Raotm Tech Session - Standards Review Burner Management And Combustion Control

Transcript

T10 - Standards Review - Burner Management and Combustion Control Rev 5058-CO900E Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Industrial Combustion Team Overview Background and Industry Experience PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. RA’s IC&PG Team History The Story of Rockwell Automation’s Industrial Combustion and Steam Generation Team  Rockwell Automation acquired Electronic Corporation of America (ECA) in the mid ‘80’s, who owned FIREYE  The FIREYE ‘Systems’ Team merged into Rockwell Automation’s solutions business  Have many years experience working with agencies like FM, NFPA, IEC, etc.  Since this initial merger Rockwell Automation has complimented this team with highly skilled individuals who have brought many years experience working for companies like ABB Bailey, Foxboro, Babcock & Wilcox, Combustion Engineering, Riley Stoker, Modicon, Cleveland Electric Illuminating, North American Manufacturing, Forney and others.  Over 900 systems provided worldwide in a wide variety of combustion applications. PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. RA’s IC&PG Team Expertise  4  Extensive experience working with Factory Mutual  Extensive Knowledge of Safety Standards and Guidelines  NFPA 85 Boiler & Combustion Code  NFPA 86 Furnace & Ovens  NFPA 87 Fluid Heaters (Chem. Plant Oil Heaters, vessels, etc.)  FM (7605) Approval Standard for PLC based BMS  CSA B149.3 (Canada)  BLRAC Recommended Good Practices  ANSI/ISA S84.00.011/IEC 61511 SIL Ratings for Systems  IEC 61508 SIL Ratings for Hardware PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Combustion Control & Burner Management Burner Management (BMS): - Combustion “SAFETY” and operator assistance in safely starting, monitoring and stopping the fuel fired burners - Used in conjunction with a combustion control system in any fossil fuel fired “industrial” combustion application. Industrial Combustion and Power Generation Combustion Control (CCS): - Regulates air/fuel ratio for stable flame and energy optimization - Used in conjunction with a burner management system in any fossil fuel fired “industrial” combustion application. Balance of Plant (BOP): - A “catch-all” for common activities in a powerhouse that excludes, burner management and combustion control - ESP, Plant Master, demineralizer control, feedwater control, coal/ash handling, scrubber control, soot blower control, etc. PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Definitions       NFPA – National Fire Protection Association FM Factory Mutual – Insurance Underwriter SIL – Safety Integrity Level Critical Input – Any Input that if lost will cause a trip Critical Output – Any Outputs that drive fuel delivery devices Fail Safe System – Inputs & Outputs - High is Normal / Low is Trip PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 6 Rockwell Automation IC&PG SIL Certification PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Industrial Steam Generation  Large Central Power House (i.e. – Paper Mill or Large Industrial Complex)  Boiler Steam Generation  Burner Management Systems  Combustion Control Systems  Balance of Plant Systems  Multiple Burners / Fuels including:  Natural Gas  Oil  Black Liquor  Bark/Wood Chips/Sawdust  Coal  Others PUBLIC INFORMATION 8 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Industrial & Process Heating  Any Industrial facility where steam or heat is used in the manufacturing process  Burner Management & Combustion (Temperature) Control Systems  Industrial Boilers  Non-Boiler Applications including: - Furnaces - Ovens - Dryers - Kilns - Heaters - Oxidizers PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Codes and Application Highlights Survey of Applicable Codes for Fired Equipment PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. NFPA Standards  NFPA 85 – Boiler and Combustion Systems Hazards Code (2011 Edition) (2015 due out in Jan)  NFPA 86 – Standards for Ovens and Furnaces (2015 Edition)  NFPA 87 – Recommended Practice for Fluid Heaters (2015 Edition) PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri NFPA 85 Key Highlights  “The burner management system (BMS) shall be provided with independent logic, independent logic solving hardware, independent input/output systems, and independent power supplies and shall be functionally and physically separate device from other logic systems.”  “The BMS safety functions shall include, but shall not be limited to, purge interlocks and timing, mandatory safety shutdowns, trial timing for ignition, and flame monitoring.”  “Diagnostics shall be included in the BMS design to monitor processor logic function.”  “Logic shall be protected from unauthorized changes.”  “Logic shall not be changed while the associated equipment is in operation.”  “No single component failure within the logic system shall prevent a mandatory master fuel trip” PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri NFPA 86 Key Highlights  Programmable logic controller-based systems listed for combustion safety service shall be used…..”  “Safety devices shall not be bypassed electrically or mechanically.”  “Output checking shall be provided for PLC outputs controlling fuel safety shutoff valves and oxygen safety shutoff valves.”  