BP's Kirk Adams and Emerson's David Shepard present at the 2011 Emerson Exchange in Nashville. A refinery SRU project replaced the BMS/combustion controls on two SCOT units, four Claus units, and two incinerators. The BMS platform was DeltaV SIS and the combustion controls was done in DeltaV. Many different factors led to a successful project. During the engineering phase, a standard state based approach simplified design for multiple types of equipment and made it easy to coordinate combustion controls with the BMS. Having an engineered approach to test the trips was also important. Special Bypass Functionality and AMS Quickcheck helped reduce startup time.

1. Elements of a
Successful Burner
Management Project

2. Presenters
 Kirk Adams
 David Sheppard

3. Introduction
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the
unit is not running
– Summary / Questions?

4. Successful Project Considerations
Design
Yearly Testing
Down Time

5. BP SRU Project
 Over 600 SIS IO
 Majority of the safety related scope centered on
replacement of the burner management systems on
the eight fired equipment 4 Claus, 2 SCOT, and 2
incinerators
 DeltaV System used as Process Controls System
including Combustion Controls
 New Remote Instrument Enclosure
 Asset Management System
 SRU Unit never goes into full Turnaround

6. Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?

7. DeltaV SIS advanced function blocks
simplify configuration
 IEC 61508 certified modules
and functionality for BMS
– Cause and Effect Matrix (CEM)
– Step Sequencer
– State Transition
 Provides very efficient
configuration and powerful
application software.
 Available dynamos and
faceplates make the application
very transparent for the
operator.

8. Example BMS States
S03
Shutdown, S04
S02
Not Ready
Pre-Purge In Ignite Pilot
Shutdown, progress Purge Complete
S01
& Ready S05
Startup failure
Pilot only
S06
Running
Trips from States
5, 6, 7, 8, 9, 10, 12
Mixed firing, set
low fire position
S12
S07
S13
Cold Start, Set
Waste Gas Only S08 Low fire position
S10 S09
Ignite Main with
Mixed Gas Main without pilot, not at Pilot
Temp

9. 3 Main Logic Part to a BMS System
In order to define a BMS you must know 3 fundamental items.
1. States & Transitions – When to move from one to another
2. Outputs – Valve Positions defined for each State
3. Trips – Including which is active during each State
Once these are defined, the DeltaV SIS logic can be programmed in
An easy to follow manner.
The following
Example is a
Single Burner-
Multi Fuel
with 13 states:

10. Outputs – Defined per State
 Once the States are defined, the position of each Output (Valve,
igniter, etc) is defined in each state in a simple table
Nitrogen to block valve
XXXXX-10 Oxygen to block valve
Pilot gas downstream
Main natural valve
Main combustion air
Main combustion air
Trim combustion air
Trim combustion air
Pilot combustion air
Pilot gas upstream
downstream block
Waste gas control
Waste gas control
Tuning Command
Tuning Command
Oxygen to control
Oxygen to control
valve solenoid #1
valve solenoid #2
Burner Switch #1
Burner Switch #2
valve solenoid 2
Main natural gas
upstream blockgas
valve solenoid 1
Sour Water Gas
Control Valve
Description
solenoid #1
solenoid #2
Pilot Igniter
block valve
block valve
Solenoid
valve
valve
valve
valve
(FO)
Outputs
State Output Control Output Description
XYXXXX-11
XYXXXX-12
BYXXXX-14
FYXXXX-13
BXXXXX1-
BXXXXX2-
FYXXXX-3
FYXXXY-3
FYXXXY-4
FYXXXX-4
FYXXXX-7
FYXXXY-7
FYXXXX-9
XYXXX1-1
XYXXX2-2
XYXXX1-5
XYXXX2-6
PXXXX-8
Tag
15
15
Notes
States
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation, XX=Set the
State Name State output % open
Shutdown, Not Ready S01 D D D D D D D D D D D D D D D D D D D
Shutdown & Ready S02 D D D D D D D D D D D D D E D D D D D
Pre Purge in Progress S03 D D D D D D D D D D D D D E D D D D D
Purge Complete S04 D D D D D D D D D D D D D E D D D D D
Ignite Pilot S05 D D D D D D E E D D D D D E E D E D D
Pilot Only Running S06 D D D D D D E E D D D D D E E D D D D
Cold start, set low fire positions S07 D D D D E E E E D D D D D E E D D D D
Ignite main with pilot S08 E E D D E E E E D D D D D E E D D D D
Main NG w/o Pilot, not at temp S09 E E D D E E D D D D D D D D D D D D D
Mixed Gas S10 E E E E E E D D E E D D D D D D D D D
Not Used S11
Mixed firing, set low fire positions S12 D D E E E E D D E E D D D D D D D D D
Waste gas Only S13 D D E E E E D D E E E E E D D E D E E

