FlexSILon BCS for burners and boilers. When less means more

Transcription

1 FlexSILon BCS for burners and boilers When less means more

2 Less effort, more safety Burners are among the most safety-critical and complex systems used in the energy and process industry. They must function seamlessly with automatic firing devices and related technical equipment for operation and monitoring, data storage, alerts, diagnostic purposes, etc. They must comply with numerous standards and directives in their planning and operation and also be cost-effective. FlexSILon BCS from HIMA is a complete solution for burner safety and boiler protection, providing maximum plant profitability and safety with far fewer components and less effort. A comprehensive solution that pays for itself In addition to basic safety-related functions, the safety system also groups other control functions which, until now, required additional components: Combined control system (multiple burner- and/or multi-fuel burner systems) Fuel-air ratio monitoring Start/stop sequences Boiler and process protection Boiler pressure and temperatur level control Local operation and monitoring (HMI) Connection to control systems (e.g. DCS, SCADA, etc.) Installing the future today FlexSILon BCS offers clear economic benefits while also meeting all the functional safety requirements for operating your plant as required by international norms and standards. With FlexSILon BCS, your plant is already prepared today for tomorrow's safety requirements. HIMA. Safety. Nonstop. It s a philosophy more than 100 years in the making. It s built on HIMA s singular focus on safety and is proven by decades of technology breakthroughs. It represents our commitment to providing maximum safety and uninterrupted plant operations. Our goal isn t just to design the world s best safety systems. It s to help keep your business safe and running. No shutdowns. No failures. Maximum uptime. Maximum profitability.

3 References ADNOC, AFC, Agip, Air Liquide, Akzo Nobel, Aventis, BASF, Bayer, Bayer Schering Pharma, BK Guilini, Boehringer Ingelheim, Borealis, BP, Celanese, Chevron, Clariant, CNOOC, CNPC, Conoco Phillips, DOW, DSM, DuPont, ENI, E.ON, Evonik, ExxonMobil, Henkel AG, Hoffmann-La Roche, HOLBORN, Huntsman, INEOS, KOC, Kuwait Petroleum Corporation, LANXESS, Linde, Lösche, Lukoil, LyondellBasell, MAN Turbo, Mauell, Mehldau & Steinfath, MERCK, MiRO, Momentive Performance Materials, National Oil Company (Libya), Nigerian National Petroleum Corporation, NIOC, Novartis, OMV, PDO, PDVSA, Pemex, Petrobras, PetroChina, PETRONAS, QP, RWE, Saacke, SABIC, Sanofi-Aventis, SASOL, Saudi Aramco, Shanghai HUAYI Group, Shell, Sinopec, Sonatrach, Statoil, Thai Petrochemical, Thyssen Krupp, Toschiba, TOTAL, Turkmengaz, Uhde, UNOCAL, Uzbekneftegaz, Vinnolit, Weishaupt, Yara 3

4 FlexSILon BCS A complete solution comprising hardware, software and service Many companies have individual modules and solutions for plant safety. HIMA offers you a total solution from a single source. FlexSILon BCS is the complete solution for automatic burner control and boiler protection. The core components are the proven HIMax and HIMatrix safety systems; the SILworX configuration, programming and diagnostic tool; and the unique expertise of our experienced engineers, who assist you throughout the entire lifecycle. HIMA thereby guarantees maximum plant safety and highest availability while achieving maximum profitability. FlexSILon BCS is the comprehensive solution for automatic burner control and boiler protection. BCS Burner controls Boiler protection Function block library Event recording SCADA PDA DCS/ SCADA DCS Your benefits at a glance All automation functions in one system Complete hardware and software TÜV-tested function blocks HIMA LIFECYCLE SERVICES Maximum safety and maximum profitability Can be integrated in any automation environment Original equipment (OEM) Revamps, modernisations or new plants Modbus/OPC Boiler protection Combined control system Maximum plant availabilty Burner management & combustion control Touch-display visualisation Maximum plant availabilty Alternatives: Combined control system* Burner management & combustion control P P P T T L T Boiler L L Oil Oil Gas Gas Coal Coal * also for boiler protection 4 5 5

