This document discusses burner management systems (BMS), including their objectives, design standards, logic, types, and interface with SCADA systems. A BMS is defined as a control system dedicated to boiler safety during startup, operation, and shutdown. The document outlines BMS logic including purge, igniter, and main flame interlocks. It describes early hardwired and solid state systems, as well as modern microprocessor-based and PLC-based BMS. PLC systems offer flexibility, redundancy, and integration with SCADA. In summary, the document provides an overview of BMS design, functionality, and system types.

1. Preferred Utilities Manufacturing Corp.
Burner
Management Systems
A Technical Discussion

2. Preferred Utilities Manufacturing Corp.
 Introduction
 Burner Management System Objectives
 BMS Design Standards and Definitions
 BMS Logic
 BMS Strategies and Hardware
 Types of Burner Management Systems
 BMS Interface to SCADA Systems
 Summary

3. Introduction
..a starting point.
Burner Management
Systems..

4. Introduction
What is a BMS?
 A Burner Management System is defined as
the following:
 A Control System that is dedicated to boiler
safety, operator assistance in the starting and
stopping of fuel preparation and burning
equipment, and the prevention of mis-operation
of and damage to fuel preparation and fuel
burning equipment. 1
1. From NFPA 8501 “Standard for Single Burner Boiler Operation”

5. Burner Management Objectives
 Sequence burner through safe start-up
 Insure a complete pre-purge of boiler
 Supervise safety limits during operation
 Supervise the flame presence during
operation
 Sequence a safe shutdown at end of cycle
 Integrate with combustion control system
for proper fuel and air flows

6. 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
 National Fire Protection Association (NFPA 8501
/8502 or others)
 Industrial Risk Insurers (IRI)
 Factory Mutual loss prevention guidelines
 Each burner management system should be
designed to accomplish a safety shutdown in the
event of an unsafe condition. (FAIL SAFE)

7. BMS Design Standards
 U.S. National Fire Protection Association
(NFPA)
 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
 Factory Mutual loss prevention guidelines.

8. NFPA 8501
 NFPA 8501 Standard for Single Burner
Boiler Operation
 Single Burner Boilers with fuel input greater than 12.5
mBTU/Hr (Approx. 250 BHP)
 Single Fuel or Combination of Fuels (Common being
Natural Gas / No.2 Oil / No. 6 Oil)
 Simultaneous Firing

9. NFPA 8502
 NFPA 8502 Standard for Prevention of
Furnace Explosions / Implosions in Multiple
Burner Boilers
 Multiple Burner Boilers with fuel input greater than
12.5 mBTU/Hr
 Single Fuel or Combination of Fuels including
Pulverized Coal
 Emphasis on implosion protection (larger boilers with
induced draft systems)

10. 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 stack”1
 Magnitude and intensity of explosion depends on
relative quantity of combustibles and the proportion of
air at the time of ignition
1. From NFPA 8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers”

11. BMS Definitions
 Furnace Explosions can occur with any or a
combination of the following:1
 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
1. From NFPA 8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers”

12. BMS Definitions
 Furnace Implosions
 More common in large Utility Boilers
 Caused by any of the following:
» Malfunction of equipment regulating boiler gas flow
resulting in furnace exposure to excessive induced
draft fan head capability
» Rapid decay for furnace gas temperature and
pressure due to furnace trip
1. From NFPA 8502 “Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers”

13. BMS Basic Definitions
 Common Terminology
 Supervised Manual
» Manual Burner Lightoff with Interlocks
 Automatic Recycling (Single Burner Only)
» Automatic Burner Start and Stop based on preset
operating range (ie.. Drum pressure)
 Automatic Non Recycling (Single Burner Only)
» Automatic Burner Start and Stop based on Manual
command to start.

14. Types of Flame Scanners
 Infrared (IR) Detectors
 Single Burner Applications
 More Suitable with Oil Burning Flames
 Ultra-Violet (UV) Detectors
 Multiple Burner Applications
 More Suitable for Gas Burners and
Combination Gas / Oil Burners
 Self Check Scanners
 Flame Signal is interrupted at set intervals to
verify proper operation of scanner

