Flame Monitoring

Flame Ignition,
Flame Monitoring
and Burner Control
Ignition of Flames
Flame Monitoring
Automatic Burner Control Systems
 Flame Monitoring

Ignition of Flames High-Energy Ignition Devices

Reliable ignition systems which function without delay are Durag high-energy ignition equipment (fig. 2) ignites oil and gas
necessary for the ignition of large industrial burners for steam burners of any capacity in industrial applications and power plants.
generation or process furnaces. These systems must also have a The energy required for ignition of the burner is stored in a high-
guaranteed perfect functioning under start and differing load voltage capacitor in the device. The energy is then switched to the
conditions. According to the German TRD (Technical Regulations for ignitor tip via a wear-resistant electronic switch. The resulting spark
Steam Boilers) gas, oil and coal combustion systems must be fitted with discharge at the ignitor tip will ignite the fuel. For reliable ignition
a suitable ignition system. The following during the start phase, the ignitor delivers 20
ignition systems are differentiated according to sparks/s for 60 seconds and then switches
TRD: down to 5 sparks/s. When the operating
voltage is switched on, the ignitor will
gas-electric (Hegwein system) automatically begin to spark. The ignition
oil-electric (Hegwein system) function of the ignitor is signalled via an LED
electric (spark ignitors, Durag system) and the potential-free contacts of the ignitor
acknowledgment relay.
The main requirement in all cases is that The ideal position of the ignitor tip for
the respective ignition system ignites the flame igniting oil burners is generally at the edge of
within the required safety time, stipulated in the atomizing cone directly in front of the
the TRD. The ignition device can be installed for swirler. The actual position is determined by
the following uses: adjusting the ignitor tip axially by hand. If
heavy oil is being fired, it is necessary to
Continuous ignitors: sufficiently preheat it to between 90C and
The ignition system provides permanent 130C. In the case of gas burners, the position
ignition energy, for example for flames Figure 1: Required Ignition Energy of the ignitor tip is not of critical importance.
which are not stable under all load conditions ( e.g. coal burners) There must, however, be a mixture of fuel and air present at this
Intermittent ignitors position. For a soft start, a low flow velocity (start-up position of the
The ignition system provides ignition energy only in certain load burner) should be set.
conditions, for example for flames which require support under low
load conditions ( e.g. heavy oil burners)
Interrupted ignitors
The ignition system only provides ignition energy for the start of
combustion for easily combustible fuels and stable flames (e.g. gas Pneumatic Retraction Device
burners)
Reliable ignition of a burner using a high-energy ignitor assumes an
It can be seen from the diagram (fig. 1) that ignitor types can be exact positioning of the ignitor tip at the edge of the fuel-air mixture or
classified according to differing fuels. While electrical ignitor systems are in the fuel-air mixture. The temperatures in the area are, in most cases,
suitable mainly for gas and light oil operations, gas or oil-electrical so high that the ignitor tip would burn off. In order that the ignitor tip
ignitors are suitable mostly for heavy oil and coal operations. does not suffer any unnecessary wear, the ignitor lance should be pulled
In general the ignitor should have 5-10% of the capacity of the main from the ignition position once the fuel has been successfully ignited.
burner. To automate the ignition process, it is in most cases sensible to
NFPA (National Fire Protection Association) categorizes ignition install a pneumatic retraction device (fig. 2), which will take over the task
equipment into four different classes according to power output. of moving the ignitor tip into the area around the burner which during
the ignition process has an ignitable fuel-air mixture. It will also pull the
Class 1: ignitor lance out of the area of the flame once successful ignition is
Pilot burners whose heat release is more than 10% of the capacity achieved.
of the main burner. The retraction device consists of a pneumatic cylinder with a hollow
Class 2: piston rod into which the ignitor lance is inserted. The control of the
Pilot burners whose heat release lies between 4% and 10% of the cylinder occurs via a solenoid valve. The piston of the retraction device
capacity of the main burner. is provided with a permanent magent. Via corresponding switches,
Class 3: which are fixed to the retraction device, the two end of travel positions
Pilot burners whose heat release is less than 4% of the capacity of can be displayed.
the main burner.
Class 3 special:
Electrical high-energy ignition devices which are suitable for direct
ignition of the main burner.

