It’s Time: Upgrade your BMS for Code Compliance
Introduction
Many companies installed Burner Management Systems (BMS) 20-30 years ago. Since then, the technologies employed, and the safety standards and code compliance requirements have change significantly. 30 years ago, the Internet was brand new, and now it almost thinks for itself[1] – just imagine how out of date those BMSs are now.
Maintaining code compliance on fired equipment isn’t optional, it is mandatory. Code compliance in the past doesn’t mean code compliance now. Old systems based on outdated standards are now considered unsafe or non-compliant, so companies must update them to meet current code compliance, as “grandfathering” is not permitted.
Risk
Code Compliance
In the past 20 – 30 years there have been several revisions to B149.3. Over the years, Alberta Municipal Affairs had granted certain “variances” to B149.3. These variances allowed companies to use alternate methods to meet the “intent” of the code. As of today, all fired equipment need to be compliant with the applicable gas code – with no allowable variances. Note, the CSA has just released B149.3:25 (2025 update) , and Alberta is expected to adopt it in early 2026.
The Risk
The government mandates these CSA codes to help ensure the safe operation of fired equipment. This is to protect operating personnel, equipment, and the environment. The risks associated with not being code compliant, are probably higher than any owner / operator is willing to take. Non-compliance can also have legal ramifications; including substantial fines and/or potential jail time could be imposed.
Understanding the Risk
Having an audit or assessment undertaken on your equipment will help you understand where there are gaps in your system and how critical they are. InnoTech offers the Operational Technology Health Assessment (OTHA) as a great first step to help you identify and prioritize issues in your facility. This proven process compares your equipment against current code compliance and facility standards and considers the lifespan and part and support availability of your equipment.
Mitigating the Risk
The next step is to address the gaps within your system and create a plan for migration. This includes putting processes and procedures in place to avoid mishaps in the meantime. This plan shows due diligence (in the eyes of Alberta Municipal Affairs) which is important as you take steps to bring your fired equipment into compliance.
With the gap assessment completed, the next steps include control panel design, configuration, testing, and commissioning. This is a lot to consider if you don’t know where to begin. Luckily for you, InnoTech has extensive experience with BMS migrations and follows a trusted process to ensure compliance with the required standards.
The sooner, the better, as your BMS is likely already on borrowed time.
Reliability
Outdated systems cause a myriad of issues. Issues like; hardware obsolescence and spare part availability, maintenance costs, and limited technical expertise and customer support on the old system. When a system becomes obsolete and the vendor of that system no longer supports it, it can be hard to maintain system uptime to meet production demands.
The Risk
Without the availability of system hardware and support, when the system fails, there’s a high probability that it can’t be restored or repaired in a timely manner. The plant will now experience unplanned and extended operational downtime, resulting in loss of revenue.
Understanding the Risk
Just as it is important to understand the risk from a code compliance standpoint, you should also have an audit or assessment conducted on your equipment. This process will provide you with the necessary information to identify obsolescence risks in your system and determine their severity. Again, InnoTech’s Operational Technology Health Assessment (OTHA) is an excellent first step in understanding what needs to be addressed in your facility and in what order. This proven process compares your equipment against current code compliance and facility standards and considers the lifespan as well as parts and support availability of your equipment.
Mitigating the Risks
In the meantime, ensure spare parts are on hand and readily available for that dreaded call on the Saturday night of a long weekend. This ensures that if anything were to happen while you plan for your migration, you’re ready to resolve the issue quickly. Before it affects operations or becomes a larger problem.
Replacing your system with a tried, true, and new model, means that your system will last as long as possible before spare parts and support are no longer available.
Software / Firmware Obsolescence
Along with the hardware and system equipment no longer being supported, the software is equally as likely to no longer be supported by the vendor. Though the system may still operate, there are a myriad of risks looming from obsolete software.
The Risk
Cybersecurity attacks are becoming more common and frequent as technology advances. Especially as more and more industrial facilities connect their networks to the cloud and internet. Consequently, outdated software becomes more vulnerable to these attacks, acting as a “chink in the armor” for the entire facility. As a result, a breach can lead to operational malfunctions and data leaks. Ultimately, these losses can deliver a significant blow to a company’s reputation.
Understanding the Risk
Software obsolescence issues are (but not limited to) the following:
- Operating system (OS) issues (Windows XP, etc.) where patching is no longer available.
- Vendor / hardware specific software is no longer available or supported.
- Older software and firmware are incapable of supporting current cybersecurity standards and will not address the latest threats.
- Growing demand for remote access to multiple OT systems remains unsupported.
Obtaining a full understanding of the risk your facility faces will require a risk assessment to understand where the risks are, what they are, and to prioritize their mitigation.
Mitigating the Risk
Once again, the call is to migrate your system as soon as possible. Regarding software, it’s important to consider if the new system will integrate with your current site network and needs. At a minimum, you should ensure facility firewalls are sufficiently equipped to block attacks and that backups can mitigate the loss of data. Having personnel in place to monitor security threats is a highly beneficial next step.
Opportunity
A Burner Management System maintains the safety of your burner system. However, replacing your BMS results in efficiencies and cost savings for your facility as well.
The Opportunity
A new system not only increases the efficiency of your site, but also removes the risks stated above. Additionally a heater that burns Oxygen more efficiently decreases the potential for creating toxic chemical emissions, like Nitrous Oxide (NOx ). Furthermore, even a small efficiency increase of just 1% can lead to thousands of dollars in savings on operating costs.
Understanding the Opportunity
Reducing the toxic chemicals created in the process can help industrial sites meet their emission reduction targets. Leading to an increase in the safety of the environment and their site.
Capturing the Opportunity
Our process control experts can support in the selection of a BMS that is best suited for your site, ensure regulatory compliance is met, increase worker safety, and maximize efficiency. Read more about InnoTech’s industry leading Burner Management System (BMS) upgrades [link to blog].
What’s next?
Ready to take on your BMS migration? Talk to one of InnoTech’s experts or book a consultation today!
[1] AI