Materials System Specification

34-SAMSS-619 Burner Management Systems for Watertube Boilers Instrumentation Standards Committee Members
Awami, Luay Hussain, Chairman Tuin, Rienk , Vice Chairman Bogusz, Zbigniew Jozef Dakhil, Tareq Khalil Dhafeeri, Farhan Taieh Ell, Steven Tal Fadley, Gary Lowell Qaffas, Saleh Abdal Wahab Mahmood, Balal Trembley, Robert James Falkenberg, Anton Raymond Grainger, John Francis Jumah, Yousif Ahmed Khalifa, Ali Hussain Madhi, Fawaz Abdullah Qarni, Mahdi Ali

23 October 2007

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 Scope............................................................ 2 Conflicts and Deviations............................... 2 References.................................................... 3 Definitions..................................................... 3 General Requirements.................................. 5 Burner Management System Design Requirements........................................ 5 Inspection and Testing................................. 14

Previous Issue: 31 January 2005 Next Planned Update: 22 October 2011 Revised paragraphs are indicated in the right margin Primary contact: Sprague, James Lawrence on 966-3-8746414 CopyrightSaudi Aramco 2007. All rights reserved.

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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

Scope 1.1 This Specification, together with the purchase order, referenced SAMSSs and specification sheets, and the engineering documents required herein, prescribe the minimum requirements for Burner Management System (BMS) hardware and software for Watertube Boilers. Included in this specification are requirements for: 1.2 Logic Hardware and Software Logic Sequence Local BMS Operator Interfaces

Not included in this specification are requirements for BMS subsystems consisting of: Field Sensors Ignition System Flame Monitoring System Fuel Shutoff and Vent Valves Control Room Operator Interface

If the purchase order includes these BMS subsystems, then the vendor shall be furnished with SAES-J-602, which contains information relevant to those systems. Flame monitoring is separately covered in specification 34-SAMSS-617 and ISS 8020-617-ENG. If the purchase order includes the manufacture of watertube boilers and/or boiler instrument connections, combustion air flow elements, flame scanner connections, soot blower hardware, or thermowells, then 32-SAMSS-021 shall also be supplied to the vendor. 2 Conflicts and Deviations 2.1 Any conflicts between this specification and other Saudi Aramco Materials System Specifications (SAMSS's), Engineering Standards (SAESs), Standard Drawings (SASDs), or industry standards, codes and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Process and Control Systems Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP302 and forward such requests to the Manager, Process and Control Systems Department of Saudi Aramco, Dhahran.

2.2

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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

References Material or equipment supplied to this specification shall comply with the latest edition of the references listed below, unless otherwise noted. 3.1 Saudi Aramco Documents Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standard SAES-J-602 Burner Management, Combustion, and Waterside Control Systems for Watertube Boilers

Saudi Aramco Materials System Specifications 32-SAMSS-021 34-SAMSS-617 34-SAMSS-623 34-SAMSS-821 Manufacture of Industrial Watertube Boilers Flame Monitoring Systems Programmable Controller Based ESD Systems Control Panel-Outdoor

Saudi Aramco Form and Data Sheet 8020-617-ENG Flame Monitoring Systems

Saudi Aramco Inspection Requirements Form 175-344400 3.2 Industry Codes and Standards National Fire Protection Association NFPA 85 4 Definitions Burner Management System (BMS): The BMS is the control system dedicated to boiler furnace safety, operator assistance in the starting and stopping of fuel preparation and burning equipment, and for preventing misoperation of, and damage to, fuel preparation and burning equipment. The BMS includes the following subsystems: Logic System Field Sensors
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Programmable Controllers Based ESD Systems

Boiler and Combustion Systems Hazards Code

Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

Ignition System Flame Monitoring System Fuel Shutoff and Vent Valves Local Flame Safety Shutdown Panel Control Room Indication and Control Equipment

Automatic: The Saudi Aramco mandatory BMS sequence in which pushbutton actuations initiate the boiler start-up, purging, positioning, timing, and fuel/air valve manipulations. In automatic BMS logic, operators are not required to manipulate any burner front controls (e.g., manually open gas cock). Burner starts are actuated from either the local Flame Safety Shutdown (FSS) panel or the control house, with the initial burner light off always accomplished at the FSS. The operator manually initiates (via pushbutton) each of the following sequences: Purge Initial ignitor/burner start Subsequent ignitor/burner starts and stops Boiler normal shutdown

Supervised Manual: A BMS in which a trained operator has primary responsibility for the proper start-up, operation, and normal shutdown of a boiler, with interlocks to ensure that the operation follows established procedures. A supervised manual BMS logic system is distinguished from an automatic system in that the operator must visually verify and manually manipulate some burner front equipment as part of the BMS procedure for each burner startup. Remote burner light-off is not available with a supervised manual system. A burner front panel (in addition to the FSS panel) is required for a supervised manual system. Master Fuel Trip: Sometimes called main fuel trip or MFT; an event that results in the rapid shutoff of all fuel to a boiler. MFT trip initiators are listed in this SAMSS. Buyer Or Purchaser: The company actually placing the order for the material, (e.g., Saudi Aramco, AOC, ASC, or third party contractor). Buyer's Representative: The person acting on behalf of the buyer, who may be from the engineering, inspection, purchasing, or user organization. Vendor: The other party to the order for the material who may or may not be the manufacturer of the equipment.

