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

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Basic Flame Characteristics (regardless of fuel)

UV/IR Concentrations Flame Flicker Frequencies

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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