Description:

Fired equipment is found throughout the process industry in many applications, including various types of boilers, ovens, kilns, incinerators, reboilers, bath heaters, process heaters, furnaces, etc. The hazards associated with the burner operation are managed by an instrumented system commonly referred to as the burner management system (BMS). The BMS provides interlocks and permissives to prevent misoperation of equipment and to safely handle faults caused by equipment failure. These events potentially result in uncontrolled fires, explosions, or implosions and in the unintended release of the materials being heated. This course shall provide a thorough overview of the BMS unit operation, as well as, the associated combustion control techniques typically used to maintain a safe firing rate with emphasis on understanding associated hazards and design requirements to mitigate these hazards.

Objectives:

This course starts with a review of the NFPA, API, ISA, IEC and FM standards that describe Burner Management System design. The requirements of a Burner Management System, based on the standards, are then used to design an example Burner Management System. The details of the design and the design rationale are presented so that attendees will understand how to expand the design into custom solutions often needed by particular fired device installations. In addition the course will present an overview on combustion control fundamentals, burner management system design and application of safety instrumented system concepts to burner management systems.

Most OEM supplied fired devices come pre-equipped with a Burner Management System. However, these designs most often are not capable of meeting all of the requirements associated being classified as a safety instrumented system. As such, if this issue is not identified in time it could result in significant budget / schedule issues on new installations or modification to existing installations. This issue is becoming more and more present and problematic in industry at this time. Thus, this course will identify these risk items so the attendee is knowledgeable and can address these items at the appropriate stage in the project to allow them to be cost effectively managed.

Skills You Will Learn:

• Understand the hazards associated with the combustion process with emphasis on special hazards associated with arctic installations including low NOx burners
• Develop a thorough understanding of NFPA, API, ISA, FM and IEC standards requirements for Burner Management Systems associated with their modes of operation: pre-firing, purging, light off, normal operation and shutdown / post-purge
• Develop an understanding on combustion control and instrumentation requirements for Burner Management Systems
• Develop an understanding on application of the Safety Lifecycle to Burner Management Systems
• Be able to identify Burner Management System safety functions based on standards and hazard analysis
• Select safety integrity levels appropriate for reducing process risk to an appropriate level for the example problem
• Be able to quantitatively verify that SIL requirements for Burner Management System designs are met by the selected example equipment
• Be able to determine manual test frequencies
• Be knowledgeable on documentation requirements

About the Instructor:

Usman Khan, PE, TUV FSEng - Usman Khan is a Professional Engineer in multiple North American jurisdictions with over 19 years of experience in instrumentation controls and process safety in the oil and gas, and chemical industries. His technical expertise and experience encompass both multi-discipline engineering, as well as, operations of oil and gas assets. Usman’s work passion is centered on safety in design, specifically with fired equipment. Usman was most recently the I&C and Process Safety Technical Authority for an operating oil and gas company where he managed the full design lifecycle of a multi-billion greenfield project and set company technical standards in addition to his regular day job of supporting existing producing assets. With his 360-degree experience working for instrumentation and control OEMs, EPCs and oil and gas companies in a wide variety of roles in project management and operations, Usman brings a unique perspective to the table. He currently serves in an engineering leadership role, managing a group of engineers and safety professionals for aeSolutions’ Houston office.   

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