A Training on

Incinerator BMS
Instrument EDC/VCM

Contents

BMS Fundamentals
BMS Design Standards
Incineration Fundamentals
PFD For Incinerator
Engros Waste Streams / Vents
Control Side of Incinerator
Hard Wired BMS Interlocks
Overview of New PLC based BMS at Incinerator B
Summary

Burner Management System

BMS Fears in Burner Units (Fired Equipment)

Start Up Fear
Fuel has accumulated while burners are not operating
and then is ignited when a burner is lit

Shutdown Fear
Fuel accumulates after a burner goes out while
operating, then subsequently finds a source of ignition

Burner Management System

BMS - Purposes

Primary Purpose
To allow and ensure the safe start-up and shutdown of
the Fired Equipment

Secondary Purpose
To prevent overheating fired equipment and the
catastrophic release of process streams that result

Burner Management System

How is Burner Managed?

Sequence control (Permissives)

Shutdowns/Trips (Interlocks)

BMS Design Standards

NFPA

NFPA 85 Boiler and

Combustion Systems
Hazards Code
NFPA 86 Standard for Ovens
and Furnaces

What is Incineration??

Incineration is an Oxidation Reaction

The Oxidation reaction is highly Exothermic
The reaction is fairly complete.
The Oxidation Reaction

C x H y O z Cl t ( x ( y t ) / 2)O2 xCO2 tHCl [( y t ) / 2]H 2 O

In presence of sufficient Oxygen :

o All Carbon (C) will form Carbon Dioxide (CO2).
o Most Chlorine (Cl) will form Hydrogen Chloride (HCl).
o All residual Hydrogen (H) will form Water (H2O).

Process Flow Diagram

Oxidizer
Used to destroy all organic compounds.
Waste Heat Boiler Used to recover usable heat released from the waste.
Quench Absorber Used to cool hot products of combustion and remove most acid
formed.
Scrubber
Used to remove residual traces of acid and Chlorine

Quench
Absorber

Scrubb
er
Oxidizer
WH Boiler

Engros Waste Streams

Waste Constituents

Heavies assumed to be heavily chlorinated and High boiling Constituents. [ie C2H2Cl2, C2HCl3]
Lights - assumed to be non chlorinated Low boiling constituents.[i.e. CH4, C2H6, C2H6]

Four Major Components of

Incinerator

Oxidizer Chamber

Waste Heat Boiler

Quench Absorber

Scrubber

Controlling the Combustion Reaction

Items to be Controlled:

Oxidizers operating temperature and the exhaust gas oxygen conte

Control air flow to match demands made by the waste Vent
and Natural Gas
Add Natural Gas should Oxidizer Temperature drop below 180
Add Cooling Water should Oxidizer Temperature rise above 2
Add additional Combustion Air should the Stack Oxygen
Content drop below 3%.
Between 1800OF and 2200OF, we expect no additional Fuel or Coolin
water to be used

H C l Vent
ra tio
FY

L ig h t C o lu m n s

FE
ra tio
FY

D C Vent

FE
ra tio
FY

H eat Vent

FE
ra tio
FY

O xy Vent

sp = 2200F

FE

T IC

Ta n k F a rm V e n t
TE

C o o lin g W a te r

LV -6 0

O x id iz e r

sum
FY

TE

ra tio
FY

T IC

AE

T o W a s te
H e a t B o ile r

O2

A to m iz in g S te a m

N a tu ra l G a s

FE
F IC

C o m b u s t io n A ir

FE

UY

>

sp = 1800F
A IC

sp = 3%

Controlling the Waste Heat Boiler

F IC

P IC
>

UY

B o ile r F e e d W a te r

P ro d u c t S te a m

FE

S te a m D ru m

H o t P r o d u c ts o f C o m b u s t io n

PT

FE

S te a m
C hest

LT

L IC

To Q u e n c h A b s o rb e r

B o ile r B lo w - D o w n

Items to be Controlled:
Control Boiler feed water addition to match steam production rate
Add additional water, should the steam drum level drop below a predetermined level.
Control the Steam production rate to maintain desired pressure in the steam
drum

The Quench Absorber

The purpose of the Quench/Absorber is to cool the gases and remove most of
the Acid gases formed
A b s o rb e r E x h a u s t

Q u e n c h e r/A b s o rb e r
A b s o rb e r M a k e - U p W a te r

Items to be Controlled:
B o ile r E x h a u s t
L IC
LT

Control Make-up water by maintaining tower sump level

Control bleed from the system to maintain a given
density of Bleed solution.

sp

AE

D e n s it y

A IC

sp

A b s o r b e r B le e d
R e c y c le A b s o r b e r
Pum p

The Scrubber
The purpose of the Scrubber is to remove the remaining Hydrogen Chloride
[HCl] and Chlorine{Cl2] from the gas stream prior to exhausting to the
atmosphere.
E x h a u s t to
A tm o s p h e re

S c ru b b e r
S c ru b b e r M a k e -U p W a te r

C a u s t ic S o lu tio n

Items to be Controlled:
Q u e n c h / A b s o rb e r
E xhaust
L IC
LT

sp

AE

AE

pH

A IC

sp

Acid absorbed in solution will lower the pH of the

recycle solution
Control Caustic addition to maintain pH
Control Water addition to maintain sump level

