progress Purge Complete S01 & Ready S05 Startup failure Pilot only S06 Running Trips from States 5, 6, 7, 8, 9, 10, 12 Mixed firing, set low fire position S12 S07 S13 Cold Start, Set Waste Gas Only S08 Low fire position S10 S09 Ignite Main with Mixed Gas Main without pilot, not at Pilot Temp
  • 9. 3 Main Logic Part to a BMS SystemIn 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 StateOnce these are defined, the DeltaV SIS logic can be programmed inAn easy to follow manner.The followingExample is aSingle Burner-Multi Fuelwith 13 states:
  • 10. Outputs – 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 Nitrogen to block valve XXXXX-10 Oxygen to block valve Pilot gas downstream Main natural valve Main combustion air Main combustion air Trim combustion air Trim combustion air Pilot combustion air Pilot gas upstream downstream block Waste gas control Waste gas control Tuning Command Tuning Command Oxygen to control Oxygen to control valve solenoid #1 valve solenoid #2 Burner Switch #1 Burner Switch #2 valve solenoid 2 Main natural gas upstream blockgas valve solenoid 1 Sour Water Gas Control Valve Description solenoid #1 solenoid #2 Pilot Igniter block valve block valve Solenoid valve valve valve valve (FO) Outputs State Output Control Output Description XYXXXX-11 XYXXXX-12 BYXXXX-14 FYXXXX-13 BXXXXX1- BXXXXX2- FYXXXX-3 FYXXXY-3 FYXXXY-4 FYXXXX-4 FYXXXX-7 FYXXXY-7 FYXXXX-9 XYXXX1-1 XYXXX2-2 XYXXX1-5 XYXXX2-6 PXXXX-8 Tag 15 15 Notes States 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation, XX=Set the State Name State 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
  • 11. Not Used Ignite Pilot Mixed Gas State Name States Waste gas Only Purge Complete Pilot Only Running Shutdown & Ready Ignite main with pilot Shutdown, Not Ready Pre Purge in Progress Outputs State Output Control Main NG w/o Pilot, not at temp Cold start, set low fire positions Mixed firing, set low fire positions Output Description S13 S12 S10 S09 S08 S07 S06 S05 S04 S03 S02 S11 S01 Notes Tag Description Main natural gas E E E D D D D D D D D D 1 XYXXXX1-1 Main natural valve upstream blockgas downstream block E E E D D D D D D D D D 1 XY206C2-2 valve Main combustion air E E E D D D D D D D D D 1 FY2XXXX-3 valve solenoid #1 Main combustion air E E E D D D D D D D D D 1 FY205CY-3 valve solenoid #2 Trim combustion air E E E E E E D D D D D D 1 FY212CY-4 solenoid #1 Trim combustion air E E E E E E D D D D D D State XX=Set the output % open 1 FY212CX-4 solenoid #2 Pilot gas upstream E E E E D D D D D D D D 1 XY202C1-5 block valve Pilot gas downstream E E E E D D D D D D D D 1 XY202C2-6 block valve Waste gas control E E E D D D D D D D D D 1 FY215CX-7 valve solenoid 1 Waste gas control E E E D D D D D D D D D 1 FY215CY-7 valve solenoid 2 Oxygen to control E D D D D D D D D D D D 1 PY237C-8 valve Oxygen to control E D D D D D D D D D D D 1 FY240C-9 valve E D D D D D D D D D D D 1 XY250C-10 Oxygen to block valve Nitrogen to block valve E E E E E E E D D D D D 1 XY224C-11 (FO) Pilot combustion air E E E E D D D D D D D D 1 XY203C-12 valve Outputs – Defined per State E Sour Water Gas D D D D D D D D D D D 1 FY216C-13 Control Valve Solenoid E D D D D D D D D D D DStates 1 BY217C-14 Pilot Igniter Burner Switch #1 E D D D D D D D D D D D 1 BX201C1-15 Tuning Command Burner Switch #2 E D D D D D D D D D D D 1 BX201C2-15 Tuning Command D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation, Outputs
