What to Expect During a Custom Burner Management System Retrofit

If you’re an industrial operations manager facing aging or obsolete burner management system (BMS) controls, you’re not alone. Outdated BMS components can pose serious safety hazards, introduce compliance concerns, and negatively impact operational efficiency. A custom BMS retrofit isn’t just a technical upgrade, it’s an investment in safety, performance, and peace of mind.

Modernizing Burner Safety Without Compromising Production

Downtime is costly – every facility needs to prioritize how to avoid it, but every operation has unique needs. Engineered Combustion Systems (ECS) understands this, so we customized every BMS retrofit to fit your unique system architecture, plant layout, and compliance requirements.

Below, we will walk through a typical retrofit process, from initial assessment to post-startup support, to help you understand what to expect and why a strategic, code-compliant approach matters.

Step 1: System Assessment and Compliance Review

Every successful retrofit begins with a thorough evaluation of your existing system. This process includes:

• Reviewing legacy BMS controls, interlocks, and flame safeguard devices
• Identifying outdated or unsafe components and wiring
• Comparing current systems with applicable standards (NFPA 85, 86, 54)
• Documenting risks, deficiencies, and upgrade priorities

This assessment lays the foundation for a safe, efficient, and regulation-ready retrofit.

Step 2: Engineering a Custom Retrofit Solution

Once your system has been assessed, a solution is developed based on your equipment, process needs, and compliance objectives. Common upgrades include:

• New flame safety relays or integrated PLC/HMI platforms
• Upgraded sensors, shutoff valves, and limit switches
• Prewired, pre-engineered control panels
• Updated interlock logic and wiring diagrams
• Retrofit-compatible components that reduce onsite disruption

The goal: a smooth integration that minimizes piping or structural changes while enhancing system safety and control.

Step 3: Panel Fabrication and Pre-Testing

Before installation, all control panels and components undergo rigorous in-house testing:

• Factory Acceptance Testing (FAT) for safety and logic validation
• Simulations of purge cycles, flame detection, and fault responses
• Program logic, wiring, and relay checks

This proactive step ensures the system performs correctly before it ever arrives on-site.

Step 4: Installation and Commissioning

A carefully coordinated installation minimizes disruption to plant operations. This phase includes:

• Safe disconnection of the existing BMS
• Installation and wiring of the new control panel and field devices
• Full I/O validation and logic testing
• Live burner testing, sequence checks, and safety verifications
• Operator training for system use and troubleshooting

Installation is typically timed during planned downtime to limit impact on production.

Step 5: Post-Startup Support and Documentation

Once the system is live, thorough documentation and support are key to long-term success:

• Electrical schematics, P&IDs, and logic diagrams
• Software backups and reset procedures
• System manuals and operator guidance
• Access to technical support when needed

This ensures your team can operate the new BMS safely, efficiently, and confidently.

Why Your BMS Retrofit Partner Matters

A successful BMS retrofit is about more than new equipment. It’s about having the right integration partner. Look for a provider that:

• Understands legacy BMS and code-compliant retrofits
• Offers complete turnkey services, from design to support
• Uses proven components from leading brands like Honeywell, Maxon, and Siemens
• Delivers clear documentation and reliable post-installation support

Trust ECS for Your BMS Retrofit

Engineered Combustion Systems is your expert source for custom burner management system retrofits. With decades of experience and deep knowledge of NFPA standards, we deliver solutions that improve safety, streamline operations, and minimize downtime. Whether you’re upgrading a single burner or an entire facility, ECS has the engineering and field expertise to get the job done right.

Ready to take the next step?

The ECS team specializes in custom BMS retrofits for industrial and process heating applications. With decades of integration experience and deep knowledge of combustion controls, ECS designs retrofit solutions that minimize downtime and ensure full code compliance.

Call (248) 549-1703 or Request a Quote to begin planning a safer, smarter BMS retrofit.