ZEECO, INC. ZEECO, INC.
2010 ZEECO, INC. ZEECO, INC.
ProFlameTM
Integrated Flame Scanners
Rob SchmitzWestern Regional Sales ManagerZeeco Power Group
ZEECO, INC.
What is the purpose of a Flame Scanner?
▪ Provides a safety input to a Burner Management System (BMS) for pilot and main flames
▪ Helps prevent boiler explosions by meeting approval
agencies' various testing requirements
▪ Designed to detect target flames and discriminate from background interferences
ZEECO, INC.
Flame Scanner Applications
▪ Power Plants
⚫ Duct Burners
⚫ Steam Boilers
⚫ Air Heaters
⚫ CFB
▪ Petro-Chemical / Refineries
⚫ Incinerators
SRU’s
⚫ Heaters
⚫ Power Boilers
ZEECO, INC.
▪ Pulp & Paper
⚫ Dryers
⚫ Power Boilers
⚫ Black Liquor Recovery
⚫ Combination (Bark)
▪ Other Industrial Plants
⚫ Wood/Laminate Flooring
⚫ Steel Industries
⚫ Cement Plants
⚫ Wastewater Treatment
⚫ Food Processing
⚫ Education - Universities
Flame Scanner Applications
ZEECO, INC.
Types of Flame Scanners
▪ Direct Contact Sensors
⚫ Flame Rod – typically used on small heat input gas
burners or gas pilots
▪ Optical Sensors
⚫ Ultraviolet Radiation – typically used on gas flames
and light oil flames
⚫ Infrared Radiation – typically used on oil and coal
flames
⚫ Visible Light Radiation – typically used on residential
heaters
ZEECO, INC.
Flame Detection vs. Flame Discrimination
▪ Flame detection is
detecting the
radiation from a
target burner
▪ Flame discrimination
is being able to tell
the differentiate the
target flame from the
background flames
ZEECO, INC.
Existing Methods of Flame Discrimination
▪ Gain adjustment - The signal is sent through a
buffer, which can be used to strengthen or weaken
the response of the detector
ZEECO, INC.
Flicker Frequency
▪ IR from flash light is steady frequency
▪ IR or UV from flame varies as a function of the combustion process
▪ Wavelength (IR or UV) is not flicker frequency
▪ Wavelengths react with the sensor to cause current flow
▪ Flicker frequency is used to help the scanner discriminate by applying a filter to the frequency of the flame
ZEECO, INC.
Flicker Frequency for Flame Detection
ZEECO, INC.
Basic Flame Characteristics (regardless of fuel)
UV/IR Concentrations Flame Flicker Frequencies
ZEECO, INC.
Traditional Scanner Technology Problems
▪ UV Tube scanners respond to any UV spark/arc, X-Ray or
Gamma Ray source, leading to false flame-on positives when
burner is not on
▪ UV Tubes only have an operating life of 10,000 hours before
needing replaced
▪ UV Tubes need electro-mechanical shutters to check the tube to
see if the tube is not indicating a flame-on without a flame present
(run away tube)
▪ UV Tubes are easily blinded by water vapor as a by-product of
combustion, atomization, FGR or liquid fuel firing
ZEECO, INC.
Traditional Scanner Technology Problems
▪ Current UV Silicon Sensors only have a 20% response range in
the UV spectrum
▪ Current UV Silicon Sensors use optical filters to block visible and
IR, but have a leak in the IR spectrum at 700nm, which still
makes the “UV” sensor respond to IR radiation. Optical filters
absorb 20-30% of available UV
▪ IR sensors pickup the IR from adjacent burner flame tips, bark
beds, liquor flames, slag and hot refractory
ZEECO, INC.
Failure Analysis Summary
▪ Traditional scanners can indicate false flame-on signals
resulting in:
⚫ Difficulty completing the start-up cycle
⚫ Not triggering a safety shutdown (fuel SSO valves
stay open)
▪ Traditional flame scanners poorly operating can lead to
nuisance trips
ZEECO, INC.
Successful Application Parameters
▪ Utilizing UV radiation located at the most stable part of
the flame envelope (base)
▪ Utilizing high UV flicker frequencies at the flame base
▪ Using a UV sensor with 100% response in UV range
without the use of an optical filter
▪ Using UV sensor that “sees through” water vapor
absorption to increase available UV for flame detection
regardless of fuel or atomization technique
ZEECO, INC.