15. Single Burner BMS Inputs
OIL
GAS
STEAM
FEEDW ATER
PSL
TSL
TSH
PSL
High Steam Pressure (D)
Low Low Drum Level (D)
PSL PSH
PSL
ATOMIZING
MEDIUM
Fuel
Gas
Press
Low
(D)
Fuel
Gas
Press
High
(D)
FT
FT
Atomizing
Medium
Press Low (D)
Fuel Oil Flow (A)
Fuel Oil Temp High (D)
Fuel Oil Temp Low (D)
Atomizing Medium Flow > Min (D)
Fuel Oil Press Low (D)
PSH
PSL
FT
PSH
PT
LSLL
LSLL
Purge Purge Air Flow (D)
Minimum Air Flow (D)
AE TE
(D) - Descrete Signal Used ByFlame Safeguard System
Common Alarm Output (D)
Remote Annunciator
(ByOthers)
SafetyShut Off &
Vent Valves
Control Valve &
Shut Off Valve
SafetyShut Off
Valves
Control
Valve
Control
Valve
SafetyShut Off
& Vent Valves
IGNITER
GAS
Flame / No Flame (D)
FS
FD FAN
HAND O FF AUTO
Li mi t s M ade
H
ol d t o Purge
S C R L M O D E
R E S E T
FUEL SELECT
G AS O I L
BURNER
O FF O N

16. BMS Logic
 Burner Management Systems can be broken
down into “Interlock Groups”
 Typical BMS Interlock Groups:
 Boiler Purge
 Igniter Header Valve Management
 Main Fuel Header Valve Management
 MFT (Master Fuel Trip) Logic

17. Purge Interlocks
BOILER TRIPPED
AND PURGE / RESET PB
START FD FAN
AND
PERMISSIVES SATISFIED:
- MAIN FUEL VALVES CLOSED
- NO FLAME PRESENT
- FD FAN RUNNING
- MINIMUM AIR FLOW SWITCH MADE
- WATER LEVEL SATISFACTORY
- ATOMIZING MEDIUM ON
- FUEL SUPPLY PRESSURE NOT LOW
ENERGIZE FUEL RELAY
PURGE SIGNAL TO CCS
NOT AND
START-UP
TIMER
AND
PURGE AIR
FLOW SWITCH
MADE
FD DAMPER IN
FULL OPEN
POSITION
PURGE TIMER SET
PURGE COMPLETE
REMOVE PURGE TO CCS SYSTEM TRIP
YES
NO

18. Igniter Interlocks
AND
ENERGIZE IGNITER AND
IGNITER HEADER VALVES
NOT
SYSTEM TRIP
PURGE COMPLETE
AIR DAMPER IN LOW FIRE
POSITION
FUEL VALVE IN LOW FIRE
POSITION
10 SECOND DELAY
FLAME
PROVEN
10 SEC PILOT TRIAL
FOR IGNITION
TIMER COMPLETE
AND
PERMIT FOR MAIN
FLAME

19. Main Flame Interlocks
AND
NOT
SYSTEM TRIP
IGNITER TIMER
COMPLETE
FLAME
PROVEN
10 SEC MAIN FLAME
TRIAL
TIMER COMPLETE
AND
RELEASE TO
MODULATE TO CCS
ENERGIZE MAIN
FUEL VALVES
DE-ENERGIZE
IGNITION
COMPONENTS

20. Single Burner Main Fuel Trip
FOR OIL:
- LOWFUELPRESSURE
-LOWTEM
PERATURE(HEATEDOILS)
-LOSSOFCOM
BUSTIONAIR
-LOSSOFFLAMEORFAILTOESTABLISH
-LOSSOFCONTROLSYSTEMENERGY
- POWERFAILURE
- LOWWATERLEVEL(AUXLEVELCONTACT)
- LOSSOFATOM
IZINGM
EDIUM
- EXCESSIVESTEAMDRUMPRESSURE
- HIGHOILTEM
PERATURE(HEATEDOILS)
TRIP BOILER
FOR GAS:
- LOWFUELGASPRESSURE
- HIGHGASPRESSURE
-LOSSOFCOM
BUSTIONAIR
-LOSSOFFLAMEORFAILTOESTABLISH
-LOSSOFCONTROLSYSTEMENERGY
- POWERFAILURE
- LOWWATERLEVEL(AUXLEVELCONTACT)
- EXCESSIVESTEAMDRUMPRESSURE
OR
OR
TRIP IGNITER,
IGNITER VALVES,
OPEN IGNITER
VENT
TRIP MAIN FUEL
VALVES, OPEN
VENT VALVE
(GAS ONLY)
FUEL CONTROL
VALVE TO
CLOSED
POSITION
TRIP MFT RELAY

21. BMS System Types
 Early Burner Management Systems
 Hardwired Systems
 Solid State Systems
 Microprocessor Based Systems
 Fireye E110 / Honeywell 7800 series with fixed
Logic.
 PLC Based Systems
 Programmable Logic Controller (PLC) Based
 Powerful, versatile, expandable, more reliable.

22. Early Burner Management Systems
 Hardwired Systems
 Relay and Timer Driven. Found on older
installations
 Typical of Late 50’s, 60’s
 Solid State Systems
 Solid State Processors and Relays
 Found on Systems provided in the 70’s and 80’s
 Proprietary Hardware (ie.. Forney and Peabody)
 Spare Parts are extremely hard to find.