Only isolated PLC contacts shall be used in the required safety circuits.”  Flow and pressure “transmitters” can be used in place of pressure switches if the transmitter is dedicated to safety service.  “Access to the PLC and it’s logic shall be restricted to authorized personnel.”  “An excess temperature limit controller shall be provided and interlocked into the combustion safety circuitry…..” PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri NFPA 87 Key Highlights  “Does not apply to fired heaters in petroleum refineries and petrochemical facilities that are designed and installed in accordance with API560, Fired Heaters for General Refinery Service, API RP 556 Instrumentation and Controls for Fired heaters and Steam Generators, and API RP2001 Fire Protection in Refineries.” PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri NFPA Equivalency Clause  NFPA 85, 86 and 87 will allow variations to it’s published codes and standards through it “Equivalency” paragraph which states: “Nothing in this standard is intended to prevent the use of systems, methods, or devices of equivalent or superior quality, strength, fire resistance, effectiveness, durability, and safety over those prescribed by this standard.” Local authority having jurisdiction has final say over what is acceptable PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri IEC Safety Standards PROCESS SECTOR SAFETY INSTRUMENTED SYSTEM STANDARDS Manufacturers & Suppliers of Devices Safety Instrumented Systems Designers, Integrators & Users IEC 61508 IEC 61511 PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri IEC 61508  17  This is a Basic International Standard that defines the requirement that Electric/Electronic/Programmable Electronic devices must meet when used in Safety applications.  Performance based Standard  Includes all activities related to the Safety Life Cycle  Covers possible hazards caused by Failure of the Safety Functions  Does not cover SIS with SIL requirements less than 1 PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri IES 61511  A Process Sector Specific International Standard covering Functional Safety for Safety Instrumented Systems  It defines the requirements that users must meet when designing, implementing and maintaining a Safety Instrumented System in Process Plants.  Performance based Standard  The document differentiates between Safety certified devices and off the shelf general purpose devices. PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri ISA/ANSI S84.01  The Americanized version of IEC 61511. PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri IEC - Safety Integrity Levels (SIL) for Safety Instrumented Systems (SIS)  Safety integrity is the probability that an SIS will perform its safety function(s) when the process demands it.  Safety Integrity is specified as a discrete level, from 1 to 4 or Safety Integrity Level (SIL). DEMAND MODE OF OPERATION Safety Integrity Level (SIL) Target Average Probability of Failure on Demand Target Risk Reduction 4 -5 -4  10 to <10 >10,000 to  100,000 3 -4 -3  10 to <10 >1000 to  10,000 2 -3 -2  10 to <10 >100 to  1000 1 -2 -1  10 to <10 >10 to  100 CONTINUOUS MODE OF OPERATION PUBLIC INFORMATION Safety Integrity Level (SIL) Target Frequency of Dangerous Failures to perform the safety instrumented function (per hour) 4 -9 -8  10 to <10 3 -8 -7  10 to <10 2 -7 -6  10 to <10 1 -6 -5  10 to <10 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri SIL Determination  . P2 P1 1 0 0 0 1 1 1 3 1 2 3 2 3 5 >4 3 4 6 5 P3 D1 1 A1 2 E1 A2 3 D2 A1 4 E2 A2 E1 0 E2 7 2 2 1 3 2 5 3 3 6 4 D - Extent of Damage D1: slight injury D2: severe irreversible injury to one or more persons or death of a person D3: death of several persons D4: catastrophic consequences, multiple deaths E - Exposure Time E1: seldom to relatively frequent E2: frequent to continuous 1 3 7 4 1 0 4 6 8 1 1 4 D4 B 0 1 3 D3 B 0 0 0 4 2 Risk Parameters: 3 A - Hazard Avoidance/Mitigation A1: possible under certain conditions A2: hardly possible P - Occurrence Probability P1: very low probability P2: low probability P3: relatively high probability DIN EN IEC DIN VDE-19250 (AK) Fundamental safety aspects for measurement and control equipment IEC 61508 (SIL) Functional safety of programmable electronic systems (PES) EN-954 (Category) Safety of machinery - Safety related parts of control systems PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 21 Summary  At Rockwell Automation the IC&PG Team uses the NFPA standards as our base system design.  The code issue can be very confusing and are open a lot of different interpretations.  The customer needs to advise what specific codes/standard that they require to be applied to their application. PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyri Burner Management System (BMS)  Description: Burner Management System  A BMS is a SAFETY SYSTEM  A BMS is only for the safe start-up, monitoring and shutdown of a combustion system.  