Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility
A multi-fuel boiler project for a chlor alkali production facility resulted in significant modernization and operational improvements. The client's legacy relay-based Burner Management System (BMS) was upgraded to a DeltaV CHARM Safety Logic Solver, providing enhanced visibility, safety, and operational flexibility. This project not only modernized the client's system but also ensured compliance with NFPA 85 codes and met all Safety Instrumented Systems (SIS) requirements.
Challenge
The client’s existing BMS was based on outdated relay logic technology, limiting visibility into critical boiler parameters. Operators struggled with frequent system trips but lacked the ability to identify the root causes. Their legacy system provided no direct diagnostics, forcing operators to visually inspect equipment and restart the system manually. Additionally, the client required operational flexibility to switch between multiple fuel types — natural gas, hydrogen, and oil — without system shutdowns.
The client sought improved support and expertise with a configuration provider with SI-BMS experience. Their need for seamless integration, combined with complex fuel-switching requirements, posed significant technical challenges.
Solution
aeSolutions successfully delivered a comprehensive upgrade of the client’s BMS, integrating it into the existing DeltaV platform. Key elements of the solution included:
• Integration with DeltaV: The new BMS was implemented using DeltaV’s CHARM Safety Logic Solver, ensuring compatibility with the client’s existing system and reducing the learning curve for operators.
• Enhanced System Visibility: Operators gained real-time insight into key metrics such as pressure levels and temperature through custom Dynamos on the control room interface. First-out diagnostics were also added, enabling quicker root-cause analysis and reducing downtime.
• NFPA 85 Code Compliance: The upgrade ensured the boiler system met the latest NFPA 85 safety codes, enhancing both safety and reliability.
• Multi-Fuel Flexibility: The system was designed to allow seamless fuel switching between hydrogen, natural gas, and oil without requiring shutdowns. Custom Safety Instrumented Functions (SIFs) were implemented to manage the complexities of multiple fuel types safely.
• Close Client Support: aeSolutions was able to provide prompt, on-site technical support as needed, ensuring smooth project delivery and ongoing assistance.
Results
The results of this project provided significant benefits to the client by improving both safety and operational efficiency. The upgraded BMS ensured compliance with NFPA 85 codes, enhancing safety and reducing the risk of boiler-related incidents. With the ability to switch seamlessly between hydrogen, natural gas, and oil, the system offered the client greater operational flexibility. The inclusion of real-time diagnostics and first-out alarms allowed for faster troubleshooting, reducing downtime, and improving system availability. Additionally, the operators benefited from a streamlined process, as they could now manage startups from the control room, minimizing manual interventions. To ensure a smooth transition, aeSolutions replicated the client's existing control graphics through custom Dynamos, maintaining familiarity for operators and preventing workflow disruptions. These enhancements collectively improved safety, reliability, and ease of operations for the client.
Industry: Chlor Alkali Production
Geography: Southeast
Unit Operation: Burner Management System (BMS), DeltaV