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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

General Requirements Engineering Units All dimensions and measurements shall be in the International System of Units (SI), and may be followed by the equivalent value in English units between brackets. When not critical, the equivalent dimensions and measurements may be rounded off to their nearest practical value.

Burner Management System Design Requirements 6.1 Logic System 6.1.1 Logic System Hardware and Software Programmable logic controllers (PLCs), which are fault-tolerant and failsafe, shall be used for BMS logic hardware. The BMS is considered a specific type of Emergency Shutdown System, and as such, the BMS system must meet all requirements of specification 34-SAMSS-623, "Programmable Controller Based ESD Systems", with the exception of paragraph 7.1: ESD System Segregation. BMS hardware and software segregation shall meet requirements of SAES-J-602, paragraphs 6.2.2 and 6.2.3. 6.1.2 Logic System Software Functional Requirements 6.1.2.1 General Description 6.1.2.1.1 The system shall be designed in accordance with NFPA 85. The design shall also meet the requirements detailed in this Specification, the referenced Specifications and Instrument Specification Sheet(s), and the engineering documents attached to the Purchase Order. The Saudi Aramco mandatory BMS logic system design is an automatic system as defined in NFPA 85 and this SAMSS, and is the basis for the logic sequences contained herein. Use of a supervised manual system is not permitted. The development of a BMS application program requires specific engineering documents to define exact BMS I/O. These documents will consist of, as a minimum, boiler system Piping and Instrument

6.1.2.1.2

6.1.2.1.3

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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

Diagrams (P&IDs). They may also include ILDs, ISSs, boiler manufacturer data, and/or other information. These engineering documents shall be provided to the BMS vendor as part of the purchase order. 6.1.2.1.4 Operation of the ignitor gas header valves, main fuel gas/oil header valves and initiation of the light-off sequence, up to proving the main flame on the first burner, shall be accomplished only from the local flame safety shutdown (FSS) panel. The system design shall incorporate interlocks to inhibit ignitor/burner start from the control room until the first burner has been proven. Light-off of subsequent ignitors/burners shall then be possible from either the FSS panel or the control room BMS operator interface. The system design shall provide for manual activation of the Master Fuel Trip (MFT) of the boiler from the local FSS panel and also from the control room.

6.1.2.1.5

6.1.2.2 Boiler Start-Up 6.1.2.2.1 The system design shall provide the functional sequences and timing logic necessary for the safe start-up of the boiler. The boiler start-up sequence shall comprise the following stages: 6.1.2.2.2 Prepurge Permissives Purge Light-Off First Ignitor/Burner Light-Off Subsequent Ignitor/Burners.

The stages up to and including the light-off of the first ignitor/burner in the sequence shall be initiated by the operator from the local FSS panel only.

6.1.2.3

Pre-Purge Permissives 6.1.2.3.1 The following is a list of permissives which must be established before the purge can be initiated. Drum level satisfactory
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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

6.1.2.3.2

Instrument air header pressure satisfactory Fan(s) running Purge air flow greater than 25% MCR air rate (70% MCR air rate for single burner boilers) No flame in the furnace All burner fuel gas safety shutdown valves closed and vent valves open All burner fuel oil safety shutdown valves closed, if applicable Main fuel gas header safety shutdown valve(s) closed and vent valve(s) open Main fuel oil header safety shutdown valve and recirculating valve closed, if applicable Main ignitor gas header safety shutoff valves closed and vent valve open All air registers at predetermined open position Atomizing steam/oil delta P satisfactory, if applicable Fuel gas header pressure (upstream of safety shutdown valve) satisfactory Fuel oil header pressure (upstream of safety shutdown valve) satisfactory, if applicable Ignitor gas header pressure satisfactory.

The status of the above listed permissives shall be displayed by indicating lamps or LEDs on the local FSS panel. When all the appropriate lamps are illuminated, the logic shall enable the purge sequence circuit which shall be indicated by a "Purge Available" lamp on the local FSS panel.

