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Introduction
The following paragraphs outline a general method for implementing a typical boiler Burner
Management System (BMS). Several general guidelines to implement operation strategies for such a system
are also provided.
This document is intended for use by the control systems designer as a guide for basic design. Final
and detailed BMS design is required per the applicable design specifications. This narrative contains
provisions required for compliance with the NFPA 8501 Standard for Single Burner Operation. The control
systems designer is responsible for compliance with this standard, and all other applicable federal, state and
local standards and regulations.
General
The Burner Management System must be designed to ensure a safe, orderly operating sequence in the
start-up and shutdown of fuel firing equipment and to reduce possible errors by following the operating
procedure.
The system is intended to protect against malfunction of fuel firing equipment and associated
systems. The safety features of the system shall be designed to provide protection in most common
emergency situations, however, the system cannot replace an intelligent operators reasonable judgment in all
situations.
In some phases of operation, the BMS shall provide permissive interlocks only to insure safe startup of
equipment. Once the equipment is in service, the operator must follow acceptable safe operating practices.
It is essential that all parts of the BMS are in good working order and in service whenever the burner
is in service if the system is to provide the protection for which it is designed. Regular maintenance and
inspection of the system and its associated hardware is essential for its continued safe operation.
This narrative gives a description of a typical BMS as it relates to the various operating phases and the
operation of the fuel firing equipment and associated systems.
BMS Functions
The BMS shall be designed to perform the following functions:
1.
Prevent firing unless a satisfactory furnace purge has first been completed.
2.
Prohibit start-up of the equipment unless certain permissive interlocks have first been
completed.
3. Monitor and control the correct component sequencing during start-up and shut-down of the
equipment.
4.
Conditionally allow the continued operation of the equipment only while certain safety
interlocks remaining satisfied.
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5.
Provide component condition feedback to the operator and, if so equipped, to the plant control
systems and/or data loggers.
6.
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.
7.
Execute a MFT upon certain adverse unit operating conditions.
Operation
Per NFPA 8501, section 2-1.3(b), a common cause of furnace explosions is Fuel leakage into an idle
furnace and the ignition of the accumulation by a spark or other source of ignition. Proper attention to the
design of the interlocks and trip system to provide a safe light up of the boiler furnace is required.
Furnace Purge
Before any fuel firing is permitted, either initially or after a boiler trip, a satisfactory furnace purge
cycle must be completed. Prior to starting a furnace purge cycle, the operator must ensure that the following
purge requirements are satisfied[i]:
1.
Drum level within operating range (not high, not low)
2.
Instrument air header pressure within operating range
3.
Fan is in service
4.
Purge airflow capable of a minimum of 70% of the full load airflow established through the
unit[ii].
5.
All flame scanners reading "No Flame"
6.
Natural gas block valves are proven closed
7.
Fuel oil block valves are proven closed
8.
Air dampers are in the fully open position
9.
Natural gas, or fuel oil, header pressure upstream of block valve is satisfactory
10. Pilot gas header pressure is satisfactory
11. Burner Control System is energized
12. A "No Master Fuel Trip condition" condition is established
As each of the above conditions is reached, their respective indicator lights[iii] shall illuminate as
"PURGE PERMISSIVES" on the operator control console.
Once all of the above conditions are satisfied, the "PURGE AVAILABLE" light shall illuminate
indicating that the START PURGE switch is enabled by the system logic. Activating the START PURGE
control, when the "PURGE AVAILABLE" light is illuminated, will begin a timed furnace purge cycle as
indicated by a "PURGE IN PROGRESS" light illuminating. As indicated in NFPA 8501, section 6-2.4.1(i),
the purge shall be ...sufficient for at least eight air changes of the furnace.
If the operator is starting the boiler from the cold condition, or restarting after a Master Fuel Trip
event, the procedure outlined in the following paragraphs is required. If the boiler is recycling or otherwise
starting from a warm condition, the MFT circuit will reset automatically and the procedure will skip directly
to the main flame light off sequence.