5 Always the right decisions at the right time The new safety standards and norms require safety to be monitored throughout a plant s entire lifecycle from initial analysis, implementation and operation through to decommissioning. With HIMA LIFECYCLE SERVICES, you benefit from firing technology and functional safety expertise to ensure nonstop and profitable plant operations at every stage. Throughout the lifecycle, our experienced and highly qualified safety specialists are your point of contact, looking after your interests in an independent, expert and reliable manner. HIMA consulting services: Functional safety for burners and boilers 1. Assessment and Specification Development of a safety plan SIL assessment Specification and procedures Concept design Development of FSM Specific training courses on basic and detail engineering 2. Design and Engineering Basic and detail engineering SIL verification DCS integration Inspection and factory acceptance test (FAT) Specific training courses 3. Installation and Commissioning System installation and testing Commissioning DCS integration Specific training courses 4. Validation Functional tests under operating conditions Support during site acceptance test (SAT) Support during the test phase including modifications 5. Operation and Maintenance 24-hour hotline, 24-hour on-call service, 24-hour spare parts service On-site support Maintenance Specific training courses 6. Modification On-site support 24-hour hotline, 24-hour on-call service, 24-hour spare parts service Specific training courses 7. Decommissioning On-site support for decommissioning, removal or plant relocation Specific training courses 6

6 HIMax One system for everything SILworX The world s most advanced safety application manager The intuitive user interface and fully graphical drag&drop programming featured in SILworX make handling easier, reduce application errors and speed up the engineering process. A range of user levels, the display of all status and diagnostic information, and comprehensive validation tools guarantee quick planning and commissioning. With SILworX, you have one licence for all functions. Various special function blocks can be easily programmed. Combined control concepts including O2 correction thanks to high-performance processing power Optimised fuel utilisation and low operating costs due to combined control system TÜV-certified function blocks up to SIL 3 Tasks can be protected by passwords Start/stop function Shorter commissioning and troubleshooting times due to comprehensive diagnosis TÜV-tested and approved fuel-air ratio monitoring Comfortable changeover of SIL and NonSIL modules during operation (if safety-related requirements in the loops change) Boiler protection with monitoring of pressure, temperature and level Compliance with relevant requirements from furnace/burner standards and norms Safe separation of different functions through multitasking 7 Non-safety-related areas may be modified without influencing safety-related areas (since program areas and tasks are non-reactive) Operation and monitoring concepts Small, local LCD monitors or LED displays for operation and monitoring tasks Control boxes for the robust burner proximity area, which contain autonomous burner controls with operation and monitoring devices Complex visualisation systems for the superordinate plant area TÜV-certified function blocks considerably reduce the programming costs and time, thus lowering the complexity of the acceptance procedure for the overall system. BMS function blocks for burner applications: Pre and post purging Gas igniter Main gas burner Main gas burner with igniter rod Oil burner with pressure atomiser Oil burner with steam atomiser Fuel-air ratio monitoring BCS function blocks for the combined control: Nonstop operation during the entire lifecycle of a plant PID control algorithm Three-point driver Ramp Curve with 20 pairs of configurable points Flow PTD correction Synchronisation monitoring of analog process points 8 9

7 One technology, always the right solution HIMA provides the industry s largest range of different safety systems. All systems are based on the same technology, proven and refined over decades. This enables HIMA to guarantee customers the right, individual safety solution fast and flexibly. SIL 3 Nonstop operation Maximum performance Maximum configuration flexibility for life Various mechanical concepts Ideal for mid-size and large applications SIL 3 Fast, flexible and compact Extremely cost-effective Distributed applications Applications with just a few I/O points SIL 3 For highest fault-tolerance requirements Scalable redundancy Central and distributed installations Ideal for small and mid-size applications Broad range of I/O modules Planar4 SIL 4 Hard-wired system Programming: solder, termipoint and wire wrap Extremely robust Scalable redundancy 10