Figure 2: High Energy

Ignitor (DURAG System)

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Flame Monitoring

Pilot Burners
Fuels that require a higher amount of energy for ignition are
generally ignited with an ionization-monitored pilot burner (fig. 4). Pilot Figure 3: Safety Times according to TRD
burners are principally operated using gas as the fuel. Special designs for Fuel Burner Type maximum Furnace Maximum Safety Time in Seconds
light fuel oil (Diesel) are also available. Capacity in kW at Start-Up)1 in Operation
Compact pilot burners consist of the burner tube with mounting
flange and flange for the air line, the gas tube with the nozzle and the 10 10 1
Gas Main Burner > 10 50 5 1
electrode support ring, as well as the powerhead, which contains the > 50 120 3 1
ignition transformer and flame monitor for intermittent or continuous > 120 2 1
operation. Installation costs on site are thus reduced to a minimum.
Only in plants where pre-warmed air is used or where the ambient Ignition Burner 5% 10
> 5% 8% 5
temperature is greater than 60C is it necessary to forego this compact > 8%
design and mount the ignition transformer and flame monitor of the maximum same as
separately. Furnace Capacity of Main Burner
The built-in ionization electrode is used to monitor the flame. The the Main Burner
direct current is used as the flame signal. The ionization and rectification Oil Oil Throughput in kg/h Safety Times in Seconds (max.)
effect of the flame allows this current to flow from the burner tube
ground, via the flame, to the ionization electrode and, ultimately, to the up to 30 10 10
flame monitor. over 30 5 1
Pilot burners are normally only employed for igniting the main )1 The furnace capacity at the end of the safety time at start-up is decisive.
burner. There are, however, applications in which the pilot burner is
used both as a pilot and support burner. In such cases, it is left on for a
longer period of time, or during the entire period of operation of the
main burner.
Due to the long, tight flame, these pilot burners can be installed
such that, in the vast majority of cases, a retraction device is not Figure 4 :
required. Pilot burner
(Hegwein System)

Figure 5: Cross section of a

Hegwein Ignitor
1 Mixing Chamber with Mixing
Ring
2 Flame Rod
3 Spark Rod
4 Gas Nozzle
5 Electrode Holder
6 Gas Tube
7 Connecting Rods
8 Support for Connecting Rods
9 Ignitor Tube with Mounting
Flange
10 Air Pressure Test Point
11 Gas Port 1/2
12 Inside: Spark Transformer 5 kV
13 Inside: Flame Monitor
14 Multipole Plug and Socket
Figure 6: Connector
Supply of a Gas
Burner 15 Air Port 1
16 Flame Indication Lamp

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 Flame Monitoring

Flame Monitoring Physical Process

Systems for flame monitoring and evaluation are used in furnace During the process of fossil fuels combustion, carbon monoxide
plants. The prime objective of flame monitoring in boiler plants, process (CO), carbon dioxide (CO2), nitrogen oxide (NOx), sulphur oxide (SOx),
heatings and the like is the one of complying with the safety-related water vapour (H20) and others emanate as combustion products.
demand of unequivocal recognition of a flame. A prime precept for this In this combustion process, during which complex physical and
objective is preventing fuels from getting into the combustion chamber chemical processes evolve, the aforementioned combustion products,
unless the combustion process is guaranteed. If the system recognises due to their high temperature and energy rates, emit electromagnetic
the extinction of flames, it shall initiate an immediate shut-off of the fuel waves in the form of light of different wavelengths. Their span reaches
supply. Apart from and concomitant to this requisite, a highest possible from the short-wave UV up to the long-wave IR-range. In the sense of
degree of instrument fail safety, reliability and availability must be given, process time, the radiation emission is not constant. Due to the
as is established in the relevant instructions. Figure 3 shows the required backflash behaviour of the flame a dynamic process takes place,
safety times for oil and gas operation. manifesting itself through intensity fluctuations (flame flicker).
Monitoring and evaluation of flames must proceed independently of It is only this dynamic portion of the light signal - which lies in the
the type of furnace plant, its operating mode and characteristics; i.e. at: range of between 1 and 200 Hz - that is utilised for flame recognition.
The portion of constant light emission of the flame and the signal of
variable load conditions, light of constant intensity emitted by other, alien radiation sources, e.g.
gas recirculation tasks, boiler pipes or combustion chamber walls, are not to be included for
oxidation-reducing measures (NOx, SOx), flame monitoring and valuation and are suppressed.
multi-burner systems,
multi fuel firings (oil, coal, gas) and change of fuels,
alternating fuel compositions. Requirements for Flame Monitoring
All in all, the objective of flame assessment is the one of giving the
Systems
user of the furnace plant reliable data on his combustion process, thus Flame monitoring systems must in principle meet an extensive list
securing the overall grade of effectiveness, availability, economic of demands. Not only must these systems provide reliable flame
efficiency as well as pollutant emission control. monitoring under all operating conditions of a boiler, they must also
So as to fulfil these tasks, flame detector devices are composed of a meet the following criteria:
flame sensor for detecting and conversion of light into an electric signal
and a control unit. system must be safe from the influences of ambient light,
Figure 6 shows the application of an ignition device and a flame selective recognition of individual flames during multiple burner
monitor in combination with a flame safeguard control on the supply of operation,
a gas burner. fail-safe and dependable operation,
sufficient sensitivity and
high economy.