11. Not Used
Ignite Pilot
Mixed Gas
State Name
States
Waste gas Only
Purge Complete
Pilot Only Running
Shutdown & Ready
Ignite main with pilot
Shutdown, Not Ready
Pre Purge in Progress
Outputs
State Output Control
Main NG w/o Pilot, not at temp
Cold start, set low fire positions
Mixed firing, set low fire positions
Output Description
S13
S12
S10
S09
S08
S07
S06
S05
S04
S03
S02
S11
S01
Notes Tag Description
Main natural gas
E
E
E
D
D
D
D
D
D
D
D
D
1 XYXXXX1-1 Main natural valve
upstream blockgas
downstream block
E
E
E
D
D
D
D
D
D
D
D
D
1 XY206C2-2 valve
Main combustion air
E
E
E
D
D
D
D
D
D
D
D
D
1 FY2XXXX-3 valve solenoid #1
Main combustion air
E
E
E
D
D
D
D
D
D
D
D
D
1 FY205CY-3 valve solenoid #2
Trim combustion air
E
E
E
E
E
E
D
D
D
D
D
D
1 FY212CY-4 solenoid #1
Trim combustion air
E
E
E
E
E
E
D
D
D
D
D
D
State XX=Set the output % open
1 FY212CX-4 solenoid #2
Pilot gas upstream
E
E
E
E
D
D
D
D
D
D
D
D
1 XY202C1-5 block valve
Pilot gas downstream
E
E
E
E
D
D
D
D
D
D
D
D
1 XY202C2-6 block valve
Waste gas control
E
E
E
D
D
D
D
D
D
D
D
D
1 FY215CX-7 valve solenoid 1
Waste gas control
E
E
E
D
D
D
D
D
D
D
D
D
1 FY215CY-7 valve solenoid 2
Oxygen to control
E
D
D
D
D
D
D
D
D
D
D
D
1 PY237C-8 valve
Oxygen to control
E
D
D
D
D
D
D
D
D
D
D
D
1 FY240C-9 valve
E
D
D
D
D
D
D
D
D
D
D
D
1 XY250C-10 Oxygen to block valve
Nitrogen to block valve
E
E
E
E
E
E
E
D
D
D
D
D
1 XY224C-11 (FO)
Pilot combustion air
E
E
E
E
D
D
D
D
D
D
D
D
1 XY203C-12 valve
Outputs – Defined per State
E Sour Water Gas
D
D
D
D
D
D
D
D
D
D
D
1 FY216C-13 Control Valve Solenoid
E
D
D
D
D
D
D
D
D
D
D
D
States
1 BY217C-14 Pilot Igniter
Burner Switch #1
E
D
D
D
D
D
D
D
D
D
D
D
1 BX201C1-15 Tuning Command
Burner Switch #2
E
D
D
D
D
D
D
D
D
D
D
D
1 BX201C2-15 Tuning Command
D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation,
Outputs

12. 
Trip Input Description
Trips
S11
S13
S12
S10
S09
S08
S07
S06
S05
S04
S03
S02
S01
State
Notes Tag Description
1 - Loss of
T
T
T
T
T
M
M
M
M
M
M
M
main flame
BSLXXX1/2 signal
2 - Low
T
T
T
T
T
T
M
M
M
M
M
M
Natural Gas
PT7XXX/Y/Z Pressure
3 - Hi Hi
T
T
T
T
T
T
T
T
T
T
T
T
combustion air
PTXXX1/2/3 pressure
4 - Low Total
T
T
T
T
T
M
M
M
M
M
M
M
FTXXX1/2/3 Combustion
FTXXX1/2/3 Air Flow
5 - Hi Hi level
T
T
T
T
T
T
T
T
T
T
T
T in Waste gas
LTXXXX/Y/Z KO Hi Hi
6 - drum
thermal
this state! T
T
T
T
T
T
T
T
T
T
T
T
TTXXX reactor
TTXXXX temperature
7 - Manual
T
T
T
T
T
T
T
T
T
T
T
T
ESD Button,
HS2XXX2 RIE
8 - Manual
T
This cause needs to be “masked” in T
T
T
T
T
T
T
T
T
T
T
ESD Button,
HSXXX3 Local
9 - Hi Hi level
in
T
T
T
T
T
T
T
T
T
T
T
hydrocarbon
LTXXX1/2/3 10 -drum 1
Low level
in high
T
T ThisT
T
T
T
T
T
T
T
T
T
T
pressure
"T" = Trip, "M"=Mask (no trip)
stream drum
LTXXX1/2/3 11 - Hi Hi level
in
T
T
T
T
T
T
T
T
T
T
T
hydrocarbon
LTXXX1/2/3 12 -drum 2
Hi Hi level
in
Trip Matrix / Appropriate Masking
T
T
T
T
T
T
T
T
T
T
T
T
hydrocarbon
LTXXX1/2/3 13 -drum 3
Hi Hi level
in
this state. T
T
T
T
T
T
T
T
T
T
T
T
hydrocarbon
LTXXX1/2/3 drum 4
14 - Loss of
T
T
T
M
M
M
M
M
M
M
M
M
pilot flame
BSLXXX signal
15 - Trip on
Different Trip conditions are be masked in different states.
T
causeThas to be able to trip in T
T
T
T
T
T
T
T
T
T
T
Software
HSXXXX Shutdown