8 Benefit from our industry expertise Boxberg lignite-fired power plant In the new power plant block R of the lignite-fired power plant owned by Vattenfall Europe Generation AG, five HIMax systems are used as ESD systems in the boiler and burner safety device. SILworX function blocks simplified the engineering. Helmut Mauell GmbH created the control technology. HIMA was responsible for the project management, engineering, programming and commissioning of the safety systems. Shell ethylene cracker in Moerdijk In the ethylene cracker at the Shell production site in Moerdijk, Netherlands, HIQuad controllers are used in F&G applications and BMS. Four H51q controllers are used to monitor one medium-pressure and three highpressure boilers. Seven other systems monitor the 18 cracking furnaces in the ethylene plant. HIMA s service encompassed all safety-related controllers, project management for the systems, hardware and software engineering and on-site support. Find more case studies on 11

9 FlexSILon BCS better for your bottom line Good for the environment. Protection for burners and boilers. Safety that pays for itself. Combined solutions for burner control system and boiler protection. Thanks to the HIMax combined control system, fossil fuels are optimally utilised. Reduced gas emissions and pollution. Optimal, cost-effective burner operation thanks to nonstop operation and maximum availability. Certified to every standard. Approvals made easy. IEC 61508, IEC 61511, EN and EN 746-2: our experts design solutions that fully comply with standards. SIL safe. Ultimate flexibility. The combination of TÜV-certified systems and engineers as well as TÜV-tested function blocks reduce the time and effort spent on approvals and shorten therefore the approval process. Safety for the future thanks to the implementation of all BCS functions on one SIL 3 platform. Perfect integration into any DCS. Tested safety. Safety and security. Thanks to their independence from the DCS and a special security certification (Achilles), HIMA solutions protect every system against cyber attacks, including from the Stuxnet virus. 12 Always the right decisions. TÜV-tested BCS function blocks for HIMax, HIMatrix and SILworX engineering tool. Consulting and customer service at all stages of the safety lifecycle from partial tasks to the entire project. 13

10 Why HIMA? HIMA is the world s leading specialist for safety-related automation solutions. HIMA solutions provide maximum safety and maximum availability and can be integrated into any automation environment. More than 25,000 HIMA systems have been installed in over 80 countries, protecting the equipment of the world s largest companies in the oil, gas, chemicals, pharmaceuticals and power generation industries for more than 40 years. In the fields of railway, logistics and machine safety, HIMA solutions are leading the way to increased safety and profitability. HIMA develops solutions that provide both maximum safety and availability for processes, plants and machinery nonstop. The HIMA LIFECYCLE SERVICES concept gives customers an overview of all the requirements of functional safety allowing them to always make the right decision at the appropriate time. HIMA solutions therefore offer maximum safety, strengthen a plant's productivity and profitability whilst ensuring compliance to global statutory requirements. HIMA was founded in Germany in Since 1970, the company has achieved numerous milestones in the field of safetyrelated automation engineering, including the introduction of the world s first TÜV-certified safety system. Today, approximately 150 of 600 employees work exclusively on research and development tasks. Through a steadily growing network of subsidiaries, sales and service centres, as well as representatives in more than 50 countries, HIMA implements projects of all sizes all over the world. Thanks to its corporate independence, the family-run company is able to work in any project structure taking on complete projects or partial tasks, and working both directly for end customers and as part of a team with EPCs, MACs and PCS manufacturers. This enables HIMA to continue to concentrate on safety solutions. The results are quality products, unrivalled specialist knowledge and customer confidence built on decades of successful projects

11 V HIMA Paul Hildebrandt GmbH + Co KG FlexSILon, HIMax, HIMatrix and SILworX are registered trademarks of HIMA Paul Hildebrandt GmbH + Co KG Specifications are subject to change. HIMA Paul Hildebrandt GmbH + Co KG Albert-Bassermann-Str. 28 I Brühl, Germany Phone I Fax info@hima.com I For a detailed list of all our subsidiaries and representatives, please visit our website: