Managing Hot Oil Heaters with PF3100 BMS Controllers

The Profire Solution

To support the OEM-supplied heater packages, Profire delivered a burner management controls package built around six PF3100 controllers, with one controller dedicated to each hot oil heater.

While the OEM supplied the heater and burner package, Profire provided the burner management and combustion controls, safety components, controls integration, and commissioning support needed to bring the system into operation within the broader plant environment.

Each PF3100 was configured for fuel-air ratio control (parallel positioning), with VFD control and feedback to support combustion performance. The system also included an O2 analyzer for field instrumentation.

To integrate the heaters into the plant’s control environment, Modbus communications were converted to TCP/IP Ethernet to match the plant’s communications protocol. This setup allowed independent control of each heater, with all the necessary operating data transmitted back to the main control room.

Startup and commissioning support included loop checks and on-site operator training. Throughout the commissioning process, we identified gas quality issues, pilot-related performance concerns, and low-fire air inlet challenges.

The gas quality issues were mitigated with filtration systems, scrubbers, and knockout pots.

Key elements included:

• PF3100-based six-heater control: 6 x PF3100 BMS controllers, one per heater
• Parallel positioning / fuel-air ratio control: True fuel-air ratio control with VFD control and feedback
• Field instrumentation support: O2 analyzer included for field instrumentation
• Controls integration: Modbus converted to TCP/IP Ethernet for plant-wide communications
• Commissioning support: Loop checks, startup commissioning, on-site training, and turnover
• Technical optimization feedback: Recommendations provided to improve pilot performance and inlet air control on future heater builds

The Result:

The completed system gave Momentum Midstream a burner management and combustion control solution for six large-BTU hot oil heaters that aligned with the plant’s expansion goals, communications requirements, and safety expectations.

With the controls package integrated into the broader plant environment, the site gained a more complete platform for safely operating and monitoring these heaters within a demanding midstream gas processing facility.

During commissioning, site-specific issues such as poor gas quality, pilot performance challenges, and low-fire air inlet struggles were identified.

This gave Momentum Midstream and the heater OEM the opportunity to work through real operating conditions in the field before the new heaters became operational.

Profire also provided the OEM with commissioning feedback, offering insights to improve pilot performance and inlet air control on future heater designs.