A primary requirement is the ability to reliably distinguish between

the monitored flame, those of neighbouring or opposing burners, as
well as other energy sources in the combustion chamber.
The systems employed today accomplish this task using a variety of
technical approaches with different optical flame sensors and
controllers.

Figure 7: Requirements for Flame Monitoring

UL 372 EN 230 EN 298

"Primary Safety Controls for Monobloc Oil Burners - Automatic Gas Burner Control Systems
Gas- and Oil-Fired Safety, Control and Regulation Devices and for Gas Burners and Gas Burning Appliances
Appliances" Safety Times with or without Fans

Minimum Requirements Minimum Requirements Minimum Requirements

Fail-safe Hardware Respond to flame frequencies Sensors for visible light are not allowed (only
UV and IR, exception possible)
Fail-safe Software Flame simulation (alien light does not occur
as a flame) Respond to flame frequencies (not 50 Hz and
Electromagnetic compatibility harmonic frequencies)
Self checking and fail safe
Various constructive requirements Self checking and fail safe
Final tests (checking documents, durability,
Certification by Underwriter Laboratories marking (CE conformity) Final tests (checking documents, durability,
(UL) marking (CE conformity)
Approvals from authorized organizations
(i.e. notified bodys, TV) Approvals from authorized organizations
(i.e. notified bodys, TV)

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Flame Monitoring

Flame Monitoring Guidelines voltage guideline 73/23/EWG and the gas appliance guideline
90/396/EWG. The latter is, however, only relevant if the flame
Flame monitoring systems are considered safety equipment and monitoring equipment is installed on gas burners in hot-water
may only be installed once they have been certified by authorized generators with a maximum water temperature of up to 105C. If the
testing laboratories, according to all locally applicable product equipment is installed in a steam generating system, e.g., power plants,
standards. It is necessary, however, to distinguish between the product this guideline does not apply.
standards for the American-oriented market (USA, Canada, and Asia) The CE symbol is merely an administrative symbol. The
and those for the European-oriented market (European Union in manufacturer must confirm in writing via a CE declaration of conformity
particuar). Making matters more difficult, however, is the fact that many that the relevant guidelines have been observed. This must be signified
standards within the EU have not yet been brought in to line with one by affixing the CE symbol to the device. Testing of the devices is not
another. demanded in every case. If the flame monitoring equipment is also
The essential requirements for flame monitoring systems are installed in systems which fall under the gas device guideline, the
derived from the European product standards. These are EN 230, Oil requirements of this guidleine must likewise be observed. In general,
Atomization Burners in a Monoblock Configuration, and EN 298, conformity of the flame monitoring equipment with the gas device
Burner Management Systems for Gas Burners and Gas Devices with and guideline must be proven by an authorized testing laboratory using the
without Blowers, which each describe requirements for flame monitors so-called EG design test certification.
on oil and gas burners. These product standards have in the mean time
become binding throughout the EU, so that former national regulations
for flame monitors (e.g., DIN 4787 and DIN 4788) are no longer Steam Boilers and Thermoprocess
meaningful.
The product strandards relevant to the American market are UL 372,
Systems
Primary Safety Controls for Gas and Oil Appliances, Canadian There is likewise a series of various national and international
Standards Association standard CSA-C22.2 No. 199-M89, Combustion regulations for equipping and operating steam boilers and combustion
Safety Controls and Solid-State Ignitors for Gas- and Oil-Burning systems.
Equipment, and FM Class 7610, Combustion Safeguards and Flame If the flame monitoring equipment is operated in a steam boiler, the
Sensing Systems. The first two standards are comparable to the related regulations must be observed. In Germany, this would be, for
European standards EN 230 and EN 298. On the other hand, FM Class example, the Technical Rules for Steam Boilers (TRD 411 to 414 and
7610 basically describes just the function of the devices, without TRD 604). At present there are efforts underway to harmonize the
addressing whether they are fail-safe. various national regulations within the EU. One example of this is the
pressure device guideline 97/23/EG, which will become binding for all
member states of the EU on May 29, 2002. This probably means that
CE Label plants will no longer then be tested according to TRD. Rather, they will
be required to prove conformity with the new regulations prEN 12952
In addition to the product standards mentioned above, all flame EN Water Tube Boilers and prEN 12953 EN Large Water Tank Boiler .
monitoring equipment installed within the borders of the European Those regulations for the American market which are comparable
Union must fulfill the requirements of various EU guidelines. There are to TRD are NFPA 8501 Standard for Single Burner Boiler Operation and
three EU guidelines that are of particular meaning for flame monitoring NFPA 8502 Standard for the Prevention of Furnace Explosions
equipment. These include the EMV guideline 89/336/EWG, the low- /Implosions in Multiple Burner Boilers.

