Custom Engineered Burner Management System (BMS) for Oil India Ltd
CRA designed, engineered, manufactured, and supplied a comprehensive Burner Management System (BMS) for Oil India Limited to ensure safe, reliable, and compliant operation of flare pilots and process burners. The system provides fully automated sequencing, continuous flame monitoring, and fail-safe shutdown under normal, upset, and emergency conditions, eliminating manual intervention while enhancing operational reliability, personnel safety, and compliance with oil and gas safety standards.
Ensuring Fail-Safe Burner Operation Under Variable and Hazardous Conditions
Oil India Limited required a robust burner management solution capable of maintaining safe combustion and continuous flame availability across a range of operating scenarios. Key challenges included:
• Preventing unburnt hydrocarbon accumulation during ignition failures
• Ensuring reliable flame detection and rapid response to flame-out conditions
• Achieving seamless integration with existing PLC/DCS and emergency shutdown systems
• Maintaining compliance with API 521 / API 537 and plant safety philosophies
• Reducing operator dependency while enhancing system availability
The system needed to be highly reliable, automation-driven, and suitable for critical oil and gas operating environments.
Integrated PLC-Based Burner Management System with Redundant Safety Logic
CRA designed and delivered a fully integrated BMS solution built around PLC-based control architecture with layered safety and redundancy. The system ensures precise sequencing of purge, ignition, flame monitoring, and shutdown functions for pilots and burners.
Key System Elements Delivered
• PLC-based BMS with redundant flame detection architecture
• Pilot ignition system with high-energy spark igniters
• Automated purge and start-up sequencing logic
• Flame failure and emergency shutdown interlocks
• Seamless interface with plant PLC, DCS, and ESD systems
Fail-Safe System Logic and Modular Architecture Aligned with Oil & Gas Safety Standards
• Fail-safe system logic aligned with international oil & gas safety standards
• Redundant flame detection to ensure continuous flame supervision
• Modular panel and field hardware design for maintainability
• Low-energy consumption ignition systems with high reliability
• Design provisions for future system expansion and upgrades
Controlled In-House Fabrication with Multi-Stage Testing and Compliance Validation
• In-house panel manufacturing and system assembly
• Pre-dispatch testing of logic, interlocks, and ignition sequencing
• Factory validation of flame detection and fail-safe shutdown logic
• Compliance checks against applicable API and plant safety requirements
• Complete documentation, wiring schedules, and test records
Reliable, Automated, and Safe Burner Operation
Reliable, Automated Burner Operation with Enhanced Safety and System Availability
• Fully automated burner sequencing and flame supervision
• Rapid response to flame failure with immediate safe shutdown
• Reduced operator intervention and enhanced personnel safety
• Improved operational reliability during normal and emergency conditions
• Seamless integration with Oil India’s existing control infrastructure
Demonstrating CRA’s Capability in Delivering Safety-Critical Burner Management Systems
This project highlights CRA’s expertise in delivering critical burner safety and control systems for the oil and gas sector. By combining robust control engineering, proven safety logic, and high-quality manufacturing, CRA provided Oil India Limited with a dependable Burner Management System that enhances operational safety, regulatory compliance, and long-term reliability.
The successful execution reinforces CRA’s capability to engineer and supply safety-critical automation systems for complex and high-risk industrial environments.
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