Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility
A critical pipeline transportation facility required a custom Safety Instrumented Burner Management System (SI-BMS) upgrade for their incinerator operations. The project involved implementing a SI-BMS compliant with NFPA 86, integrating alarm and first-out features, and establishing seamless communication with their existing Distributed Control System (DCS). aeSolutions provided an Allen-Bradley control system featuring a GuardLogix controller with POINT Guard Safe I/O, a new Human-Machine Interface (HMI), and extensive on-site support, significantly improving the reliability and safety of the client’s operations.
Challenge
The client faced numerous challenges with their existing incinerator burner management system. The previous system lacked first-out indications and alarm features, making troubleshooting operational shutdowns time-consuming and inefficient.
Additionally, there were challenges in implementing a new BMS. Handling multiple burners and switching fuel sources between fuel oil and waste gas added further complexity to operations. Moreover, integration between the new BMS and existing DCS required extensive on-site testing and validation. The remote geographic location compounded these challenges, requiring extended on-site support due to logistical constraints related to weather and travel.
Solution
Leveraging dual expertise in safety engineering and control systems integration, aeSolutions implemented a tailored SI-BMS that significantly enhanced operational transparency and control. The new SI-BMS solution provided clear first-out alarms, pinpointing exact causes for shutdowns and drastically reducing troubleshooting time. aeSolutions ensured NFPA 86 compliance and delivered a robust solution capable of managing the complex operational scenarios involving four burners with interchangeable fuel sources.
One of the key factors in the success of this project was aeSolutions’ project delivery team, which brought together our risk-focused industry experts and hands-on technical specialists. This enabled real-time responsiveness to client needs during commissioning. Changes to the Safety Requirements Specification (SRS) and system configuration were executed seamlessly, including on-site, in direct response to client feedback and operating conditions. The team’s ability to evaluate safety impacts and implement adjustments quickly, without compromising compliance, demonstrated the strength of integrating safety and controls expertise within one provider.
aeSolutions worked closely with the client’s DCS programmer to resolve integration challenges, coordinating communication protocols and aligning system behaviors across platforms. This flexibility not only helped overcome technical hurdles but also ensured that the final system supported the client’s preferred operational practices.
Results
The client’s operational efficiency, reliability, and resilience substantially improved upon commissioning of the new BMS solution. Operators gained immediate clarity from the introduction of first-out alarms, resulting in quicker resolutions and significantly reduced downtime. The upgraded system consistently achieved reliable startups, eliminating previous issues related to intermittent operational failures.
Furthermore, aeSolutions’ flexible and collaborative approach in adjusting and refining system configurations during commissioning directly supported the client’s unique operational needs. This approach not only ensured safety and compliance but also provided tangible time savings, thereby delivering immediate and ongoing value. Following this project’s success, the client has continued to engage aeSolutions for additional critical infrastructure projects, highlighting the sustained value and effectiveness of our tailored solutions.
Industry: Oil & Gas
Geography: Pacific Northwest
Unit Operation: Customized Safety Instrumented Burner Management System (SI-BMS), POINT Guard Safe I/O, Human-Machine Interface (HMI)