23. MicroProcessor Based Systems
 Microprocessor Based System providing:
 Burner Sequencing
 Ignition
 Flame Monitoring
 Fixed Program with Limited Configuration
Changes
 Components Selected Based on Requirements
 Programmers, Flame Amplifiers, Message Displays

24. FLAME
SCANNER
FIELD WIRING
Fireye™ BMS Layout
AUTOMATIC PRIMARY SAFETY CONTROL
AMPLIFIER
EP PROGRAMMER
FIELD WIRING

25. MicroProcessor Capabilities
 Simple, Cost Effective
 Features
 Selectable Flame Amplifiers / Scanners
 Remote Display
 Remote Data Communications via Modbus Port
 Modernization kits are available to integrate with older
systems
 Spare Parts Normally Readily Available

26. When These Systems are Used
 “Simple” Boiler Installations
 Packaged Firetube / Watertube Boilers (Steam /
Hot Water)
 Single Burner
 One Fuel at a Time
 No Flue Gas Re-Circulation
 Upgrades from Previous MicroProcessor Based
Systems

27. PLC Based Burner Management Systems
 PLC Based Features
 NFPA 8501, 8502
 Watchdog timer
 UL 508 Certification
 Redundant Scanners
 Logic+ Message Center
 Shows program status
 Displays alarms
 Prompts operator

28.  Each PLC based burner management system should
incorporate a number of design techniques which
help detect and act upon unsafe failure modes which
can occur in any microprocessor based system.
These design features include the following:
 Critical Input Checking
 Critical output channel monitoring
 Electro-mechanical Master Fuel Trip (MFT) Relay
 Redundant Watchdog Timers
 Low Water Cut-out Monitoring During Blow Down
PLC System Basic Design Features

29. PLC Based System Capabilities
 Provision for Multiple Fuel Firing
 Capped gas input during curtailment
 Changeover from gas to oil at any load
 Simultaneous firing of waste and fossil fuels
 Redundant Scanners, change scanner with fuel
 Single or Multiple Burner Applications
 Integration of BMS with SCADA

30. PLC Based Operator Interfaces
 Features
 Clear Written Messages to indicate status, required
operator interaction, trip/alarm indication
 High Visibility through two lines of display
 Messages reduce time consuming troubleshooting
 Prioritizes Messages
» First Out Alarms
» Warning / Alarm Messages
» Status Messages / Prompts Operator

31. PLC System Layout (Typical)
Logic+ Message
Display
SWITCH SILENCE LIGHT
Door Mounted Lights / Pushbuttons
FLAME AMPLIFIER
(SINGLE /
REDUNDANT)
FIELD DEVICES
PLC CPU I/O I/O I/O I/O
I/O EXPANSION I/O
COMBUSTION
CONTROL SYSTEM

32. Benefits of PLC Based Systems
 Flexibility / Reliability
 Programming Software allows changes to
system
 Choice of PLCs
 GE / Modicon / Allen Bradley / Koyo
 Choice of Flame Scanners
 PPC / Fireye / Honeywell / Iris / Coen
 Application Specific
 Quantity of Burners / Fuels is not restricted

33. When to Use PLC Based Systems
 “Complex” Boiler Installations
 Larger Packaged Units / Field Erected Units
 Multiple Burners
 Multiple Fuels, On-line Fuel Changeovers
 Flue Gas Re-Circulation
 Replace Existing Relay Logic Systems
 Requirement to maintain consistent control
platform (spare parts, etc..)

34. BMS SCADA Interface
 BMS Systems can be integrated into a
SCADA System
 Allows Remote Monitoring of Flame Status
 Allows Remote Control of BMS
 Events (ie.. Burner trip) can be routed to
Historical Portion of SCADA for fault
evaluation
 Burner Operation can be trended over time

35. BMS SCADA Interface
 Interface Methods:
PLC CPU I/O I/O I/O I/O
Communication
Interface
(If Necessary)
MODBUS
COMMUNICATION
PROTOCOL
MODBUS
COMMUNICATION
PROTOCOL
BMS LOGIC+ SYSTEM
SCADA PC
FIREYE E110 SYSTEM

36. BMS SCADA Interface

37. Summary
 Benefits Associated with New Burner
Management Systems
 Help Improve plant safety
 Help qualify for reduced insurance cost
 Reduce Startup and Down Time with
comprehensive alarming and diagnostics

38. Summary
Review of Topics Discussed
 Objectives of Burner Management Systems
 BMS Design Considerations
 Basic BMS Logic
 Types of Burner Management Systems
 How BMS Systems can be integrated with
Plant Wide SCADA Systems

39. Preferred Utilities Manufacturing Corp
For further information, contact...
Preferred Utilities Manufacturing Corporation
31-35 South St. • Danbury • CT
T: (203) 743-6741 • F: (203) 798-7313
www.preferred-mfg.com