Figure 8: Guidelines for Flame Monitoring and Burner Control

Germany Europe USA Canada

Steam Vessels TRD 411 Oil Firing Systems prEN 12952 Water Tube Boilers NFPA 8501 Standard for Single
TRD 412 Gas Firing Systems prEN 12953 Large Water Room Burner Boiler Operation
TRD 413 Pulverized Coal Firing Boilers NFPA 8502 Standard for the Pre-
Systems
TRD 414 Wood Firing Systems 97/23/EWG Pressure Appliance vention of Furnace Ex-
TRD 604 Operation of Steam Boi- Directive plosions/ Implosions in
ler Plants Multiple Burner Boilers
Furnaces / Ovens VDE 0116 Electrical Equipment of EN 746 Industrial Thermo- NFPA86 Standard for Ovens and
Furnaces processing Equipment Furnaces
90/396/EWG Gas Appliance Directive
Burner UL 726 Oil-Fired Boiler
Assemblies
UL 795 Commercial-Industrial
Gas Heating Equipment

Flame Monitors and DIN 4787 Atomizing Oil Burners EN 230 Monobloc oil burners UL 372 Primary Safety Controls CSA C22.2. No. 199-M89
Combustion Automation DIN 4788 Gasburners EN 298 Automatic Gas Burner for Gas- and Oil-Fired Combustion Safety
Control Systems for Appliances Controls and Solid-State
Units Igniters for Gas- and Oil
Gas Burners and Gas FM Class 7610
Burning Appliances Combustion Burning Equipment
with or without Fans Safeguards and Flame
EN 60730-2-5 Automatic Electrical Sensing Systems
Controls for Household
and Similar Use

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 Flame Monitoring

Sensors for Flame Monitoring

Today, mainly four different methods are used to monitor flames.
Each method processes a different characteristic of the flame (fig. 11).

Temperature Detectors
Temperature sensors, for example thermocouples, are used
nowadays for flame monitoring on small burners and sometimes on
flares. For a reliable detection of the flame, a correct positioning of the
flame sensor is required. Flame monitors with temperature sensors have
only a very poor safety standard, so are not suitable for continuous
operation.

Sound Detectors
Flames of single burners can also be detected by sound pressure
detectors. This type of detector converts the sound pressure of the flame
into an electrical signal. The disadvantages of the sound detector are,
that disturbing noises could simulate a flame signal and that this type of
flame detector can only be used for single burner furnaces. Furthermore
it is not suitable for continuous operation.

Ionization Detectors
Ionization detectors use the ionizing effect of a flame. It can be
differentiated between ionization detectors measuring the conductivity
Figure 9: Schematic
of the flame and those, which are using the rectifying characteristic of a Diagram of
flame. Detectors which are estimating the conductivity of the flame are D-LE 603 UA
not fail-safe. A short circuit between the electrodes cant be detected. It
is better to use those detectors, which are using the rectifying
characteristic of the flame. Short circuits between both electrodes can
be detected easily. Ionization detectors are used especially on small
burners and ignitors. A disadvantage is, that the electrodes can become
contaminated or burned and a reliable monitoring of the flame is no
longer possible.

Optical Detectors
Today, large burners are monitored only with flame monitors using
optical sensors. Depending on the type of fuel and on
the combustion technology, different optical
detectors with different spectral sensitivities are Figure 10:
used. Mounting at the
Infrared detectors (IR) respond only to the heat Burner
radiation of the flame with a wavelength more than 800 nm.
Only signals corresponding to the flame flickering will be
processed. Glowing parts inside the furnace must not simulate a
flame signal. Those flames whose short-wave UV energy is absorbed
by dust, water vapor or other materials, can be monitored in the infrared
range.
Ultraviolet detectors (UV) recognize the radiation of the flame
below 400 nm. All gas flames and sometimes even oil flames can
be monitored very well by UV detectors. Due to the fact, that
UV radiation is only generated by a flame, constant portions
of the radiation can also be processed for flame monitoring.
Detectors for visible light (VIS), with a sensitivity
between 400 and 800 nm are suitable as well as IR detectors for
monitoring of oil and coal flames. According to the relevant product
guidelines, gas flame may not monitored within this spectral range.

6
Flame Monitoring

Figure 11: Sensors for

Flame Monitoring

Optical Flame Sensors Table 1: Overview of Photo Elements

Type Wavelength Application
For flame monitoring photo elements are used, which convert the Silicon Semiconductors 300-1100 Oil, Coal
radiation emitted by the flame into electric signals. To this purpose, UV-
Germanium Semiconductors 780-1800 Tail Gas
sensitive gas discharge cells and semiconductors are used.
The type of the photo element selected determines the spectral Silicon 4-Quadrant Semiconductors 400-1100 Oil, Coal with strong Fluctuations
sensitivity of the flame sensor. Sensor selecting should be thus, that its Gallium-Phosphit Semiconductors (w/o filter) 190-520 NOx reduced Combustions
spectral sensitivity range be optimally adapted to the radiation Gallium-Phosphit Semiconductors (with filter) 280-410 Gas, Oil, Coal, Low UV Signal Levels
spectrum emitted by the flame. UV-Cells 190-280 Gas, l
Table 1 shows photo elements used in flame sensors for flame
monitoring.

