In industrial combustion applications, safety, efficiency, and compliance with regulatory standards are critical. Bacon Engineering, a leader in burner control technology, specializes in the design, installation, and integration of PLC-based Burner Management Systems (BMS). By leveraging programmable logic controllers (PLCs) for burner automation, Bacon Engineering delivers highly reliable and scalable solutions for industries that depend on safe and efficient combustion processes.

The Role of PLC-Based Burner Management Systems

A Burner Management System (BMS) is responsible for the safe start-up, operation, and shutdown of industrial burners. Traditional relay-based systems have long been used for this purpose, but PLC-based BMS technology has emerged as the preferred solution due to its advanced safety features, flexibility, and integration capabilities. By implementing custom-engineered PLC-based solutions, Bacon Engineering ensures that combustion systems operate within strict safety parameters while optimizing efficiency.

Core Functions of a PLC-Based BMS

A well-designed BMS is essential for mitigating combustion hazards and ensuring continuous operation. The PLC-based BMS solutions provided by Bacon Engineering incorporate:

• Automated Start-Up and Shutdown Sequences – Ensures proper pre-purge, ignition, and flame monitoring.
• Fuel Safety Management – Controls fuel shutoff valves to prevent unburnt fuel accumulation.
• Flame Supervision and Monitoring – Utilizes UV/IR flame scanners and thermocouples for real-time combustion verification.
• Interlock Management – Prevents unsafe burner operations by monitoring critical safety interlocks.
• Fault Detection and Alarm Handling – Provides immediate alerts and system shutdowns in case of failure.
• Data Logging and Remote Diagnostics – Tracks burner performance and safety metrics for continuous monitoring and maintenance.

Advanced PLC Solutions for Industrial Applications

As an expert in industrial burner automation, Bacon Engineering selects state-of-the-art PLC hardware tailored to the specific needs of each project. Their solutions incorporate redundancy, fail-safe mechanisms, and real-time communication, ensuring compliance with industrial safety regulations.

PLC Hardware and System Design

Bacon Engineering utilizes industry-leading PLC brands such as Siemens, Allen-Bradley, Schneider Electric, and Honeywell, integrating high-performance CPUs, I/O modules, and communication interfaces. These programmable controllers replace outdated relay-based systems, offering greater flexibility and simplified maintenance.

Key PLC components include:

• Central Processing Unit (CPU) – Executes control logic and manages safety functions.
• I/O Modules – Interfaces with field sensors, actuators, and fuel control valves.
• Communication Interfaces – Enables seamless integration with SCADA, HMI, or Distributed Control Systems (DCS) using protocols like Modbus, Profibus, and Ethernet/IP.
• Redundant Safety PLCs (SIL2/SIL3 Certified) – Ensures reliability in mission-critical applications.

Integration with SCADA and HMI Systems

Bacon Engineering specializes in seamless integration of BMS with SCADA and HMI systems, providing real-time visualization and control. These user-friendly interfaces allow operators to monitor burner performance, receive safety alerts, and adjust operational parameters remotely.

Typical SCADA functionalities include:

• Burner Status Visualization – Displays critical process variables, including flame status, fuel flow, and air damper positions.
• Alarm and Event Logging – Tracks system faults and historical data for predictive maintenance.
• Remote Control and Adjustments – Allows authorized personnel to modify setpoints and parameters.
• Trend Analysis and Reporting – Enables data-driven decisions for optimizing burner efficiency.

By integrating SCADA systems like Ignition, Wonderware, Rockwell FactoryTalk, and Siemens WinCC, Bacon Engineering ensures seamless plant-wide automation and control.

Field Devices and Safety Components

To ensure maximum safety and reliability, Bacon Engineering incorporates a variety of high-precision sensors, actuators, and safety interlocks into their PLC-based BMS solutions.

Key Field Devices Used in PLC-Based BMS

• Flame Detectors – UV/IR sensors and thermocouples for accurate flame monitoring.
• Pressure Switches – Ensure proper fuel, air, and draft pressure levels.
• Temperature Sensors – Monitor combustion chamber conditions to prevent overheating.
• Limit Switches – Verify valve and damper positions to ensure proper operation.
• Gas Leak Detectors – Prevent hazardous conditions by detecting unburnt fuel leaks.
• Solenoid Shutoff Valves – Provide immediate fuel cutoff in emergency situations.
• Variable Frequency Drives (VFDs) – Optimize blower and air damper control for improved combustion efficiency.

By carefully selecting and integrating these safety devices, Bacon Engineering ensures compliance with industry regulations and enhances the longevity of combustion equipment.

Compliance with Industrial Safety Standards

Bacon Engineering designs and installs PLC-based BMS solutions that adhere to the most stringent safety and regulatory standards, ensuring that industrial burner systems operate within legal and operational guidelines.

Regulatory Compliance and Certifications

• NFPA 85 (Boilers) and NFPA 86 (Industrial Ovens and Furnaces) – Governs the safety of combustion equipment.
• IEC 61508 / IEC 61511 (SIL Ratings) – Ensures functional safety of burner management systems.
• UL 1998 and UL 60730 – Certification for programmable safety controllers.
• FM, CSA, and ATEX Approval – Required for hazardous area applications.

For industries where SIL-rated safety systems are mandatory, Bacon Engineering provides SIL2 and SIL3 certified PLCs with redundant architectures to eliminate risks associated with burner failures.

Why Choose Bacon Engineering for PLC-Based BMS Solutions?

With extensive expertise in burner control technology, Bacon Engineering offers custom-engineered, PLC-based BMS solutions designed to enhance safety, improve efficiency, and simplify maintenance.

Advantages of Working with Bacon Engineering

• Tailored BMS Solutions – Custom designs for power plants, oil and gas, chemical processing, and industrial manufacturing.
• Integration with Existing Systems – Seamless connectivity with SCADA, DCS, and plant automation networks.
• Improved Safety and Reliability – Adherence to NFPA, IEC, and UL safety standards.
• Real-Time Monitoring and Diagnostics – Advanced data logging, alarms, and remote troubleshootingcapabilities.
• Future-Proof Technology – Scalable solutions that evolve with industry advancements.

Conclusion

For industries that rely on precise burner control and safety, a PLC-based Burner Management System is the optimal solution. With Bacon Engineering’s expertise in automation, safety compliance, and system integration, industrial facilities can achieve safer, more efficient, and fully optimized burner operations.

To learn more about how Bacon Engineering can upgrade your burner control system with state-of-the-art PLC technology, contact their team of experts today.