BMS System

The purpose of the BMS system is to control the safe automatic startup and the safe, automatic
shutdown of the HCl Synthesis Unit. It accomplishes this by controlling the actions of the automatic
valves while monitoring the instrumentation involved in the safety startup. Production decisions will be
handled outside of the BMS.

HMI
An HMI is included and provides information regarding the BMS. This information relates to the status
of the valves, and instruments on the safety portion of the unit. The HMI supplies the following
important information:

- Homepage: Current status of the Synthesis Unit

- Current errors in the system
- Transmitter values (range, alarms, interlock values
- Current Step
- Shut down first out interlock (The interlock that caused the system to shutdown)

- Steps: Information on the Steps involved in the sequence

- Step times
- Step Description

- Process Diagnostics: Errors in the HCl Synthesis system

- Currently active On/Off Valve errors
- Currently active Switch errors
- Currently active Transmitter errors
- Currently active IO errors
- Currently active Function errors
- Shut down first out interlock (The interlock that caused the system to shutdown)

- Alarms: Interlocks and alarms that have occurred

- I/O Diagnostics: Current status of the PLC.

- I/O Card Status
- Diagnostics data on the cards (diagnostics button on the left)
- Loop Wiring diagrams (Loop Wiring Diagram button on the right.

Ignition Reset
The “Ignition Reset” can be activated in two ways:
1 - Press the “Ignition Reset button located on the LIP panel.
2 – Press the “Reset” button located on the HMI homescreen. This requires a password:
username: eng
password: eng
The “Ignition Reset” button is used to return the system to a Ready for Ignition state.

In the event of a valve error, the valve solenoid will de-energize and the valve will go to its failsafe
position. The system will not attempt to energize this valve again until it is “reset.” This is especially
important for the Nitrogen Purge valve. The Nitrogen Purge valve is “Open” in its de-energized state. If
there is an error with this valve, the nitrogen will continue to flow until the valve is “reset”. A valve
error can occur under a few circumstances:
- The valve is out of the proper position (ex. “Open” when it should be “Closed”)
- Valve takes too long open (>5sec after command)
- An error in the loop wiring
- Contradicting inputs (The valve has both an Open and Closed signal)

If a loop wiring error occurs (the channel’s LED on the PLC is RED), the program will no longer recognize
the input. Once the issue is resolved (the LEDs for that channel will alternate between GREEN and RED),
the “Ignition Reset” button must be pressed or the PLC must be turned off, then on again in order for
the PLC to recognize the wire loop as “ok” again.
::Note if the LIP “Ignition Reset” input (DI2 Ch has a loop wiring error, the system will not recognize the
button’s input anymore. In order to “reset” it, you must use the HMI “Reset” button or power the PLC
off, then on.

Start-up procedure
Once the “Ignition Reset” lamp is on, press the “Ignition Reset” button. If all of the permissives are met
and no errors exist, then the “Ignition Reset” lamp will turn off and the “Ready for Ignition” lamp will
light up. In the event that the “Ready for Ignition” lamp does not activate, look to the diagnostics screen
on the HMI for currently active interlocks and permissives.

Once the reset button is pushed and the “Ready for Ignition” lamp is lit, then you must push the
“Ignition Start” button within 10 seconds to begin the unit start-up sequence. If the “Ignition Start” is
not pressed within 10 seconds of the “Ready for Ignition” lamp turning on, then the “Ready for Ignition”
lamp will turn off, and the “Ignition Reset” lamp will turn on. If this happens you must press the
“Ignition Reset” button again, before you can press “Ignition Start” button to start the unit.

Once started, the ignition sequence is automatic and will go through a series of steps to safely start the
burner. The actions performed at each step are described below

Step 1: N2 Purge,
- The N2 Purge solenoid valve is de-energized and the N2 purge valve opens. N2 flows to the synthesis
unit.

Step 2: Test Spark

- The N2 Purge solenoid is energized and the N2 flow stops.
- The ignition transformer is energized in the pilot burner, making a spark
Step 3: Wait
- The ignition transformer is de-energized and the spark stops

Step 4: Pilot Burner Air

- The Pilot Burner Air solenoid valve is energized and the air goes through the pilot burner

Step 5: Spark
- The ignition transformer is energized in the pilot burner, making the Ignition Spark

Step 6: Pilot Burner Hydrogen

- The Pilot Burner H2 solenoid valve is energized and the H2 goes through the pilot burner
- The pilot flame should be ignited at this point.