  • 12.  Trip Input Description TripsS11S13S12S10S09S08S07S06S05S04S03S02S01State Notes Tag Description 1 - Loss ofTT T T T M M M M M M M main flame BSLXXX1/2 signal 2 - Low T T T T T TMM M M M M Natural Gas PT7XXX/Y/Z Pressure 3 - Hi Hi T T T T T T T T T T T T combustion air PTXXX1/2/3 pressure 4 - Low Total T T T T T M M M M M M M FTXXX1/2/3 Combustion FTXXX1/2/3 Air Flow 5 - Hi Hi level T T T T T T T T T T T T in Waste gas LTXXXX/Y/Z KO Hi Hi 6 - drum thermal this state! T T T T T T T T T T T T TTXXX reactor TTXXXX temperature 7 - Manual T T T T T T T T T T T T ESD Button, HS2XXX2 RIE 8 - Manual TThis cause needs to be “masked” in T T T T T T T T T T T ESD Button, HSXXX3 Local 9 - Hi Hi level inT T T T T T T T T T T hydrocarbon LTXXX1/2/3 10 -drum 1 Low level in high TT ThisT T T T T T T T T T T pressure "T" = Trip, "M"=Mask (no trip) stream drum LTXXX1/2/3 11 - Hi Hi level in T T T T T T T T T T T hydrocarbon LTXXX1/2/3 12 -drum 2 Hi Hi level in Trip Matrix / Appropriate Masking T T T T T T T T T T T T hydrocarbon LTXXX1/2/3 13 -drum 3 Hi Hi level in this state. T T T T T T T T T T T T hydrocarbon LTXXX1/2/3 drum 4 14 - Loss of T T T M M M M M M M M M pilot flame BSLXXX signal 15 - Trip on Different Trip conditions are be masked in different states. T causeThas to be able to trip in T T T T T T T T T T T Software HSXXXX Shutdown
  • 13. Trip Input Description TripsS11S13S12S10S09S08S07S06S05S04S03S02S01State Notes Tag DescriptionTT T T T M M M M M M M 1 - Loss of main BSL201C1/C2 flame signal T T T T T TMM M M M M 2 - Low Natural PT729X/Y/Z Gas Pressure 3 - Hi HiTT T T T T T T T T T T combustion air PT217C1/2/3 pressure 4 - Low TotalTT T T T M M M M M M M FT205C1/2/3 Combustion Air FT212C1/2/3 Flow 5 - Hi Hi level inTT T T T T T T T T T T Waste gas KO LT211X/Y/Z drum 6 - Hi Hi thermalTT T T T T T T T T T T TT222C reactor TT229C temperatureTT T T T T T T T T T T 7 - Manual ESD HS210C2 Button, RIETT T T T T T T T T T T 8 - Manual ESD HS210C3 Button, Local 9 - Hi Hi level inStatesTT T T T T T T T T T T hydrocarbon LT105C1/2/3 drum 1 10 - Low level inTT T T T T T T T T T T high pressure "T" = Trip, "M"=Mask (no trip) LT203C1/2/3 stream drum 11 - Hi Hi level in State!TT T T T T T T T T T T hydrocarbon LT625C1/2/3 drum 2 This Cause is “masked” in this 12 - Hi Hi level inTT T T T T T T T T T T hydrocarbon LT625D1/2/3 drum 3 13 - Hi Hi level inTT T T T T T T T T T T hydrocarbon LT105D1/2/3 drum 4Outputs T T TMM M M M M M M M 14 - Loss of pilot BSL202C flame signal 15 - Trip onTT T T T T T T T T T T Software HSXXXX Shutdown Trips –Including Masking Based on State
  • 14. Presentation: – 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?
  • 15. Interface with Combustion Controls Typical Systems use many flags or Bits. 1. Go To Min Fire  Only One Parameter 2. Open Valves for Purge was Required. 3. Set Valves to Ignite Pilot The State. 4. Set Valves to Ignite Main Burner 5. Main Light, Release to Modulate  It Resets Itself. These items have to be Set / Reset / tested
  • 16. Presentation: – 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?
  • 17. Projects 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.
  • 18. AMS and Quickcheck
  • 19. Consistent / Complete / RepeatableTesting
  • 20. 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
  • 21. Testing Considerations – Loss of Flame
  • 22. Trips Graphic
  • 23. Bypass Considerations
  • 24. Presentation: – 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?
  • 25. Allow Stroking of any BMS Valve duringDown Time
  • 26. Presentation: – 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?
  • 27. Summary / 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
  • 28. Thank you… …any Questions?David.Sheppard@Emerson.comWWW.EasyDeltaV.Com