13. Trip Input Description
Trips
S11
S13
S12
S10
S09
S08
S07
S06
S05
S04
S03
S02
S01
State
Notes Tag Description
T
T
T
T
T
M
M
M
M
M
M
M
1 - Loss of main
BSL201C1/C2 flame signal
T
T
T
T
T
T
M
M
M
M
M
M
2 - Low Natural
PT729X/Y/Z Gas Pressure
3 - Hi Hi
T
T
T
T
T
T
T
T
T
T
T
T
combustion air
PT217C1/2/3 pressure
4 - Low Total
T
T
T
T
T
M
M
M
M
M
M
M
FT205C1/2/3 Combustion Air
FT212C1/2/3 Flow
5 - Hi Hi level in
T
T
T
T
T
T
T
T
T
T
T
T
Waste gas KO
LT211X/Y/Z drum
6 - Hi Hi thermal
T
T
T
T
T
T
T
T
T
T
T
T
TT222C reactor
TT229C temperature
T
T
T
T
T
T
T
T
T
T
T
T
7 - Manual ESD
HS210C2 Button, RIE
T
T
T
T
T
T
T
T
T
T
T
T
8 - Manual ESD
HS210C3 Button, Local
9 - Hi Hi level in
States
T
T
T
T
T
T
T
T
T
T
T
T
hydrocarbon
LT105C1/2/3 drum 1
10 - Low level in
T
T
T
T
T
T
T
T
T
T
T
T
high pressure
"T" = Trip, "M"=Mask (no trip)
LT203C1/2/3 stream drum
11 - Hi Hi level in
State!
T
T
T
T
T
T
T
T
T
T
T
T
hydrocarbon
LT625C1/2/3 drum 2
This Cause is
“masked” in this
12 - Hi Hi level in
T
T
T
T
T
T
T
T
T
T
T
T
hydrocarbon
LT625D1/2/3 drum 3
13 - Hi Hi level in
T
T
T
T
T
T
T
T
T
T
T
T
hydrocarbon
LT105D1/2/3 drum 4
Outputs
T
T
T
M
M
M
M
M
M
M
M
M
14 - Loss of pilot
BSL202C flame signal
15 - Trip on
T
T
T
T
T
T
T
T
T
T
T
T
Software
HSXXXX Shutdown
Trips –Including Masking Based on State

14. Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?

15. Interface with Combustion Controls
 Typical Systems use many flags or Bits.
1. Go To Min Fire
 Only One Parameter
2. Open Valves for Purge was Required.
3. Set Valves to Ignite Pilot The State.
4. Set Valves to Ignite Main Burner
5. Main Light, Release to Modulate  It Resets Itself.
 These items have to be Set / Reset / tested

16. Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?

17. Projects Remember Customer Needs
 Project teams consider start-up time, but sometimes
forget the yearly testing.
 Operations is the final customer!
 Successful projects consider entire Life Cycle!
 Used existing tools effectively to deliver a better
result.

18. AMS and Quickcheck

19. Consistent / Complete / Repeatable
Testing

20. Ensure Each Step is Tested
Step 1 – Sets All Transmitters to Normal
Step 2 – FT101 Vote to Trip
Step 3 – FT101 & FT102 Vote to Trip
Step 4 – Resets All Transmitters to Normal
Step 5-7 – Tests FT102 & FT103
Step 8 – Tests FT101 Over-range
Step 9 – Tests FT101 Under-range
Step 10-16 – Tests other Transmitters

21. Testing Considerations – Loss of Flame

22. Trips Graphic

23. Bypass Considerations

24. Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?

25. Allow Stroking of any BMS Valve during
Down Time

26. Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?

27. Summary / Results
 Utilized Advance Function Blocks in a
State Transition Diagram approach
 Simplified Interface with Combustion
Controls
 Consideration for Yearly Testing
using AMS and Quickcheck
 Consideration for stroking Valves
during Turn-around
 The approach can also be used for
other applications in Safety Logic
Solvers or DeltaV Controllers
 Successful Startup
 Testing of all Trips was done very
quickly and systematically

28. Thank you…
…any Questions?
David.Sheppard@Emerson.com
WWW.EasyDeltaV.Com