FSSS

and

Boiler Protection System

Basic Concepts

and

Standards
April 18, 2020 PMI Revision 00 1
Basic concept
Function of BMS
Furnace purge procedure
STANDARDS / NFPA

CONTENT
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 •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
Main Functions
April 18, 2020 PMI Revision 00 3
 • BURNER • SEC. AIR DAMPER • AUX. PRDS
MANAGEMENT CONTROL CONTROL
SYSTEM

• BOILER
• SOOT BLOWER • HP-BYPASS
PROTECTIONS
CONTROL CONTROL
• MILLING
SYSTEM

• FUEL OIL
SYSTEM

• UNIT PURGE
SG (Steam Generator) CONTROLS
BACK April 18, 2020 PMI Revision 00 4
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
April 18, 2020 PMI Revision 00 5
 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.

April 18, 2020 6

 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.

April 18, 2020 7

 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.

Basic Concepts of BMS

April 18, 2020 PMI Revision 00 8
 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.

April 18, 2020 PMI Revision 00 9

 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. 
April 18, 2020 PMI Revision 00 10
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.

April 18, 2020 PMI Revision 00 11

 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.

April 18, 2020 PMI Revision 00 12

 SIMPLIFIED BLOCK DIAGRAM OF
BURNER MANAGEMENT SYSTEM.

C.C.R

FUEL ABC
V/V LOCAL
CONTROL B DAS
AIR BOX
DAMPER M
FLAME
DETECTOR
S MILL
CONTROL
IGNITION
IGNITER CONTROL BOILER
PANEL PLANT
April 18, 2020 13
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.

April 18, 2020 14

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

April 18, 2020 15

April 18, 2020 PMI Revision 00 16
 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 today’s 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.

STANDARDS AND CODES

April 18, 2020 PMI Revision 00 17

 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.

NFPA
April 18, 2020 PMI Revision 00 18
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

April 18, 2020 PMI Revision 00 19

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

April 18, 2020 PMI Revision 00 20

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

April 18, 2020 PMI Revision 00 21

 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
April 18, 2020 PMI Revision 00 22
 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

April 18, 2020 PMI Revision 00 23

April 18, 2020 PMI Revision 00 24