At the end of the purge cycle, and providing that the purge requirements remained satisfied, the
damper control shall position the inlet damper for light-off, approximately 10% to 30% airflow, depending on
burner design, required turn-down, etc. The "PURGE COMPLETE" light will illuminate and the boiler trip
circuit shall be ready for reset, and so indicated by a "MFT RESET" light.
Provided the start-up permissives remain satisfied, the system shall initiate a burner startup period
timer set for no more than 10 minutes. If the operator does not initiate a start-up within this time, the boiler
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control system will exit the PURGE COMPLETE condition and the operator must begin again with the
pre-purge cycle. If the MFT has been reset, the boiler control system will trip the MFT when leaving the
PURGE COMPLETE condition.
Upon completing a satisfactory purge, the operator must press the RESET MFT pushbutton. The
boiler control system will indicate that the MFT has been reset with a steady on MFT RESET light. At this
point, the boiler control system is ready to allow the main flame start-up sequence.
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control system. If the pilot flame is present, the main flame light-off sequence continues.
If the pilot flame fails, the boiler control system initiates a pilot flame failure shutdown. Additional
attempts of pilot light-off are permissible provided a successful pilot light-off is made within 10 minutes after
the furnace purge.
Note that if the pilot flame continues to fail after several attempts, the boiler should be inspected to
determine the fault and the condition corrected.
Shutdown
Per NFPA 8501, section 6-2.4.5, The normal shutdown cycle for the boiler shall accomplish the
following in the order listed:
(a) Shut off fuel supply to the main burner.
(b) Interrupt spark and shut off fuel supply to igniter, if in operation.
(c) For oil:
1. Where used, open the recirculating valve.
2. Shut off atomizing medium, if desired.
(d) For gas, vent piping between safety shutoff valves to atmosphere.
(e) Perform a post purge of the boiler furnace enclosure.
(f) Shut down fan, if desired.
For a safety shutdown, a manual reset is also required.
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In the event of an MFT, the control system shall initiate the following:
1. Execute a shut down as listed above.
2. Illuminate the appropriate indicator lights and alarms.
3. Return the system to the pre-purge state
Boiler restart will be inhibited until all pre-purge requirements are satisfied.
Alarms
The following is a list of recommended alarm conditions:
1.
2.
3.
4.
5.
6.
7.
Operator Interface
The above describes a traditional operator interface using discrete switches and indicator lights. The
control designer is encouraged to incorporate a graphical user interface or similar options in order to enhance
the ease of use and readability of the boiler control system operator interface.
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Endnotes:
[i]
Prepurge permissives condition checks and furnace purge are to be initiated by the operator from the
local BMS panel (see NFPA 8501, Chapter 5 for detailed guidelines on cold starting using fuel oil, Chapter 6
for cold starting using natural gas).
[ii]
Purge air flow (NFPA 8501, section 6-2.4.1(h): The total furnace airflow shall not be reduced below
the purge rate airflow (70% of the maximum continuous airflow capacity). Reducing airflow below these
limits will lead to a MFT, and a new furnace purge will be required.
[iii]
white
green
amber
white
red
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b.
c.
d.
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6. Which of the following conditions will cause a boiler trip (MFT) to occur?
a.
Excessive steam pressure
b.
Loss of combustion air supply
c.
Low water level
d.
All of the above
7. The Boiler Management System shall be designed to...?
a.
monitor and control the correct component sequencing during start-up and shut-down
b.
allow for the unattended start-up and shut-down of the boiler
c.
allow firing the boiler without a furnace purge being completed
d.
All of the above
8. The burner startup period timer is set for ...?
a.
no more than 10 minutes
b.
no less than 10 minutes
c.
30 seconds
d.
to between 20 and 40 minutes at the discretion of the operator
9. As indicated in NFPA 8501, section 6-2.4.1(i), the purge shall be ...sufficient for at least ____ air
changes of the furnace.
a.
eight
b.
six
c.
five
d.
two
10. Which of the following is a recommended alarm condition?
a.
High furnace pressure
b.
A boiler trip signal
c.
loss of control system power
d.
All of the above
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