jeres-j-607 burner management systems for sru trains

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Jubail Export Refinery Engineering Standards

JERES-J-607 Burner Management Systems for SRU Trains

Revision 0

Responsibility JER Engineering

29 April 2008

Jubail Export Refinery Engineering StandardsJERES-J-607 Rev. 0

Burner Management Systems for SRU Trains

29 April 2008

Revision TrackingRevision0 01 00

Revision Date29 April 2008 31 March 2008 03 February 2007 Issued for a bid package.

Scope of Revision

Issued for Bid package only for review. First draft issued is based on Saudi Aramco SAES-J-607 Burner Management Systems for SRU Trains issue date 14 November, 2005. Document was modified to incorporate amendments and modifications.

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company.

Page 2 of 24

Jubail Export Refinery Engineering StandardsJERES-J-607 Rev. 0

Burner Management Systems for SRU Trains

29 April 2008

Table of ContentsSection 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Scope Conflicts, Deviations and Clarifications References Definitions General Requirements Burner Management System- Hardware Requirements Burner Management System Logic Requirements Pilot System Burner System Flame Monitoring System Control Room and Local BMS Interface Installation Documentation Testing and Inspection Contents Page 4 4 4 6 8 9 9 12 15 16 18 19 20 21

AppendixI Figures 22

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company.

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Jubail Export Refinery Engineering StandardsJERES-J-607 Rev. 0

Burner Management Systems for SRU Trains

29 April 2008

11.1

ScopeThis engineering standard establishes minimum requirements for the design, construction and installation of burner management systems (BMS) for the gas fired equipment in sulfur recovery unit (SRU) trains. SRU trains have typically 5 independently fired furnaces. The BMS system for each fired furnace is defined herein. Emphasis is placed on the use of a reliable Burner Management System (BMS), incorporating flame monitoring, safety interlocks, light-off and purge permissives, and alarms and trip functions as defined in NFPA 85. Requirements of NFPA 85 shall be applied to the BMS systems used on SRU trains. However, conflicting requirements specified in this standard shall take precedence over NFPA 85. A BMS is considered a specific type of Emergency Shutdown System (ESD). As such, all requirements of JERES-J-601 apply to this standard, except as noted herein. The BMS requirements specified in this standard are considered prescriptive and the application of ANSI/ISA-84.00.01-2004 (IEC 61511 Mod), including establishment and validation of SIL levels, is not required. This standard specifies the minimum BMS requirements for new SRU projects. BMS upgrade projects to existing SRU trains may reduce the minimum requirements of this standard to maintain consistency with other SRU units, when approved by the Saudi Aramco Proponent Organization.

1.2

1.3 1.4

1.5

22.1

Conflicts, Deviations and ClarificationsAny conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution. Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2

Where a licensor specification is more stringent than those of this standard, the Licensors specific requirement shall apply.

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company.

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Jubail Export Refinery Engineering StandardsJERES-J-607 Rev. 0

Burner Management Systems for SRU Trains

29 April 2008

2.3

Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution. Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.

2.4

3

ReferencesThe selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1

Jubail Export Refinery References Jubail Export Refinery Engineering Procedure Jubail Export Refinery Engineering Standards JERES-F-001 JERES-J-002 JERES-J-003 JERES-J-601 JERES-J-902 Process Fired Heaters Technically Acceptable Instruments Basic Design Criteria Emergency Shutdown and Isolation Systems Electrical Systems for Instrumentation

Jubail Export Refinery Materials System Specifications JERMS-L-4051 JERMS-J-4617 JERMS-J-4623 JERMS-J-4716 3.2 Ball Valves, (API SPEC 6D) Flame Monitoring Systems Programmable Controller Based ESD Systems Pneumatic Actuators On-Off Service

National and Industry Standards National Fire Protection Association NFPA 85 Boiler and Combustion Systems Hazards Code

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company.

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Jubail Export Refinery Engineering StandardsJERES-J-607 Rev. 0

Burner Management Systems for SRU Trains

29 April 2008

44.1

DefinitionsDefinitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution. Company: Jubail Export Refinery. Company Representative: A designated person from the Company or an assigned third party representative. Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2

List of Definitions Automatic BMS Operation: The Saudi Aramco mandatory method of BMS operation in which pushbutton actuations initiate furnace start-up, and where all purging, positioning, timing, and fuel/air valve manipulations are supervised and occur automatically. In Automatic BMS logic, operators are not required to manipulate burner front controls (e.g., manually open gas cocks) to light burners or pilots. Instead, burner and pilot starts are actuated from pushbuttons and monitored locally and remotely. Saudi Aramco requires the operator to manually initiate (via pushbutton) each of the following sequences: Furnace Master Fuel Trip (MFT) reset Purge Initial pilot/burner start (local operator function) Subsequent pilot/burner starts and stops Normal shutdown

Burner Valve (BV): A burner valve (BV) can be either an automated block valve or an automated bleed valve as defined below. BVs shall be selected as ZV valves per JERES-J-601; however, BVs shall not be provided with manual operators, local pushbutton operators, bypass valves, or partial stroke testing features. BVs are under complete control and supervision of the BMS system. Automated Bleed Valve - BV: This is an automatic valve used to vent fuel gas from between block BVs in both the pilot and burner fuel headers. Bleed valves shall be tagged as 'BV', and are not to be tagged as ZV.

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company.

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Jubail Export Refinery Engineering StandardsJERES-J-607 Rev. 0

Burner Management Systems for SRU Trains

29 April 2008

Automated Block Valve - BV: Sometimes called block valve, fuel shutdown valve, or SSV valve. The block valve is an automatic, fast closing, tight shutoff valve that completely shuts off fuel or air supply. These valves are located in the pilot and burner fuel headers and in the individual pilot and burner piping. Block valves can be used in conjunction with Bleed valves for gas service. Block valves shall be tagged as 'BV' and are not to be tagged as ZV. Burner Management System (BMS): The BMS is the control system dedicated to furnace safety and provides operator assistance in the starting and stopping of fuel preparation and burning equipment. Use of a BMS prevents misoperation of and damage to fuel preparation and burning equipment. The BMS includes the following subsystems: Logic System Field Sensors Pilot System Flame Monitoring System Automated Block and Bleed Valves Local Flame Safety Shutdown Panel Control Room Indication and Control Equipment

Master Fuel Trip: Sometimes called main fuel trip or MFT; an event that results in the rapid shutoff of all fuel to a furnace. Sulfur Recovery Unit (SRU) Fired Equipment: SRUs may have the following fired equipment: Air Preheater A natural draft, fuel gas fired furnace that preheats combustion air to be used in the SRU Reaction Furnace. This furnace typically uses up to 10 burners and incorporates continuous pilots. Pilots and burners are individually supervised, each with its own flame monitor. Pilots are lit via integrated spark ignitors. Firebox purging is via steam injection. Acid Gas Preheater A natural draft, fuel gas fired furnace that preheats H2S acid gas before it is comb