Ambient Light Security

The dynamic behaviour of flames is utilised for meeting the
requirement of extraneous light security. Flame-inherent frequent
fluctuations of intensity result from the flames physical backflash
Figure 12: behaviour. This dynamic particularity is utilised for distinguishing
Adjustment of the individual flames against a radiating background. So as to comply with
frequency filters the demand of extraneous light security when analyzing signals for
flame monitoring and assessment, flame-caused emissions must be
differentiated from those of constant radiation sources such as
combustion chamber walls, pipe bundles, etc.
Apart from its suitability for constant radiation sources, the demand
of extraneous light security also applies to radiation sources of constant
dynamic signals, like, e.g., electric lighting devices of frequencies of 50
Hz and their harmonics.
To that end, adjustable filters of defined cut-off frequencies are
used as a high-pass, with which flames and radiation sources below this
preselected cut-off frequency can be masked.

Selectivity
Predominantly used at multiburner plants are flame sensors that
can process the frequency behaviour of flames. The flame to be
monitored must be distinguished from the neighbouring flames. To
that purpose, the flame sensors must be fitted with high pass filters with
adjustable cut-off frequencies.
The illustration shows the possibility of discriminating two flames
with the help of frequency filters.
Although the flame sensors detects both flames, unequivocal
recognition of flame #1 is possible. At the distance of A1 from the
flames root the flames flicker at a higher frequency rate than at the
distance of A2. On this basis, a flame sensor that only evaluates
frequencies of over 50 Hz can selectively monitor flame #1. In the flame
sensor of the D-LE 603 series, several filtering steps for suppressing low-
band flame flickering frequencies can be adjusted.

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 Flame Monitoring

Positioning of Flame
Sensors
To begin with, the flame area needed for
monitoring and assessing the flame is
established by selecting the optical axis of the
flame to be captured. The brightest zone in the
first third portion should be aimed at, whereby a
possible moving away of the flame at varying
load conditions should be taken into account.
In the case of several burners in one fire
chamber, this sighting position shall collect the
least possible radiation of other flames. The
viewing direction should fundamentally aim at
the gaps between opposing burners and
burners of other levels (fig.13).
The better these basic rules of positioning
the viewing angle of the flame sensor can be
taken into consideration, the more the signals of
the respective flame will differentiate from those
of the other flames.
The view angle of the DURAG Flame Sensors
is six degrees opposed to the optical axis. The Figure 13: Positioning of
longer the viewing pipe, the more limited is the Flame Sensors
field of vision on the flame and the more
attention must be paid to the adequate visual
range of a flame sensor.
Figure 14: Schematic
Diagram of D-UG 660

Design of Flame
Monitors and Automatic
Burner Control Systems
A system for flame monitoring and
evaluation comes into operation in furnace
plants with the mentioned objectives. Today,
such flame monitors as well as automatic burner
control systems are normally equipped with fail
safe microprocessor systems (see fig. 14).
Nowadays systems based exclusively on
microcomputer operation are developed to
realize the demands and function of flame
monitors. Figures 9 and 14 show the signal
processing in a control unit and a flame sensor
equipped with a semiconductor photo-element
(GaP). Especially fig. 14 shows clearly that the
failure safety of the system is realized through a
two channel CPU system.
Various adjustable elements in the control
unit and flame sensor enable easy adaption to
the specific combustion process to be made.
Adjustments are available for the following
parameters:
switching threshold
amplification
cut-off frequency of the high-pass filter
The switching threshold and amplification
are used to adapt the flame monitor to the most
differing intensities of light emission from
various fuels under different load conditions,
whilst the adjustment of the cut-off frequency of
the high pass filter is used for the selective
recognition of specific burners in multi burner
system boilers. A remote switching of the
amplification and switching threshold is a useful

8
Flame Monitoring

aid for the different operations of the boiler plant. Fig. 15 shows the
adjustment possibilities for the equipment parameters in the flame
sensor. A pulse reduction process allows for further adaptions to the
selectivity to be made so that alien light signals with a constant
frequency can be shut out.
Altogether, the decision as to whether a flame is existent or not is a
very complex one, in which extensive analysis and observation is
involved. In this respect the following criteria have to be considered (fig.
16):

minimum direct light intensity (A)

The light emission coming from a flame must have a minimum
intensity.
minimum alternating light intensity (B)
The intensity of the alternating light portion must be above a
certain minimum.
correct light wavelength area (C)
The wavelength of the light emission must be in the UV range
(180 - 400 nm) or in IR range (800 - 2000 nm)
minimum flicker frequency (D)
The flicker frequency must be in a reasonable range (20 Hz < f
< 200 Hz) the value of which is specific for every flame.

