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Burner Management Systems

Problem

The Burner Management Systems on the power and recovery boilers at a Pulp and Paper Mill were becoming unreliable, and difficult to maintain and troubleshoot. The systems were relay-based or card-based with hard-wired logic and installed over 25 years ago.

Goal

Develop a new burner management system using current technology, standard components and a distributed control system (DCS) for control that would make the system easy to operate, troubleshoot and maintain.

The System

Working closely with the customer, Universal Dynamics developed and implemented a redundant system using programmable logic controllers (PLCs) tied to the DCS for remote control of the system via a graphics panel in the control room. For safety reasons, local graphic operator stations were provided for each burner deck, replacing the old control stations with pushbuttons and pilot lights.

In conjunction with the new Burner Management System controls, Universal Dynamics revised and implemented a new emergency shutdown and rapid drain procedure for the recovery boilers, an integral part of the boiler safety systems. The procedure prevents water from entering the recovery boiler, contacting the molten smelt bed and causing an explosion.

Full consideration was given to all relevant codes and standards during the development of the Burner Management and Emergency Shutdown systems and the resulting systems were compliant with Factory Mutual insurance requirements.

The project also included an overall upgrade of the control system DCS, new valves and instrumentation. Piping was designed to open up congested burner decks for improved accessibility to operations and maintenance staff.

Results

The mill experienced improved recovery boiler reliability and increased black liquor throughput. The auto-start capability implemented on the power boilers allowed easy stop/start control based on mill steam demand. Maximizing incineration of hog fuel in the power boilers allowed for the shutdown of the old beehive burners, and a reduction in boiler gas usage. The success of this project has led to similar turnkey projects for the Burner Management System.