6.1.2.4

Purge Sequence 6.1.2.4.1 Illumination of the "Purge Available" lamp shall indicate to the operator that the "Start Purge" pushbutton circuit has been enabled by the logic. Operation of the pushbutton shall initiate the purge sequence resulting in the following: Starting of purge timer for a minimum of 5 minutes Leak Test Gas Fuel System Illuminating "Purge in Progress" lamp
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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

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6.1.2.4.2

Extinguishing "Purge Available" lamp

Provided that the purge permissives remain satisfactory on completion of purge period timer cycle, the logic shall perform the following functions: Illuminate the "Purge Complete" lamp Extinguish the "Purge in Progress" lamp Reset the Master Fuel Trip

6.1.2.4.3 6.1.2.5

Once the Master Fuel Trip has been reset, the logic shall enable the ignitor/burner start sequence.

Light-Off First Burner This section is applicable to either an automated ignitor/burner light-off sequence or to independent ignitor then burner lightoffs. 6.1.2.5.1 The "Burner Available" lamps on the local FSS panel shall illuminate when the following permissives are satisfied: Purge complete Drum level satisfactory Instrument air header pressure satisfactory No flame in furnace Fan(s) running Combustion air flow satisfactory All burner fuel gas safety shutdown valve(s) closed/vent valve(s) open All burner fuel oil safety shutdown valves closed, if applicable Air registers on all burners at predetermined open position Ignitor gas pressure satisfactory Burner header fuel gas pressure (downstream of control valve) not high and not low Burner header fuel oil pressure (downstream of control valve) not high and not low, if applicable Atomizing steam/oil delta P satisfactory, if applicable

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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

6.1.2.5.2

Maintaining satisfactory ignitor and/or burner header pressure may require header venting through the ignitor and/or burner header vent valves. To limit venting time in these cases, the ignitor or burner header normal pressure permissive shall become part of the 6.1.2.5.4 ignitor or 6.1.2.5.6 burner pushbutton light-off procedure. Illumination of the "Burner Available" lamps enables the ignitor or burner start pushbutton circuits on the local FSS panel. The ignitor or burner start pushbutton circuits from the control room are inhibited. Operation of the selected first ignitor or burner start pushbutton shall initiate the following sequence in the logic: Check that the selected burner register is in the predetermined open position; Check and prove that the remaining air registers are in their predetermined open position (open register light-off procedure as per NFPA 8501 and NFPA 8502); If venting is required to maintain normal ignitor header pressure, then the ignitor header vent valve is opened and header pressure is proved not high and not low. Start the ignitor flame establishing period timer, open the ignitor valves and energize the spark ignition system.

6.1.2.5.3

6.1.2.5.4

6.1.2.5.5

The ignitor flame shall be proven within 10 seconds (ignitor flame establishing period). Failure to detect the ignitor flame shall result in the ignitor valves closing and the ignitor start being inhibited for a period of 2 minutes (on single burner boilers, this condition causes a MFT and forces a return to the pre-purge state). When the ignitor flame is proven, the logic shall enable the burner start circuit permitting either the manual or automatic start of the selected burner sequence, as specified, resulting in the following:
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6.1.2.5.6

Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

Enabling the main fuel (gas/oil) header valve circuit If venting is required to maintain normal burner header pressure, then the burner header vent valve is opened and header pressure is proved not high and not low. Opening of selected burner fuel safety shutdown valve(s) and closing of vent valve(s), as applicable

6.1.2.5.7

The main flame detectors shall prove the flame present within 5 seconds after main fuel enters the furnace (trial-for-ignition period). The ignitor shall be automatically de-energized after the 5 second trial-for-ignition period and all flame detectors shall continue to prove the main burner flame. Failure to prove the first main burner flame present or a system malfunction shall result in an MFT and the logic shall return the complete system to the "Purge Required" state.

6.1.2.6 Subsequent Burner Light-Offs Satisfactory completion of the first burner light-off shall enable the burner start circuits on the remaining burners. Light-off of subsequent ignitors/burners shall be possible from the local FSS panel and also from the control room. Failure to ignite a subsequent burner within its trial-for-ignition period shall close both fuel and ignitor gas safety shutoff valves and open vents on that burner only. 6.1.2.7 Master Fuel Trips (Boiler Shutdown) 6.1.2.7.1 Any of the following conditions shall initiate a Master Fuel Trip once the purge sequence has been complete and the Master Fuel trip has been reset: Drum level low low Drum level high high (after a 4-second time delay) Furnace pressure high high Main gas header valve position fault Main fuel oil header valve position fault, if applicable Furnace pressure low low, if applicable
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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

6.1.2.7.2

Combustion air flow low low Instrument air header pressure low low Instrument air surge drum pressure low low, if applicable Fan(s) tripped

After one burner has been established, then any of the following conditions shall initiate a Master Fuel Trip (each condition shall be provided with an adjustable time delay): Drum level low low Drum level high high Furnace pressure high high Main gas header valve position fault Main fuel oil header valve position fault, if applicable Furnace pressure low low, if applicable Combustion air flow low low Instrument air header pressure low low Instrument air surge drum pressure low low, if applicable Fan(s) tripped Main fuel gas header pressure low low Burner fuel gas header pressure (downstream of control valve) low low Burner fuel gas header pressure (downstream of control valve) high high Main fuel oil header pressure low low, if applicable Burner fuel oil header pressure downstream of control valve low low, if applicable Atomizing steam or air/oil delta P low low, if applicable Local/remote manual Master Fuel Trip pushbutton. Loss of all flame in the boiler.

