FOR THE PETROLEUM PROCESSING INDUSTRY

Fired equipment is critical to any petroleum processing operation. The safety, reliability, efficiency and emissions reduction of this equipment are of paramount importance. These can be significantly improved through state-of-the-art burner control systems. CSI has developed unique expertise in all aspects of burner management and combustion control. We are entirely focused on providing high quality combustion solutions for the petroleum processing industry. COMBUSTION SOLUTIONS INC.

Burner Control Systems

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Multi-Burner Fuel Pressure Regulation and Startup ControlTypical fuel trains incorporate a single, low fire-position mechanical stop for starting burners. As a result, the startup of multiple burner systems becomes increasingly difficult.

CSI has developed a unique pressure regulation strategy that combines the functions of flow and pressure control together with a sidearm startup regulator that provides a simple and extremely effective method of starting multiple burners. Our system is also very forgiving by allowing the furnace to trip to minimum fire with any number of burners in operation.

Waste Fuel PreparationThe fuels used in PPI facilities are predominently waste products from the process operation. They are dirt and soot laden with toxic components and often require heating and fuel conditioning.

The situation is further complicated as modern low Nox burners have small drillings for their burner tips. Proper selection of fuel preparation equipment is imperative for safe and reliable operation.

CSI has experience with all types of fuels and burners used in the PPI. We can develop a solution to meet specific needs.

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Fuel Flow Control and Fully Metered Cross Limiting CombustionAccurate flow measurement is especially important for reducing emissions and increasing efficiency. This can be accomplished with fully metered cross limiting combustion control systems; however, complex fuels with widely varying Wobbe #, heating value and fluid properties make fuel flow metering challenging.

CSI has extensive experience with waste fuels and can provide accurate flow measurements and control solutions for fuels commonly found in the PPI.

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CSI provides pre-packaged burner control systems that are specifically designed to handle the unique requirements of the petroleum processing industry (PPI) A. Waste Fuel Preparation B. Multi-Burner Fuel Pressure Regulation and Startup Control C. Fuel Flow Control and Metering D. Automatic Valve Leak Testing E. Fuel Pressure Monitoring and ShutdownF. Redundant Valve Trains G. Reliable Ignition and Flame MonitoringH. High Availability Safety Instrumented SystemsJ. Fuel Code Compliance amd Hazardous Area Certification

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Redundant Valve TrainsFired equipment in PPI installations are required to operate 24 hours per day for several years. Therefore reliability is of the utmost concern for the furnace operator.

CSI has developed a fully redundant valve train arrangement that en-sures uninterrupted operation. A sudden unexpected component failure will not cause the fired equipment to trip.

Online testing – Many codes require that fuel safety valves be leak tested. The leak test can be performed online without tripping the fired equipment by using both a redundant valve train and a valve proving system. A valve proving system is considerably more definitive than a partial stroke test, which cannot determine if the valve is leaking – only if the valve moves. Since fuel gas is typically dirty, a partial stroke test is inconclusive.

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G Reliable Ignition and Flame MonitoringReliable ignition systems are one of the most critical components in a burner control system. Traditional high voltage spark igniters and flame rods are unreliable for PPI installations located outdoors where high winds and moisture laden air is common.

CSI has developed a high energy ignition and specialized flame monitoring system that offers unprecedented reliability under any weather conditions.

CSI provides custom engineered systems to meet the specific requirements of the customer and their fired equipment.

Automatic Valve Leak Testing (Valve Proving System)Traditional burner control systems incorporate a double block and bleed (vent) valve train arrangement. This is common in commercial and light industrial applications where the fuel is clean, the gas pressure is low and gas can be safely vented outside of a building. Conversely, the conditions in petroleum processing facilities are quite different. The fuels are predominantly waste products that have toxic components, high fuel pressure and no safe place to vent the fuel. In these installations, the use of a fail open vent valve is particularly hazardous.

CSI has developed and perfected a valve proving system that is specifically designed for the PPI.

Our valve proving system tests the seat tightness of two series mounted fuel safety valves. The leak test is performed during the purge, as well as after each trip. Several line-mounted pressure transmitters and a unique control sequence are used to determine if either valve is leaking.

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Pressure Monitoring and ShutdownImportant elements of burner safety are high and low fuel pressure trips. Tradi-tional burner management systems utilize pressure switches or simplex pressure transmitters that require a furnace shut down for maintenance, testing or a specific component failure. These designs typically measure pressure upstream of the con-trol valve, which does not accurately represent the pressure supplied to a multiple burner system.

CSI has developed a unique fuel header pressure monitoring design that utilizes our valve proving system to create a cost effective, safe and reliable 2oo3 voting strategy for pressure monitoring as well as shut down functions. The pressure transmitters directly measure the fuel pressure to the burners, provide deviation alarms and permit online maintenance or testing.

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Key Features of CSI Burner Control Systems

Experience – through completion of numerous projects, we have obtained a thorough understanding of fired equipment used in petroleum processing facilities. We can therefore provide the optimum solution to fit clients needs.

Quality – quality is the cornerstone of our engineering and fabrication processes. We use only the highest grade components that meet or exceed most petroleum processing facility standards.

Risk reduction – we are well versed in all aspects of fired equipment and can provide solutions that ensure safety for personnel and prevent damage to equipment and the environment.

Reliability – our systems are designed to ensure high availability for several years of uninterrupted operation.

Online Maintenance –all valves and instruments can be maintained online without impacting the process.

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Online Testing – all items can be tested online to increase safety integrity levels.

Practical Skid Layouts – our skids are designed using 3D solid modeling for efficient layout and to ensure ease of operation and maintenance. We provide client walkthroughs prior to fabrication.

Rugged – our skids are designed and fabricated for rough shipping and handling and years of service in harsh conditions.

Attention to details – our in house sandblasting and painting facilities ensure supreme surface coatings. All exposed components are high grade stainless steel and all studs and nuts are plated to prevent corrosion. Fully welded construction – our skids are designed to ANSI B31.3 with appropriate weld procedures for several common materials.

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High Availability Safety Instrumented Systems (IEC61511)PPI facilities typically adhere to stringent international standards for the design of safety instrumented systems such as burner control.

CSI has certified functional safety engineers that are familiar with all aspects of the IEC 61511 standard. We have experience with most types of PLC and DCS platforms used in the PPI which allows us to provide custom solutions designed to meet the specific needs of clients.

Fuel Code Compliance & Hazardous Area CertificationThere are several code requirements for fuel fired equipment used in PPI installations. In Canada, the CSA B149.3 code covers field approval of fired equipment. Other countries may require conformance to NFPA 85/86 codes. Pressure piping systems require construction to ANSI B31.3 and field electrical systems typically require hazardous area approvals.

CSI is well versed in Canadian, US and international codes for fuels, piping and electrical systems. We have completed numerous installations in petroleum pro-cessing facilities that were certified to the appropriate codes and standards.

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High Quality, Safe and Reliable Burner Control Systems for the Petroleum Processing Industry

5475 53 Ave S.E. Calgary, AB T2C 4N2 CanadaT 1 403 547 9722 F 1 403 547 9760www.combustionsolutions.ca