Burner Management System Design | Complete Combustion
Burner Management Systems & Industrial Electrical Integration
Complete Combustion provides licensed, P.Eng-stamped electrical engineering, Burner Management System (BMS) design, and Motor Control Panel (MCP) integration for heavy industrial thermal processes across Ontario and Canada. Operating under a PEO Certificate of Authorization, we engineer safe, unified, and code-compliant electrical architectures adhering strictly to the Ontario Electrical Safety Code (ESA), CSA B149.3, and NFPA 86 standards.
Core Engineering Capabilities
1. Burner Management System (BMS) Architecture
- Dedicated Flame Safeguard Controllers: Sizing and specifying industry-standard microprocessor controllers (Honeywell 7800 Series, Fireye BurnerLogix, Siemens LMV) configured for fully automatic sequencing.
- Flame Detection & Sensing Integration: Integration of self-checking UV scanners, IR flame detectors, and flame rods matched to specific burner fuels and flame patterns.
- Interlock Verification Logic: Hardwired and safety-rated interlocks monitoring combustion air airflow proving switches, high/low fuel gas pressure switches, and valve proof-of-closure (POC) circuits prior to ignition trial.
2. Centralized Motor Control Panels (MCP)
- Unified Panel Engineering: Combining main incoming disconnect switches, branch circuit breakers, magnetic starters, soft starters, and VFDs into a single NEMA/IP-rated enclosure.
- Coordinated Thermal Overload Protection: Precise sizing of motor protection circuit breakers and electronic overload relays matched to FLA and service factors.
- Operator Interface & Pilot Controls: Front-door panel layouts featuring standardized pushbuttons, selector switches, multi-color LED status indication towers, and emergency stop pushbuttons.
3. Plant-Wide Safety Circuits & Emergency Stops
- Multi-Zone Safety Architecture: Engineering safety-rated control relays and zoned shutoff logic that immediately trip hazardous motion while allowing non-affected systems to shut down in a controlled manner.
- Conveyor Pull-Wire Integration: Integrating bi-directional pull-wire emergency stop switches along conveyor lengths and transfer points into the main safety circuit.
- Fail-Safe De-Energization: Hardwired safety loops designed to drop power instantly to SSOVs and high-inertia drives during fault conditions.
4. Utility Power Transformation & Modernization
- Step-Down Transformer Engineering: Sizing and integrating dry-type distribution transformers (480V to 120/208V) to supply plant utilities directly from the main generator or feed, eliminating secondary generators and their maintenance overhead.
- Spare Capacity Planning: Sizing splitter boxes, feeder conduits, and panel backplates with 20–30% built-in spare capacity to support future plant expansions.
Supported BMS & Electrical Platforms
- Flame Safeguard Units: Honeywell 7800 Series, Fireye BurnerLogix / Flame-Monitor, Siemens LMV5 / LMV3, Dungs MPA.
- Motor Control & Switchgear: Schneider Electric, Eaton, Siemens, Rockwell Automation / Allen-Bradley, ABB.
- Safety Components: Banner Engineering, Sick, Pilz, Guardmaster safety relays, and conveyor pull-wire switches.
Frequently Asked Questions
Why is a dedicated BMS required instead of handling flame safety in a standard PLC?
Governing codes such as CSA B149.3 and NFPA 86 mandate that industrial flame safety sequencing, purge timing, and burner shutdown functions be managed by certified, fail-safe flame safeguard controllers or safety-rated PLCs with hardwired interlocks, rather than unrated standard commercial PLCs.
Can you design an electrical upgrade that eliminates our auxiliary site generator?
Yes. We engineer step-down transformer packages (480V to 120/208V) that power all plant lighting, utility circuits, and control rooms directly from main facility feeds, eliminating the fuel and maintenance overhead of running secondary generators.
Consult with Our Engineering Team
- Office: 33 Paddington Rd, Brampton, ON L6P 2E3
- Phone: +1 647 554 8108
- Email: info@completecombustion.ca