6.1.2.7.3

For multiple burner boilers, the incorrect burner firing pattern shutdown interlock (if applicable), shall be inhibited during the start-up sequence.

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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

Once the start-up sequence has been satisfied, this interlock shall be automatically enabled by the logic. 6.1.2.7.4 In the event of an Master Fuel Trip, the logic shall initiate the following actions: 6.1.2.7.5 Close all fuel gas/oil header safety shutoff valves and open vent valves, as applicable Close all burner fuel gas/oil safety shutoff valves and open vent valves, as applicable Close fuel oil circulation and recirculation valves, as applicable Close ignitor gas header safety shutoff valves and open vent valves Illuminate appropriate shutdown lamps and initiate alarms Return system to the pre-purge state De-energize all ignitors.

A Master Fuel Trip shall not initiate a forced draft fan trip. After the trip, the combustion air shall be maintained at the pre-trip rate and burner registers frozen. After five minutes, airflow may be gradually reduced to the purge rate. Boiler restart shall be inhibited until all prepurge permissives have been satisfied with logic checked and the Master Fuel Trip reset. Each boiler trip parameter shall be included as an input to the sequence of events recorder and first out annunciator to provide discrimination of trip cause.

6.1.2.7.6

6.1.2.7.7

6.1.2.8

Burner Trips 6.1.2.8.1 Individual burner stop pushbuttons located in the control room and on the local FSS panel shall provide the means for manual shutdown of individual burners. 6.1.2.8.2 The logic shall initiate the automatic shutdown of individual burners due to any of the following conditions:

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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

6.1.2.8.3

Flame Failure on Both Flame Detectors Air Register Closed Fuel Gas Safety shutdown/Vent Valve(s) Position Fault Fuel Oil Safety shutdown Valve(s) Position Fault, if applicable

Any of the above fault conditions shall initiate an alarm at the local FSS panel and the control room. In addition each burner trip parameter shall be included as an input to the sequence of event recorder and first out annunciator. In the event of a burner shutdown, either manual or automatic, the logic shall close burner fuel gas/oil safety shutdown valve(s) and open appropriate vent valve(s). The air registers on their respective burners shall close.

6.1.2.8.4

6.2

Local BMS Operator Interfaces 6.2.1 General Local BMS panels shall be designed and constructed in accordance with 34-SAMSS-821, "Control Panel-Outdoor". 6.2.2 Local Flame Safety Shutdown (FSS) Panel 6.2.2.1 The local flame safety shutdown panel shall provide the operator with all the necessary pushbuttons and indicators required to monitor and control prepurge permissives, purge, ignitor/burner light-off and shutdown conditions. The indicators and pushbuttons shall be displayed in a logical sequence starting at the top with the permissives, then the trip functions, and finally the individual burner start-stop facilities. All indicators and pushbuttons shall be discrete, hardwired devices. CRT based, local operator interfaces with digital communications to the BMS PLC, may be used in addition to the required individual indicator lights and pushbuttons. Layout drawings of the FSS panel shall be provided for buyer approval.

6.2.2.2

6.2.2.3

6.2.2.4 6.2.3

Local Burner Front Panel

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Document Responsibility: Instrumentation Issue Date: 23 October 2007 Next Planned Update: 22 October 2011

34-SAMSS-619 Burner Management Systems for Watertube Boilers

For approved supervised manual BMS, a burner front panel is required for each burner. The burner front panel shall provide the operator with all indicators and pushbuttons required to light-off and shutdown the ignitor and burner at the burner front. As a minimum, this includes ignitor and burner ready indication, ignitor and burner "flame on" indication, and ignitor and burner start and stop pushbuttons. If the burner uses multiple fuels, a fuel selection switch is also required. 7 Inspection and Testing 7.1 Inspection Requirements Items manufactured to this specification are subject to the minimum Inspection requirements as specified in Saudi Aramco Form 175-344400, Programmable Controller Based ESD Systems. 7.2 Testing Requirements Burner Management System testing shall meet all requirements specified in 34-SAMSS-623.
Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document and reissued with editorial changes.

23 October 2007

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