FlexSILon® BCS for burners and boilers

When less means more

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.

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 profit-ability and safety with far fewer components and less effort.

A comprehensive solution that pays for itselfIn addition to basic safety-related functions, the safety sys-tem 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 todayFlexSILon 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.

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

Combined control system

Burner management & combustion control

Maximum plant availabilty

Touch-display visualisation

DCS

DCS

DCS/SCADADCS/

SCADA

Alternatives: Combined control system*Burner management & combustion control

OilOil

GasGas

CoalCoal

Function block library Event recording SCADA

* also for boiler protection

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.

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

PP TT LL

PP TT LL

Boiler

PP TT LL

Burner controls Boiler protection

Modbus/OPC

Boiler protection

Maximum plant availabilty

PDA

54 5

FlexSILon BCSA complete solution comprising hardware, software and service

BCS

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 decom-missioning. 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

Always the right decisions at the right time

SILworXThe world’s most advanced safety application manager

HIMaxOne system for everything

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 func-tion blocks can be easily programmed.

TÜV-certified function blocks up to SIL 3

TÜV-certified function blocks considerably reduce the programming costs and time, thus lowering the complex-ity 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:

� PID control algorithm

� Three-point driver

� Ramp

� Curve with 20 pairs of configurable points

� Flow PTD correction

� Synchronisation monitoring of analog process points

Non-safety-related areas may be modified without influencing safety-related areas (since program areas and tasks are non-reactive)

Tasks can be protected by passwords

Shorter commissioning and troubleshooting times due to comprehensive diagnosis

Comfortable changeover of SIL and NonSIL modules during operation (if safety-related requirements in the loops change)

Compliance with relevant requirements from furnace/burner standards and norms

Boiler protection with monitoring of pressure, temperature and level

Safe separation of different functions through multitasking

Combined control concepts including O

2 correction thanks to high-performance processing power

Optimised fuel utilisation and low operating costs due to combined control system

­­

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 sys-tems for the superordinate plant area

Nonstop operation during the entire lifecycle of a plant

Start/stop function

TÜV-tested and approved fuel-air ratio monitoring

7 98

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

� Fast, flexible and compact

� Extremely cost-effective

� Distributed applications

� Applications with just a few I/O points

� SIL 3

� Nonstop operation

� Maximum performance

� Maximum configuration flexibility for life

� Various mechanical concepts

� Ideal for mid-size and large applications

� 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

One technology, always the right solution

Planar4 � SIL 4

� Hard-wired system

� Programming: solder, termipoint and wire wrap

� Extremely robust

� Scalable redundancy

10

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 high-pressure 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 www.hima.com

11

FlexSILon BCS – better for your bottom line

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.

Safety that pays for itself.

Optimal, cost-effective burner operation thanks to nonstop op-eration and maximum availability.

Good for the environment.

Thanks to the HIMax combined control system, fossil fuels are optimally utilised. Reduced gas emissions and pollution.

SIL safe.

Safety for the future thanks to the implementation of all BCS functions on one SIL 3 platform.

Tested safety.

TÜV-tested BCS function blocks for HIMax, HIMatrix and SILworX engineering tool.

Ultimate flexibility.

Perfect integration into any DCS.

Always the right decisions.

Consulting and customer service at all stages of the safety lifecycle – from partial tasks to the entire project.

Protection for burners and boilers.

Combined solutions for burner control system and boiler protection.

Approvals made easy.

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.

Certified to every standard.

IEC 61508, IEC 61511, EN 50156-1 and EN 746-2: our experts design solutions that fully comply with standards.

12 13

HIMA is the world’s leading specialist for safety-related auto-mation solutions. HIMA solutions provide maximum safety and maximum availability and can be integrated into any automa-tion 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 appro-priate 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 1908. Since 1970, the com-pany has achieved numerous milestones in the field of safety-related automation engineering, including the introduction of the world’s first TÜV-certified safety system. Today, approxi-mately 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 con-centrate on safety solutions. The results are quality products, unrivalled specialist knowledge and customer confidence built on decades of successful projects.

Why HIMA?

1514

For a detailed list of all our subsidiaries and representatives,please visit our website: www.hima.com/contact

96 9000507 0811 V01© 2011 HIMA Paul Hildebrandt GmbH + Co KGFlexSILon, HIMax, HIMatrix and SILworX are registered trademarks of HIMA Paul Hildebrandt GmbH + Co KGSpecifications are subject to change. HIMA Paul Hildebrandt GmbH + Co KGAlbert-Bassermann-Str. 28 I 68782 Brühl, GermanyPhone +49 6202 709-0 I Fax +49 6202 709-107info@hima.com I www.hima.com