Step 7: Detect Pilot Burner Flame

The system allows a moment for the pilot flame ignite and be recognized by the flame detector

Step 8: Main Burner Hydrogen

- The Main Burner H2 Block solenoid valve is energized and the valve opens
- The Main Burner H2 Bypass solenoid valve is energized and the valve opens
- The Ignition Transformer is de-energized and the Ignition Spark stops

Step 9: Chlorine To Main Burner

- The Main Burner Cl2 Block solenoid valve is energized and the valve opens
- The Main Burner Cl2 Bypass solenoid valve is energized and the valve opens

Step 10: Detect Main Burner Flame

The system allow the Main Flame a moment to ignite

Step 11: Extinguish Pilot Burner

- The Pilot Burner Air solenoid valve is energized and the valve shuts
- The Pilot Burner H2 solenoid valve is energized and the valve shuts
- At this point the pilot burner flame should be off

Step 12: Verify Main Flame

The system allows the Main Flame a moment to stabilize

Step 13: Ignition Complete

At this point the ignition sequence is considered “complete.”
- The H2 Control solenoid valve will be energized.

- A dry contact “Release for Control” signal will be sent to the DCS signaling the ability of the DCS to
operate the flow control valves
Shutdown Procedure (From Ignition Complete)
The start-up sequence can be interrupted at any step. Depending on the cause of the sequence shutting
down, the system will either go through a Normal Shutdown or an Emergency Shutdown sequence.

Normal Shutdown
Conditions for Normal Shutdown: The HCl Unit will go through a normal shutdown sequence under any
of the following conditions:

- “HCl Unit Stop” button pressed at the LIP

- “Stop” button pressed at the HMI (Requires password. Username: eng, Password eng)
- “DCS Interlock” activated
- Any normal Interlock activated (ex. H2 Press low low, Cl2 Block valve error, etc.)
o Refer to the Functional Spec Matrix for the interlocks at each step (Note there are
possibly more interlocks than listed on the Matrix. These interlocks are related to the
safety features of the PLC hardware.)

If normal shutdown occurs before step 4

The system returns to Step 0. There is no post purge step.

If normal shutdown occurs from step 4 or step 8

Step 15 – The solenoid valves to the Pilot Burner Air valve , Pilot Burner H2 valve, H2 Control valve, H2
Bypass and the H2 Block valves are de-energized and the valves close.

Step 16 – The solenoid valves to the N2 Purge valve is de-energized and the valves opens, and the N2 is
allowed to purge the unit for 300s

If normal shutdown occurs from step 9 through 13

Step 14 – The solenoid valves to the Pilot Burner Air valve , Pilot Burner H2 valve, Cl2 Control valve, Cl2
Bypass valve, and the Cl2 Block valves are de-energized and the valves close.

Step 15 – The solenoid valves to the H2 Control valve, H2 Bypass and the H2 Block valves are de-
energized and the valves close.

Step 16 – The solenoid valves to the N2 Purge valve is de-energized and the valves opens, and the N2 is
allowed to purge the unit for 300s

Once the shutdown sequence is complete, the solenoid valve to the N2 Purge valve is energized, and the
valve closes. The unit should be ready to start again on the condition that all the permissives are met.

Emergency Shutdown
Conditions for Emergency Shutdown: The HCl Unit will go through an Emergency Shutdown sequence
under the following conditions:

- LIP Emergency Stop

- DCS Emergency Stop pressed
If either of these buttons are pressed at any time, the sequence moves to the following steps:

Step 17 – The solenoid valves to the Pilot Burner Air valve , Pilot Burner H2 valve, Cl2 Control valve, Cl2
Bypass valve, Cl2 Block Valve, H2 Control valve, H2 Bypass valve, and H2 Block valve are de-energized
and the valves close.

Step 18 – The solenoid valves to the N2 Purge valve is de-energized and the valves opens, and the N2 is
allow to purge the unit for 300s