Special Requirements:  Monitoring and testing of inputs and outputs  Boilers - NFPA 85 Standard  Ovens, Dryers, Furnaces, etc. - NFPA 86 Standard  Fluid Heaters – NFPA 87 Recommend Practices  Recovery Boilers - BLRBAC Safety response – Fail-Safe Control of purge, ignition, shutdown  Factory Mutual Approval Standard (FM 7605) for PLC Based Burner Management Systems  ANSI/ISA S84.00.01/IEC 61511 - provides procedure for how to implement the SIL standards  Customer specific standards  PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Burner Management System Value  24 A new burner management system can  Improve availability by increasing the operator’s trouble-shooting capability and accessibility of system information through enhance diagnostics  Reduce normal startup time  Protects your combustion product equipment against damage  Uses standard Rockwell Automation hardware thus reducing or eliminating the need for additional spare parts for existing RA Clients.  Potential increase in overall safety PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Design Documents (Non-SIL) NFPA 85 for Boilers NFPA 86 for Ovens and Furnaces NFPA 87 for Fluid Heaters Factory Mutual (FM)  IEC 7605 Approval Standard for Programmable Logic Control (PLC) Based Burner Management Systems  BLRBAC (Recovery Boilers Only)  Customer Standards and Specifications     PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Design Documents for SIL  All of the applicable non SIL documents  IEC 615011 Functional Safety Instrument Systems  IEC 61508 Functional Safety of Electrical / Electronic / Programmable Electronic Safety Related Systems  1756-RM001 Applying ControlLogix in SIL 2 Applications PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. What Makes a BMS Unique      Input Testing Output Monitoring External Watchdog Hardwired Trip Circuit No Online Edits system is operating PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Burner Management Design Features  A system watchdog, completely independent of the programmable controller, continually verifies the controller’s timing function, as well as its ability to execute logic and control outputs  Input channels on each l/O module are periodically tested to verify their ability to detect field device state changes to the “fail-safe” position.  Critical outputs are monitored by feeding back the status of the output as a separate input signal and comparing it to the state demanded by system logic.  The use of software interlocks help guard against unauthorized modification of the controller’s program.  A hardware trip circuit which allows the operator or the system watchdog to initiate a main fuel trip  Start-up, first out, and system alarm/diagnostic messages.  Communication with other Rockwell programmable automation controllers or operator terminals  Adaptable to any fossil fuel combustion applications with single or multiple burners PUBLIC INFORMATION  28 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. BMS Functions       Input Testing Output Monitoring External Watchdog Hardwired Trip Circuit Timer Preset Locking No Online Edits PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Input Testing  Detects Input Card Failure  Detects Input Circuit Shorted to Power  Detects Forced Inputs PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Input Test Wiring PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. BMS Functions       Input Testing Output Monitoring External Watchdog Hardwired Trip Circuit Timer Preset Locking No Online Edits PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Output Monitor     Critical Outputs are wired to Inputs Typical Outputs are to Fuel Valves & Ignition Transformer Alarms if monitoring input Disagrees With Command May Initiate Trip PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Output Monitor Wiring PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. BMS Functions       Input Testing Output Monitoring External Watchdog Hardwired Trip Circuit Timer Preset Locking No Online Edits PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. External Watchdog Trips  Processor Failure  MFT Relays Fail To De-energize  Processor Not In Run Mode (Controllogix) PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. External Watchdog Wiring PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. BMS Functions       Input Testing Output Monitoring External Watchdog Hardwired Trip Circuit Timer Preset Locking No Online Edits PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Hardwired Trip Circuit PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. BMS Functions       Input Testing Output Monitoring External Watchdog Hardwired Trip Circuit Timer Preset Locking No Online Edits PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Timer Preset Locking  Timer Presets can not be changed while the processor is running.  All Timer Preset Changes Must Be Made In Program Mode PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. BMS Functions       Input Testing Output Monitoring External Watchdog Hardwired Trip Circuit Timer Preset Locking No Online Edits PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Online Programming  NFPA does not allow program changes to be made to the processor while the equipment is operating  If the processor is switched out of RUN mode, the System will MFT. PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Procedure to Make Program Changes     Switch Processor to Program Mode Make all Changes Store Program to Non-volatile Memory (If installed) Switch Processor Back To Run Mode PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 44 Rockwell Automation Questions? PUBLIC INFORMATION Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 45