In the name of Allah the most

beneficent the most merciful

A presentation on
Flame Monitoring system





Flame monitoring is an important scheme of a
process industry where we need an appropriate
burning and heat energy


In MCR PARCO,Honewell flame
monitoring system(UV) is installed


FIRED HEATERS
The purpose of a fired heater is very
simple: To add heat to a process fluid

Very important portion of a Fired Heater
is the burners. Different Types of the
burners are available with different fuel
burning arrangements.

Each Fired Heater burner assembly is normally
having two types of burners.
1. Main Burners
2. Pilot Burners
Pilot burners are normally used to ignite the
main burners.
Pilot burners is used to avoid accumulation of
fuel in the furnace
Tripping of a heater occurs when 50%+1
burner turn off installed with in that heater


Flame Detectors
Definition

Flame detector is an instrument that is used
to evidence the presence of flame at any
burner. It can be any type but the core is to
ensure the flame presence to avoid any
unwanted situation.
The pilot flame detector is used to confirm that
the pilot has ignited. A variety of types exist
depending on the size of the burner and the
type of fuel.

The following types of pilot burner flame
detectors are installed at PARCO MCR.
1.Ionization Type Flame Detectors.
2.Ultraviolet Type Flame Detectors

In MCR Ionization flame detector is installed
at natural draft furnaces and ultraviolet flame
detector is installed at forced draft furnaces

Draft
It is the density difference between the
cold (air) and hot (flue) gases (The pressure
difference between inside the furnace and out
side the furnace). It is represent in mmH2O
Natural Draft
The draft is maintain by burning of fuel is
natural draft. In natural draft furnaces,
snuffing steam is used for create the draft and
also for purging before start up the furnace.

Forced Draft
Air is supplied to a furnace by means
of a fan or blower, which forces air
through the equipment.
Ionization Type Flame Detector
A flame rod is a simple
electrode which
complete the circuit
with body, When the
flame is established, the
D.C current energizes a
relay.

Make:ICE(International
Combustion Equipment

The contacts of this relay can be used for
control functions according to the
application. Since it only senses flame at
a point, it will not detect the main flame.
A disadvantage is that the tips burn off
after a period of time

Working principle of ionization flame detector
Flame Ionization is the process of heat in the
Flame, causing the molecules in the flame and
around the flame envelope to collide with one
another with sufficient force to free some of
the valance electrons of the atoms. In this way,
free electrons and positive ions have been
created. This ionization process allows a very
small current to be conducted through the
flame. Flame conductivity is low. Resistance can
vary from 100k to 100M ohms. Current
conducted through the flame. Flame current is
generally in the range of 2 - 4 micro-amps. If
two electrodes were placed in a flame and a
voltage was applied, a current would be
conducted between the two rods (flame rods).
Naturally the positively charged ions would
flow to the negatively charged grounding area.
Principles of Ionization Flame Monitoring
An ion is a charged atom that has either gained an
electron to become negatively charged (anion) or has
lost an electron to become positively charged
(cation). The energy released during a combustion
process will cause electrons to be knocked loose from
an atom, resulting in a positively charged particle and
a free electron. This ionization, if monitored properly,
can be used to generate a safe and reliable indication
of a flame.

During normal combustion: e.g., burning methane in
the air and getting carbon dioxide and water vapor,
the following chemical reaction occurs:
CH4 + 2O2----->CO2 + 2H2O

Flame Detection Using Flame Conductivity
If two electrodes are placed in or near the flame and a
voltage is applied to the electrodes, a current will
flow between the electrodes using the ions and the
electrons as charge carriers. A current will flow
between the electrodes when a flame is present, but
there will be no current when the flame is not present

This type of system has one serious and
potentially dangerous problem. If another
current path between the electrodes develops,
such as a coating of soot on the electrodes and
insulators, this leakage current would give the
indication that a flame is present at all times.
To overcome this dangerous failure mode,
Hegwein pilots and burners uses a flame
detection system that uses the rectification
characteristic of the flame.
Flame Detection Using Flame Rectification
In a rectifying flame ionization detection
system, an alternating potential (AC) is
supplied to the two electrodes. In addition, one
of the electrodes must have a large surface area
compared to the other electrode. To increase
the size of one of the electrodes and to
simplify construction, one of the electrodes is
the burner tube. The small electrode is then
electrically isolated from the burner tube (the
other electrode) with ceramic insulators
When the small electrode is at a positive
potential compared to the burner tube, the
positive ions are repelled from the small
electrode and attracted to the lower potential
burner tube. When the small electrode is at a
negative potential compared to the burner tube,
positive ions are attracted to the negative small
electrode and repelled from the burner tube
If the current meter reading is averaged, the result
would be a direct current (DC) value. Once the flame
is lit, the ionization of the gases occurs, and the DC
value of the ionization current hits a predetermined
threshold, the "flame on" signal is generated. If the
small electrode (sometimes referred to as the flame
rod) should short to the burner tube, the AC signal
would be large but it would be the same magnitude in
both the positive and negative directions so the
resulting DC value would be zero
If soot or other contaminants covered the
ceramic insulators and allowed current to leak
between the small and large electrodes, the AC
signal would be minimum but it would be the
same magnitude in both the positive and
negative directions so the resulting DC value
also would be zero
Tip material of ionization rod: Kanthal
Supplied voltage:110AC
In normal condition voltage:60v to 90v
Frequently Problem occurs:
Tip burn off after some time period
Rod short with body
Tip Tilted
Material deposited on the tip which eventually
touches with body due to this reason max
current flows through the rod

