Birwelco HT Ignition

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Birwelco High Tension Pilot Ignition System
The Birwelco High Tension Pilot Ignition System provides reliable initial ignition of pilot flare
gas, detection and indication of pilot flame presence, and automatic re-ignition of the pilot
in the event of loss of pilot flame.
The basic system comprises:
High Efficiency Pilot Nozzle
A high nickel alloy pilot nozzle is mounted on the fuel/air supply tube and ignition
/flame detection electrode housing. At the base of the pilot tube is a gas supply
flange. Between this flange and the gas supply line is an inspirator plate. This plate
causes air to be drawn in and mixed with the fuel gas supply to provide a flammable
gas air mixture at the pilot. The pilot nozzle is designed to meet the wind speed
recommendations of API 537.
Pilot Burner Ignition/Flame Detection Electrode
The ignition/flame detection housing contains a high alloy/ceramic electrode which

conducts the ignition spark and also monitors the presence of the pilot flame within
the nozzle (see below). The housing contains electrical connection for termination
of the HT cable and provides thermal shielding.
Controls for Monitoring and Automatic Re-ignition.
The control system is normally located in the ignition control panel at an

accessible location at ground level or a suitable location on the platform. The
control system contains a module to generate high voltage potential, a module to
sense presence of pilot flame, supporting relays, indicator lights, switches, and
terminals. Each pilot has its own ignition unit and independent controls to provide a
high level of reliability. The control system can also be switched to Manual operation
at the panel as required.
The high tension (HT) cable used for interconnection between the control system and the
ignition/flame detection housing is a high voltage silicone rubber-based cable that can be
installed within conduits or mounted on cable tray depending upon the application. It is
suitable for both high and low temperatures. Typical installations range from 15 to 200m of
installed cable however alternative arrangements can be used for greater distances
Birwelco Ltd High Tension Ignition System
Copyright 2009 - Birwelco Ltd

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Method of operation
Pilot Flame Ignition

The ignition electrode consists of a ceramic insulator and a Kanthal inner conductor
and is housed in a 1 inch stainless electrode tube that runs adjacent to the main pilot
gas and pilot nozzle assembly. The upper end of the electrode terminates inside the
pilot nozzle. The electrode provides a point for the ignition arc discharge across a
gap to ground, to igniting the pilot gas/air mixture and also acts as a conductor for
flame monitoring.
The HT system utilises a powerful ignition coil for ignition arc generation, 6kV at
22 mA. The unit delivers this relatively high current to the ignition electrode and is
effective in clearing low impedance bridges. The electrode alloy is capable of
withstanding 1450C, and the high alumina ceramic insulator is capable of
withstanding 1950C. The electronic package allows high voltage ignition via this
electrode, and also permits monitoring of the pilot flame status through the same
electrode when the spark is not active.
Pilot Flame Detection (Flame Ionisation)

The detection method is based on the proven flame ionisation principle. In the
presence of a flame, the gas immediately surrounding the flame forms an ionised
gas cloud that is capable of allowing the passage of an electrical current. The flow
of this current is detected by the control system circuitry which signals flame
present.
The ionisation signal is typically in the order of 200 micro amps and this large flame
present signal means that the control electronics can be located at considerable
distances from the ignition/flame detection housing and flare tip, as the strong signal
provides a useable flame present signal despite cable losses.
Sequence of operation
Initial Ignition
A relatively high current (22mA) and high voltage (6kV) is passed up the high
tension cable and a spark is produced within the pilot which ignites the flame.
Monitoring
When the flame is present gas within the pilot is ionised and allows a current to
pass between the electrode and pilot nozzle ground. Detection the small current
(200microA) passing through the circuit indicates flame present.
Re-ignition
If the pilot flame is extinguished the gas looses its ionisation the monitoring circuit is
broken. If Auto-Re-Ignition is selected and the control system initiates the ignition
sequence
All the above sequences are carried out using the ignition/flame detection electrode and
single cable in one circuit controlled by the control system.

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Schematic of Operating Modes

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Benefits and Disadvantages Flame Ionisation over Thermocouple
Flame ionisation Thermocouple
Material designed for location near flame Susceptible to flame damage

i.e. Kanthal/ceramic
Experience Indicates Longer life Experience Indicates Limited service life
Fast response Slow response time
Combined ignition/detection - one cable Detection - one cable plus
Ignition - one cable or one ignition pipe.
Distance limited to approx 200- 250m Distance unlimited
Reference List System 12 years/Spares 5 years
Date Contractor/Client End User/Location Spares Notes
2009 Dialog Systems Petronas MLTTB

2008 DSME Total Pazflor
2008 KBR Woodside Group HT with FFG backup
2005 KBR Scott Field Up rated Replacement tip
supplied 1999 existing HT
ignition panel
2005 KBR Statoil Langeled
2002 - Amerada Hess Jotan Spare tip supplied for tip in
1997 Existing HT ignition
A
System existing
2002 Haliburton Balanak FSPO
2000 Kerr McGee Leadon FSPO
2000 - Mobil Beryl 2009
Alpha/Skene Replacement
ignitor rods
2000 Waha Oil Co Samah
2000 Kvaerner South Pars 2 + 3
1999 Wood Group Scott Field
1998 Kvaerner Asgard B
1998 Woodside Amerada Hess Rubie
Renee
1997 Jotan A Original supply
1997 Kerr McGee Janice A
1997 Pierce/Bluewater 2005 cable
connection kit
1997 Kvaerner Petronas Masa Hitra
FSPO
1997 McDermott Qatar Gas 2004/ 2009
Replacement
Ignitor rods
1996 Shell Ursa A
Thermocouple systems approx 30-40

Thermocouple replacements approximate 6-9 requests per year

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Birwelco High Tension Pilot Ignition System

The basic system comprises:

High Efficiency Pilot Nozzle

Pilot Burner Ignition/Flame Detection Electrode

The ignition/flame detection housing contains a high alloy/ceramic electrode which

Controls for Monitoring and Automatic Re-ignition.

The control system is normally located in the ignition control panel at an

Birwelco Ltd High Tension Ignition System

Copyright 2009 - Birwelco Ltd

Pilot Flame Ignition

Pilot Flame Detection (Flame Ionisation)

Birwelco Ltd High Tension Ignition System

Copyright 2009 - Birwelco Ltd

Schematic of Operating Modes

Birwelco Ltd High Tension Ignition System

Copyright 2009 - Birwelco Ltd

Benefits and Disadvantages Flame Ionisation over Thermocouple

Flame ionisation Thermocouple

Material designed for location near flame Susceptible to flame damage

Reference List System 12 years/Spares 5 years

Date Contractor/Client End User/Location Spares Notes

2009 Dialog Systems Petronas MLTTB

Thermocouple systems approx 30-40

Birwelco Ltd High Tension Ignition System

Copyright 2009 - Birwelco Ltd

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