A Primer on Burner Management System (BMS) Assignment

Assignment Task

Executive Summary

This memorandum outlines the development and implementation of two of my primary tasks assigned during the work term. The 1st task consisted of building a catalog or Bill of Materials (BOM) and forming a database of BMS (Burner Management System) components used for the cabinet construction. Thus, helping the team to have centralized component information along with the references from previous project. The 2 ^nd and major task was dedicated towards building an autonomous I/O (Input/Output) card generation program aimed at enhancing operational efficiency within Babcock & Wilcox FPS Inc. I was involved with automating the drawing generation process using AutoCAD software, thereby reducing manual errors and expediting project timelines. The successful implementation of this system has yielded significant benefits, including improved efficiency, reduced errors, and optimized resource allocation. However, certain limitations exist, including software compatibility constraints and reliance on enabled macros. Moving forward, recommendations for interface expansion, error tracking, and user interface refinement are proposed to further enhance system functionality and drive organizational growth.

Babcock & Wilcox FPS Inc. stands as a leading manufacturer of industrial equipment, specializing in products such as Flame Scanners, Ignitors, valves, and Burner Management Systems. Within this context, the need for efficient and accurate drafting processes is crucial, given the complexity of control system designs and the number of components involved.

Recognizing this imperative, my task was to automate the I/O card generation process to improve overall team efficiency and optimize resource utilization. By automating this aspect of the workflow, valuable resources could be redirected towards other critical tasks, such as pre- inspections, cabinet designing, and Factory Acceptance Testing (FAT). Thus, the primary aim of this initiative was to streamline workflow dynamics and enhance operational efficiency by automating a key aspect of the project life cycle.

Methodology and Analysis

At the beginning of the work term, I was tasked with constructing a database consisting of commonly used parts for building a BMS cabinet. As part of the task, I was required to refer to the previous projects involving the cabinet components. Once, I had those I started with making a spreadsheet and having sheets based on the category they might fall under and within the sheets, have an option to sort out all the components. I had to consult with multiple colleagues for seeking their expertise and guidance on building the spreadsheet which is both accessible and comprehensive to most of the team.

The part of the BMS design consisted of generating an I/O list. The I/O list is an excel sheet listing all the I/Os of the system as well as the allocation of each signal to a physical I/O card.

The part of the BMS design consisted of generating the electrical drawings of the BMS. Part of these drawings are the physical IO cards with their electrical wiring. The physical cards drawing is standard, while the wiring of each IO to specific field device is project dependant. These drawings were so far done manually.

My project consisted of creating a program, using VBA and Lisp (AutoCAD programming language), that had an the IO list excel sheet as an input, and had the AutoCAD electrical drawings as an output.

Henceforth my first few steps included making a module for each type of card that I was working with. The different types of cards were: IA16I(Model2), IA16I(Model 3), OW16I, OF8 and OF8I. Each of these card drawings had their own characteristic values differing each other with respect to Switch Types, Terminal block and field layouts.

There are several ways to acquire data from excel file and project it into AutoCAD Software. My approach was using the VBA Programming Language, wherein depending on the description of the input or the output, formulas placed in certain cells would complete calculations on the length of the line, Size, Placements of text and type of layout needed. Once all the calculation are completed, the VBA Program would automatically run to open the AutoCAD software and draw the requested drawing.

The formulas in the excel cells would calculate the dimensions of the lines asked on the description of the I/O. If the description were to be spare, the dimensions of the line would change accordingly or if no text is supposed to be pasted then it would automatically result to a blank cell and so on. Once all the formulas are executed, the VBA then calls out the key modules used to generate a drawing.

Function of Macros and VBA Modules

• AddLines: Executes the drawing of all lines required for each type of card, ensuring accurate representation of I/O points.
• AddText : Handles the placement of text, acquiring coordinates for each type of description to be included in the drawing.
• DrawCircles: Responsible for drawing circles where necessary, ensuring appropriate representation of components.
• InsertBlocks : Pastes entire cards or specific types of contacts as blocks within the drawing, facilitating efficient layout design.
• RunAllMacros: Comprising multiple sub-modules, this module executes the appropriate VBA modules for each type of I/O card, ensuring comprehensive drawing generation.

FinalRun Module: The primary module responsible for executing most tasks, from acquiring I/O point descriptions to opening AutoCAD and ensuring correct drawing generation. At the end of the program, it even presents a dialogue box to the user indicating the number of cards generated and any issues encountered.

Outcomes and Benefits

The implementation of streamlined drawing generation processes has yielded a multitude of benefits, including:

• Enhanced Efficiency: Automation of the drawing generation process has resulted in considerable time savings, allowing for expedited project timelines and increased
• Reduced Errors : By minimizing manual intervention, the system has reduced the occurrence of errors traditionally associated with manual drafting processes, thereby enhancing overall accuracy and reliability.
• Optimized Resource Allocation: The control team’s valuable time may now be directed towards other deadlines of the project.

Despite its successes, the drawing generation process faces certain challenges and limitations, including:

• Software Compatibility : The software is only compatible running with the latest version of AutoCAD. As part of the VBA and certain macros used in the program, the earlier versions unfortunately are not capable of running them.
• Macro Dependency: Proper functioning of macros within the Excel worksheet is essential and any missing parts may lead to multiple errors in the drawing.
• Variations : Dealing with a big number of variations and exeptions will not allow for 100% automated tasks, as the drawings may have to be adjusted by the engineer for certain projects.

Future Directions and Recommendations

To address current limitations and further enhance system functionality, several recommendations are proposed:

• Interface Expansion : Incorporating additional features such as having options for junction box and adding options for multiple cards may be immensely helpful.
• Error Tracking : Implementing an error logging mechanism to track and address issues encountered during the drawing generation process.
• User Interface Refinement : Streamlining the user interface to improve accessibility and usability, ensuring seamless navigation and operation for users across diverse skill

While the autonomous Drawing generator has been a real asset for the team and many who have used it have shared positive feedback too, the only hiccup being is its limitation to producing just a few I/O card types at this stage. Given some dedicated time and resources, the VBA code should be capable of handling drawing generation and achieving full operational functionality.

Apart from that, I cannot help but reflect on the wealth of knowledge I have gained in the field. Learning the ins and outs of the organization's processes was incredibly fascinating. Putting my VBA coding skills to work and creating a comprehensive program was a real highlight. But what truly made the experience special was the support and friendliness of my colleagues. They were always there to lend a hand and make me feel welcome. Their expertise in the field opened so many interesting topics for me to explore that I might not have discovered on my own.

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