It is only certain that a flame exists when all these criteria are
simultaneously fulfilled.
Figure 15: Controls of the
Flame Sensor
D-LE 603 UA

Figure 16: Criteria of

Flame Recognition

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 Flame Monitoring

Flame Sensor Selecting

Selecting the right flame sensor is critical for optimum flame
monitoring. The necessary properties of a flame sensor are established
by the conditions under which combustion takes place.
These are:

1. The fuel used: coal, oil, gas, wood, etc.

2. Single or multiburner operation/selective monitoring
3. Radiation absorption through steam,
waste gas, fuel, etc.
4. Low to high or varying radiation intensities
5. Change of fuels and combi-burner monitoring
6. Change of combustion conditions.

Figure 17: Flame

The diagram shows characteristic radiation distributions of coal, oil Radiation Wavelengths
and gas fuels, on the basis of which flame sensors are selected. of different Fuels
The intensity distribution of the fuel curves shows that there is
radiation from the UV up to the IR-ranges. The flame sensor can assess
this radiation for flame recognition purposes. As a matter of course, a
flame sensor will be selected whose spectral sensitivity lies in the range
of the most intensive radiation of the
fuel in question. Recommended for
coal is a flame sensor with a
Germanium photocell. Oil can be Fig. 18: Absorption of
monitored with a Germanium photo cell in UV-Radiation through
the IR-range as well as with a Silicon photocell Dust and Steam
in the visible to infrared areas. UV-cells or UV-
sensitive semiconductors can be used for
evaluating shortwave flame radiations. Particular
combustion conditions may require monitoring the fuel
in its zone of low radiation intensity. These conditions
include, for example, absorption through steam, recirculation
of combustion waste gases, or radiation shielding through
nonburned fuel at unfavourable placement of the flame sensor
(interfered sighting on the flame).
It is the short-wave UV-radiation that, to a high degree, is
affected by absorption. If for these reasons UV monitoring is not
possible, one has to recourse to other spectral ranges. In this
sense, monitoring of gas, usually done in the UV-range, often
offers better results if done with an IR flame sensor. Inversely, for
reasons of selectivity a UV flame sensor can be applied for
monitoring coal fires.

Figure 19:
Flame Sensor Selecting

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Flame Monitoring

Flame Detector Devices

The D UG 110 / 120 and D-UG 660 control units, in combination with
any DURAG flame sensor of the D-LE 103 and D-LE 603 series, supervise
Figure 20: Flame
flames of coal, oil, gas, wood and other fuels. This is made possible by Monitoring with
the uniform signal processing in the flame sensor. D-UG 660 und D-LE 603
A flame flame detector device can be run at any burner control
system. A potential free switching contact reports the state of the flame
to the control system in the form of a binary signal. The combustion
conditions are decisive on the optimum composition of a flame detector
device.

D-UG 110/120 Control Units

The uncomplicated and cost-saving combination of a D-UG 110 /
120 and a flame sensor of the D-LE 103 series is often used in single-
burner plants, i e., where selectivity (extraneous-light suppression) is not
a requirement on the flame sensor.
The flame sensor sends pulses to the D-UG 110 / 120, whereby the
number of pulses is a measure for the flames intensity. The number of
pulses needed for a Flame ON message can be adjusted in 10 steps. A
potential free contact reports Flame ON and/or Flame OFF. An
indicator instrument for information on the flames intensity can be
connected to the current output in the 0..20 mA range.

D-UG 660 Control Unit

More information and more adjustment options can be had from a
combination of the D-UG 660 control unit and a flame sensor of the
D-LE 603 series. It is recommended for use in furnace plants with several
burners, which make great demands on selectivity at, simultaneously,
high sensitivity levels.
A display for actual values and status information and an additional
current output at the D-UG 660 offer comprehensive information on the
flame and with it, on the combustion as a whole. Sensitivity can be set
in 100 equal steps. At fuel change or to compensate for strong
movements of the flame, a secondary flame sensor connected in parallel
can take over flame monitoring. Three switches in the units front panel
are provided for changing the sensitivity setting which can be retained
for three operating states (ranges). This operating convenience makes
the D-UG 660 universally suitable for use in plants of varying fuel types
and/or load conditions. Reversible electronic filters, fitted in the flame
sensor of the D-LE 603 series permit enhancing their selectivity rate.