In MCR PARCO Ionization flame detector is
installed at

284H1--------------06
284H2--------------12
200H1--------------03
300H1--------------12
300H2--------------18
300H3--------------12
1010H1------------06

Total Ionization flame detector installed------69nos
At DHDS ionization flame detector is
installed with FIREYE flame switch.
It also contain with ignition rod and
spark plug
Make of ionization rod is GAYESCO
Supply voltage:190AC
In normal condition voltage:150v to 180v





Ionization flame detector of DHDS

Ultra-violet (UV) flame detector
In MCR PARCO,
Dynamic self check
ultra-violet (UV)
flame detector
Model:C7061F with
R7061 Amplifier
R4348 Flame
switch
installed at:


100H1----------------24
110H1----------------08
130H1A--------------08
130H1B--------------08
130H1C--------------08
284H50A-------------15
284H50B-------------15
Total UV flame detector installed------86nos
ULTRA-VIOLET RADIATIONS
The color of light depends on its wavelength. Visible
light has a wavelength ranging from about 380
nanometers (deep violet) to 840 nanometers (deep
red). A nanometer (nm) is one-billionth of a meter.
Light at wavelengths just below 380 nm is ultraviolet
(the light that causes sunburn), while light at
wavelengths just above 840 nm is infrared (radiant
heat). Other parts of the light spectrum include things
such as radio waves, microwaves, and x-rays. Visible
light is the only part of the spectrum that we can see.
Wave Length Spectrum
THEORY OF OPERATION
Working Principle:
The combustion flames of most carbon-based fuels
emit sufficient ultraviolet radiation to enable the
ultraviolet flame detector to prove the presence of a
flame in a combustion chamber. The detector
mounted outside the combustion chamber. Its
mounting flange or union is threaded to one end of a
sight pipe inserted through the wall of the combustion
chamber. The ultraviolet sensing tube in the flame
detector sights the flame through the pipe.

The C7061F is a dynamic self checking flame
detector for sensing the ultra violet radiation
generated by the combustion of gas, oil or
other fuels. When a flame is present, the UV
tube in the primary sensor senses the
ultraviolet radiation emitted. The primary
sensor produces a signal that is sent to the
amplifier in the flame safeguard control. The
amplified signal pulls in the flame relay in the
control to allow proper operation of the system

When supply voltage applied and no current
flow in the circuit, shutter will be open. when
UV tube detect the flame, current flow in the
circuit. This current off the shutter. In this way
again current stop and shutter will open. Its
frequency is 12Hz.Mean oscillating shutter
interrupts ultraviolet radiation reaching the UV
sensor 12 times per minute to provide UV
sensing tube checking function
Shutter Coil Assembly
Magnifying lens is used for focus the flame
at UV tube
Acceptable current:3A to 7A
Ambient temperature: -30 to 70
Storage temperature: -51 to 85
Supply voltage of shutter coil: 110AC
Supply voltage of UV tube: 110AC



Frequently problem occurs:
1) Blinking
2) Off indication
Action taken for blinking
i. Adjust air
ii. Clean magnifying lens
iii. Tube Alignment
Action taken for Off indication
i. Check coil resistance it should be 3.2k to 3.4k
ii. Change the UV tube
iii. If problem remain same then change amplifier card


First of all check the flame colour.The
colour of flame should be bluish
If UV tube glowing in red colour in the
presence of supply voltage, it mean UV
tube have been expired
Some time shutter break due to frequent
movement
Ultraviolet (UV) flame
detector Model:C7076F
with
R7476B Amplifier
R4348 Flame switch
is installed at:
820H1/H2--------02
820H51/H52-----02
820H3/H4--------01
It is used for detect main burner flame
Acceptable current:2.5A to 5.50A
Supplied voltage: 220 AC
More sensitive
Good sealing
Use at high temperature

THANK YOU FOR
YOUR KIND
ATTENTION.