BMS Capabilities
Mangan Burner Management Systems
Mangan Inc. has provided Burner Management Systems (BMS) since the mid-90s, with over 500 project installations across the Refining, Petrochemical, Midstream, and Terminal & Storage markets. Our work scope typically starts with a front-end engineering gap analysis against NFPA (85, 86, 87), API 538, API 556, IEC 61511, and client LOPA. This drives the requirements for instrument specification (burner, controller, flame detector, igniter, pressure transmitters, valves), SIS/SRS documentation compliance, I&E design package, system specification/integration/configuration/FAT/SAT, systems startup and commissioning, and lifecycle support of required on-line and off-line testing.
Our differentiation lies in our ability to bring depth of field, application, and BMS Capabilities under one roof. This provides us with the on-staff competency to develop BMS control narratives directly from P&IDs or to modify existing systems through reverse engineering. We support safe and efficient startup/shutdown, emergency trip and relight, and purge sequences. Our strength is rooted in decades of engineering-operations-maintenance experience and a collaborative project methodology that aligns with client expectations.
Mangan’s expertise in Burner Management Systems (BMS) spans the full range of fired equipment—including heaters, dryers, ovens, boilers, thermal oxidizers, hot oil systems, regenerators, reactor feed units, and reboiler process heaters. With a strong foundation in lifecycle support for both BMS and Safety Instrumented Systems (SIS), we are well positioned to support your BMS application throughout all project phases.
1. Allocation of Safety and Protective Functions
- LOPA recommendations
- NFPA-85 (Boiler and Combustion Systems Hazard Code),
- NFPA- 86 (Standard for Ovens and Furnaces),
- NFPA-87 (Standard for Fluid Heaters),
- API STD 560 (Fired Heaters for General Refinery Services),
- API RP 538 (Industrial Fired Boilers for General Refinery and Petrochemical Service)
- API RP 556 (Instrumentation and Control Systems for Fired Heaters and Steam Generators) and other similar
2. BMS Safety, Functional and Equipment Specifications development:
- SRS (Safety Requirements Specification) for safety and auxiliary functions per ISA/IEC 61511.
- SRS for the logic solver includes related and support systems such as power, cabinet design, communications, input, and output interfaces, and other similar. Documentation suitable for equipment quotation and requisition.
- SRS for the software and related configuration of the logic solver, to ensure the logic solver code addresses safety, reliability, and requirements per applicable standards.
3. Design, engineering, and procurement
- Competency of personnel associated with the safety system
- Planning for lifecycle phases verifications and reviews
- Planning for the FSA (Functional Safety Assessment)
- Installation and commissioning plan
- Planning and requirements for FAT, SAT, Integration tests and other similar safety validation activities
- Documentation development, management, and approvals
- Selection, specification, requisition of safety devices,and other system components
- Hardware and software specification and requisition
- Design and configuration of support systems such as communications, power, associated cabinets, and HMIs.
c. Development and management of the SIS application program for the SIS logic.
d. Design of piping related to SIS devices like transmitters and valves.
e. Mechanical and civil engineering including platforms, supports, siting and others.
f. Electrical design, schematics, power, controls, conduit, wiring, and related items.
g. Instrumentation specification, interfaces, process calculations and parameters.
h. SIL Availability and Reliability calculations using recognized tools such as ExSILentia, Fault Tree, SIL Solver. Special calculations including the impact of systematic failures, shared components, and other cases.
i. BMS Capabilities related to DCS interface, interlocks, and communication systems
4. FAT, SAT, Commissioning, and Functional Safety Assessments
- FAT Hardware and software at Mangan Integration facility or other location
- Application program validation using emulation or automated software testing applications
- Integrated test for DCS, other safety PLC or associated systems
- Full SAT for SIS, BMS, and other interlock systems
- Testing of DCS logic
- Inspection, calibration checks of SIS and BMS field devices
- Startup, on-line testing
- Perform Functional Safety Assessment (1-4) at intervals per IEC 61511.
b. Functional Safety Assessments: Provide the templates for check list, reports, planning. Lead the panel sessions, complete the reports, recommendations
5. Operations and Maintenance: Collaborative work
- Analysis and resolution of BMS trips, failures and modifications
- LOPA revalidations
- Development and update of operations and maintenance procedures
- Training and operating manual development
- Developing off-line/on-line Proof Test Procedures
- Training, scheduling, and proof testing for SIS and Burner Management Systems (BMS)