Figure 21: Signal

Transmission between
the Control Unit and the
Flame Sensor

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 Flame Monitoring

D-LX-100 System
The new DURAG D-LX 100 Compact
Flame Monitor is the first system of its kind
to meet current American and European
flame monitoring standards. The D-LX 100
was designed for continuous, intermittent
and 72-hour operation. The flame
monitors compact design integrates the
flame sensor and control unit into one
compact housing. This greatly reduces
overall cost and simplifies installation.
Additional costs normally required for
mounting the control electronics in a
service cabinet or separate housing unit
are no longer applicable.
The D-LX 100 Compact Flame Monitor
has been developed to monitor flames in
single burner systems. The integrated relay
output may be used to interface with the
fuel control valve. Applications for the
D-LX 100 range from small heating plants
to process combustion systems.
Figure 22:
D-LX 100 System

Figure 23: Application

with Fibre Optics

12
Flame Monitoring

Fibre Optics for Flame Detecting Ignition and Flame Monitoring in

Devices Claus Plants
The direct installation of conventional optical flame sensors on a Over the years, Claus plants have developed into a special area of
burner is often limited due to high ambient temperatures or too little application for flame monitoring equipment and ignition devices. Claus
available space. The view of the flame is frequently obstructed by plants are used in all refineries remove sulfur from fuels and contribute,
mechanical components of the burner or materials around the sighting among other things, to reducing acid rain.
tube that absorb the radiant energy of the flame. In such cases, it is Due to the high toxicity and aggressiveness of the fuel burned (H2S),
advisable to employ flame sensors with fiber optics. By installing a fiber there are special requirements for equipping a burner in a Claus plant.
optic system in the burner, it is possible to monitor the radiant intensity Also, measures must be in place in the Claus plant to provide explosion-
in direct vicinity of the flame and bridge the sometimes long distances proof protection. The area around the burner is generally classified as
to the burner wall. Zone 1 with respect to explosion protection. All electrical equipment
In principle, all burners can be equipped with flame sensors using must therefore meet the particular requirements for explosion
fiber optics. Such flame sensing systems, however, are particularly protection.
suited for the following applications: Fig. 24 shows a typical layout of flame monitoring and ignition
equipment in a Claus furnace. For flame ignition, the D-HG 400 High-
Energy Spark Ignitor has proven itself to be the most effective. The
burners with only a narrow opening for monitoring the flame. pressure-proof model of the D-VE 500 Pneumatic Retraction Device
burners whose burner plate or site of installation allows very little guarantees at all times that no toxic gases from the burner chamber are
room for the flame sensor. released into the atmosphere. A protective hood over the retractor
burners whose ambient temperature around the sighting tube is shields it from the ambient environment and also protects personnel
so high that the use of flame sensors with electronic components from any possible injuries from the moving piston rod.
is not possible. The transparent flame of the Claus furnace is best monitored using
tiltable bucket burners; the flame sensor must be positioned on UV flame scanners. The highest level of energy emitted from the flame
the tiltable bucket in order to follow the movement of the flame. admittedly does not lie in the classic UV-C range, rather in the somewhat
burners in which the space between the sighting tube opening longer wavelength UV-A and UV-B range. UV flame scanners in the D-LE
and the flame contains particles which absorb the radiant energy 603 UA series are particlarly well-suited for for monitoring such flames.
of the flame (e.g., cement kilns). These are equipped with a semi-conductor photoelement and have a
spectral sensitivity that covers the UV-A and UV-B range. However, very
good results may also be achieved with a highly sensitive UV-C flame
scanner from the D-LE 603 US series. As a controller, a D-UG 660 should
be installed in this application. This device offers the user a high degree
of flexibility when making the settings.
Since the outage of a Claus furnace can bring an entire refinery to a
standstill, and generate very high resulting costs, the flame monitoring
in a Claus plant is generally performed in a redundant manner. This
enables the flame to be reliably monitored without any problems, in
every situation. Even if an outage occurs in one of the flame monitoring
systems, the plant can continue to operate without interruption.