ProFlame Scanner Features
▪ Integrated solid state sensor/amplifier
eliminates costs for amplifier cabinets
▪ State-of-the-art unfiltered solid-state
UV sensor for detecting the flames
from gaseous and liquid fuels
▪ Easily configurable frequency and
gain settings for ease of tuning
▪ Intuitive display to assist in
troubleshooting
▪ Dual signal channel design with
electronic self-check for continuous
use in SIL3 applications
ZEECO, INC.
Solid State Scanner Summary
▪ Flame-On Signal
⚫ Uses amplitude (flame intensity) as a component of flame detection
⚫ Uses flame flicker frequencies as a component of flame discrimination
⚫ Uses relay threshold to determine flame relay status based on amplitude and frequency components of flame signal
▪ No Flame Signal
⚫ Scanner not properly sighted, or field of view is obstructed
⚫ Low flicker flame or high flicker flame (flare, process burner, etc.)
⚫ Gain not properly set (too high, or too low)
⚫ Relay threshold not properly set
⚫ Scanner, scanner wiring or quick disconnect cable is defective
ZEECO, INC.
Case 1 - Combination Boiler
Problem: Former scanners were not
able to discriminate the target flame
from other burners and bark grate
Results: Plant can properly
sequence burners to start
automatically without operator
assistance
ProFlame Successes
ZEECO, INC.
Case 2 - Power Boiler
Problem: Former scanners were not
able to discriminate the target flame
from other burners and pilots
Results: Plant can properly
sequence burners to start
automatically without operator
assistance
ProFlame Successes
ZEECO, INC.
Case 3 – Recovery Boiler
Problem: Former scanners were not
able to discriminate the target flame from
other burners and liquor
Results: Retrofit provided reliable
operation preventing the need for Class
1 pilot upgrade saving over $250k
ProFlame Successes
ZEECO, INC.
Scanner Sighting
ZEECO, INC.
Accessories – Swivel Mount
ZEECO, INC.
Accessories – Cooling Jacket
ZEECO, INC.
Approvals
▪ CE (EN298 and EN230)
⚫ TÜV
⚫ ATEX and IECEx
▪ GOST-R (Russia)
▪ Marine - Lloyds Register
▪ InMetro (Brazil)
▪ North American
⚫ UL
⚫ CSA and cUL
⚫ FM
ZEECO, INC.
Dipswitches: Flicker frequency settings (1-6) both A + B
dipswitches must either be ON or OFF.
Green LED indicator: Flame-On state
Intensity indicator: Flame signal (Adj. dipswitch OFF) or raw
signal (Adj. dipswitch ON).
0-100% Potentiometer: Flame-On stabilization (delay)
Yellow LED: Active gain range indicator
Test points: To measure raw flame signal (mVac)
6 position rotary switch: Gain range II (High gain range)
6 position rotary switch: Gain range I (Low gain range)
Red LED Indicator: Flame-Off state
ProFlame Tuning Controls
▪ 1
▪ 2
▪ 3
▪ 4
▪ 5/10
▪ 6/9
▪ 7
▪ 8
▪ 11
ZEECO, INC.
Signal Strength/Analog Output
ZEECO, INC.
ProFlame Wiring
WH = White (N.C.)
BN = Brown (Common)
GN = Green (N.O.)
PK = Pink (4-20 mA output)
YE = Yellow (Gain range select)
RT = Red (24V dc positive)
BU = Blue (24V dc neutral)
GY = Grey (Earth ground)
SH = Shield (Instrument ground)
ZEECO, INC.
Thank You
Slide 1 Slide 2 What is the purpose of a Flame Scanner?Flame Scanner ApplicationsFlame Scanner ApplicationsTypes of Flame Scanners Flame Detection vs. Flame DiscriminationExisting Methods of Flame DiscriminationFlicker FrequencyFlicker Frequency for Flame DetectionBasic Flame Characteristics (regardless of fuel)Traditional Scanner Technology ProblemsTraditional Scanner Technology ProblemsFailure Analysis SummarySuccessful Application ParametersProFlame Scanner FeaturesSolid State Scanner SummaryProFlame SuccessesProFlame SuccessesProFlame SuccessesScanner SightingAccessories – Swivel MountAccessories – Cooling JacketApprovalsProFlame Tuning ControlsSignal Strength/Analog OutputProFlame WiringSlide 28