D e n s it y

A IC

sp

S c r u b b e r B le e d
R e c y c le S c r u b b e r
Pum p

O P T IO N

Incinerator BMS Description

Hard Wired Relay Based System

Two Burner System: Auxiliary and Main Burner

Two Separate UV Type Flame Scanners

o Auxiliary Burner Flame Scanner For Pilot and Auxiliary
o Main Burner Flame Scanner Only Main Burner

Incinerator BMS Interlocks

Different BMS
Interlocks

Main Interlock Start Permissives

Is Air Blower Running? (Start Air Blower)

Is Flame Detected? (Fire Eye Flame Detectors)
Is Plant Instrument Air Supply OK? (PSL)
Is Combustion Pressure OK? (PSL)
In Natural Gas Pressure? (PSL)
Is Natural Gas Pressure to Auxiliary Burner OK?
(PSH)
Is Natural Gas Pressure to Main Burner OK? (PSH)
Is Atomizing Steam Pressure OK? (PSL)
Is Cooling Water Supply OK? (PSL)
Is Thermal Oxidizer Temperature OK? (TSH)
Is Steam Drum LeveOK? (LSLL)
Is HCl Tower Level OK? (LSLL)
Is HCl Recirculating Flow OK? (FSL)

Pre Purge Interlock

Are Auxiliary Main Gas and Block Valve Closed and

Vent Valve Open?

Are Main Burner Main Gas and Block Valve Closed

and Vent Valve Open?

Are Pilot Burner Main Gas and Block Valve Closed

and Vent Valve Open?

Are All Vents Main Valve and Block Valve Closed and
Vent Valve Open?

System Purge
Start Permissive and Pre Purge Interlock is OK, BMS
signals Combustion Air Control Valve to Open
10 minutes time delay holds, to verify Combustion
Valve Open (Limit Switch) and Flow is normal.

A Purge Period of 5 Minutes.

DCS Analog Output Signal Drives the Combustion Air

and Natural Gas Control Valve to Open. (Verified by
Limit Switches)

Ignition and Pilot Trial

DCS Analog Output Signal Drives the Combustion Air

and Natural Gas Control Valve to Open. (Verified by
Limit Switches)

10 sec pilot trial for Ignition begins

Is Pilot Flame Detected Within 10 sec?

Auxiliary Burner Trial

Once Pilot Burner Sensed, Auxiliary Burner Trial is

Initiated.

A 10 sec Timing Period

Is Auxiliary Flame Detected by Flame Scanner

Within 10 sec?

Auxiliary Burner Ramp Up

Auxiliary Burner maintains Low Fire Position and

release control to DCS for process control.

Two Control Strategies:

Main Burner Trial

With Flame On and Chamber Temperature above 760

Deg Centigrade, Main Burner Light Up is Enabled.
Main Burner combustion and gas control valves
driven to Low Fire Position.
A 10 sec Timing Period

Is Main Flame Detected by Flame Scanner Within 10

sec?

Waste Admit Control

Vents Line Up and Air demand ratio control is

implemented in the DCS
Is Chamber Above Waste Admission
Temperature? (TSL)
Is Individual Waste or Vent Pressure OK? (PSL)

Vents are Line Up from DCS

Incinerator BMS Interlocks

Different BMS
Interlocks

New BMS System Overview &

Advantages

PLC bases Burner Management System

Interactive HMI for Operator access
Advance capabilities of monitoring and diagnosis
Interlocks are displayed on HMI through cause and effect
diagram
Provision to display first in cause of tripping
Soft bypassing of securities for maintenance requirement
Dedicated sequence of Pilot trial to facilitate ratio
adjustment during Auxiliary burner startup
Adjustable settings of Flame Scanner Module (UV / IR)
More than 350 loops termination carried out in new BMS
Panel along with termination of more than 200 loops in DCS
Marshalling

Pre Commissioning Issues

Limited capabilities of monitoring and diagnosis
No HMI for overall system and field operations
monitoring
Time consuming troubleshooting
No latching of faults
Too many relays creating point of failure
Flame Scanner setting adjustment not possible
Logic modification was difficult
By passing was done through hard wired

New BMS Panel

Commissioning Phase Challenges

Safe Removal of loops from DCS during running

plant

Inactive points from DCS

Safe removal of more than 400 terminations from DCS Marshalling
Protocol for loop isolation followed (PVC tape application, safe keep)
Time taken 2 days vs. initially planned half day, plus 2 days for
reinstallation and back in service

Number of terminations and cables rerouting

Removal of more than 1100 terminations from field panel

Pulling of all cables from old panel followed by panel removal
New panel installation
Cables insertion in new panel from individual glands
Cable rerouting, termination and dressing inside new panel

Commissioning Phase Challenges

Cables Short length Issue
Identified during cables routing and installation in new panel
Installation of new cable segments and butt jointing

Loop testing and verification

Individual loop testing from field to BMS
Individual loop testing from BMS to DCS

Pre Start-up Logic Issues

Reverse indications of low pressure switches on field HMI and DCS
Difference in temperature reading on field HMI vs. temperature on
TIs head
Modification of 24v supply going in field for energizing relay in old
panel

Thank You