Figure 24: Claus Plant

Sample Application

13
 Flame Monitoring

Automatic Burner Control System Function Summary

The DURAG Automatic Burner Control Systems comprise of The automation unit accomplishes all necessary steps from burner
start-up up to control function releasing. Fundamentally, this includes:
the flame sensor and
- Pre-purge with air damper control
the programming unit. (not applicable at non-master burner operations)
- Flame simulation controlling
The DURAG D-GF 100 Burner Control System controls and monitors - Ignition
gas and oil burners of any capacity. The control functions of this system - Solenoid valve control
cover the tasks of prepurge, ignition and solenoid valve control, through - Switching-off with post-purge
to the enabling of the output regulation. Thanks to its flexibility, the (not applicable at non-master burner operations)
program sequence for prepurge, ignition, fuel supply and air supply may
be adjusted to the requirements of the plant, with simultaneous
consideration given to applicable guidelines. These units may be used Boiler pre-purge is adjustable in 10 steps. A further switch permits
in applications ranging from large power stations to small remote adjusting the control units sensitivity threshold to the flame sensor
heating plants, or in chemical processes or thermal flue gas combustion signal. An LED indicator bank serves as a program step and interference
systems. By employing microprocessors with corresponding software code indicator.
and hardware, this burner management system offers improved
evaluation capability and a heightened degree of safety and availability.
In combination with flame sensors from either the D-LE 103 or Inputs and Outputs
D-LE 603 series, the burner management system is fully suited to
monitor flames of different fuels and combustion techniques, in single Control outputs for:
burner or multi-burner systems. Different UV and IR flame sensors are - Air damper ON/OFF
available to optimally adapt the flame monitoring system to local - Solenoid valves MV1, MV2, MV3
conditions. The response threshold (sensitivity) of the flame monitoring - Fan
system may be set to one of ten different levels using a rocker switch on - Ignition transformer
the front panel of the Programming Unit. The safety time may be fixed Signal outputs for:
between 1 and 5 seconds, depending on fuel and operating conditions. - Flame ON/OFF
- Failure
Control inputs for:
- Fuel type
- Pre-purge suppression
- Air pressure
- Air damper positioning (end-of-travel switch)
- External flame monitor
- Controller as a contact chain for regular switching-off
- Limiter as a contact chain for incident-based switching-off

Figure 25: Integrating

an Automatic Burner
Control System into the
Process

14
Flame Monitoring

DURAG Information and Evaluation

System D-IAS
This system, designed for long-term monitoring of multi-burner
furnace plants, is used for combustion quality assessment and, at the
same time, for a clear layout presentation of different function groups.
Up to 80 measuring signals are read. This makes it possible to recognise
at one glance a correlation between the flame sensor signals of an entire
block of 16 or more burners, and the fuel supply, the oil quantity, the
dosing speed or other influential quantities.
Whereas video-monitoring and spectrometer analyzing are applied
only in special cases,the DURAG Information and Evaluation System is
conceived as a useful completion of a central control station for
continuous state-of-operation monitoring. Its clear and user-specific
diversely adjustable presentation and storage of data are of great help
in judging present operational conditions and those prevailing up to
several days ago.

Figure 26:
DURAG D-IAS Information
and Evaluation System

15
 Flame Monitoring

The ORFEUS System evaluations, which in turn allow analysis of the combustion chamber to
be made.
In addition to monitoring temperature and fluctuations in the The detected changes are recorded using special software and,
burner, the ORFEUS System (locally determined combustion chamber after a training phase, used to establish an optimized control strategy for
spectroscopy) enables thermally excited particles surrounding the the combustion chamber.
burner, and present in the combustion chamber, to be detected online With ORFEUS, new insights may be gained into process techniques,
without making direct contact. This is achieved using a combination of for which until now only models were available. There is tremendous
emissions spectroscopy, modern video technology and knowledge- potential for operating combustion systems more economically, and
based systems. With spectroscopy, particle radiation is used to ORFEUS technology makes exploitation of it possible.
determine temperature and detect thermally excited particles (e.g. SO2, Recorded data may also be evaluated to optimize the performance
S2, OH, CH, etc.). The wavelength of the radiation may be located of plant components or the normal operation of the combustion
anywhere from the UV range to the near IR, depending upon the system. Mobile systems may also be used at prepared measuring
particular combustion process. Geometric flame characteristics such as locations to monitor combustion, record data or, for example, shorten or
position, size and form are gained using special video technology and simplify the commissioning process. Such systems are also used by the
online evaluation. TV Sddeutschland in Mannheim, among others, for inspecting
Localized and chronological characteristics result from these industrial combustion systems.

Figure 27: Flame Analysis

and Combustion Control
with the ORFEUS System

Flame Monitoring

DURAG Industrie Elektronik Georg Hegwein VEREWA ORFEUS DURAG, Inc.

GmbH & Co KG GmbH & Co. KG Umwelt- und Prozemetechnik GmbH Combustion Engineering GmbH 1970 Christensen Ave.
Kollaustr. 105 Am Boschwerk 7 Kollaustr. 105 Kleiststr. 10 West St. Paul, MN 55118
D-22453 Hamburg, Germany D-70469 Stuttgart, Germany D-22453 Hamburg, Germany D-45128 Essen, Germany USA
Tel. +49 (40) 55 42 18-0 Tel. +49 (711) 13 57 88-0 Tel. +49 (40) 55 42 18-0 Tel. +49 (201) 820 72 30 Tel. +1 (651) 451-1710
Fax +49 (40) 58 41 54 Fax.+49 (711) 13 57 88-5 Fax +49 (40) 58 41 54 Fax +49 (201) 820 72 41 Fax +1 (651) 457-7684
www.durag.de 02/99 - All specifications subject to change without notice