Combustion, Flare Ignition & Flame / Pilot Monitoring

Flare ignition system

Flare Igniters are used for igniting waste gas from pipe flares, air and steam assisted flares, and ground flares. In most flare systems the pilot burner cannot be accessed for service or replacement while the flare is in operation. Flare pilot burners provide reliable ignition and stable burning even under the most difficult ambient conditions, ensuring safe operation.

Features

• API 537 / EN ISO 25457 approved by Bureau Veritas
• Integrated and protected thermocouple(s)
• Fast temperature detection by thermocouple(s)
• Complete delivery; cables, junction boxes and ignition unit
• Easy fit cable connectors
• Made entirely of high-temperature resistant stainless steel
• Option for second thermocouple

Benefits

• Reliable ignition and stable flame under all weather conditions

Gas burner

We supply compact gas burners with integrated ionization flame monitor and high voltage ignition. With high flexibility in product design and versions, and a wide 15–4500 kW output range, we can configure the right burner for any application in industry and heating. All burners can be supplied in explosion protected versions

Features

• Compact and integrated modular design:
  • Integrated spark transformer, flame monitor or burner control
  • Integratable optical flame monitor
  • Optimal electromagnetic compatibility
  • Various oil ignition burner series with different options available
• Standard outer tube lengths: 240 … 8,000 mm
• Nominal heat release 15 … 4,500 kW
• Fuel flexibility
• Flexible operating mode: 1-stage, multi-stage or modulating operation
• Explosion protection: Zone 1/21 and zone 2/22 (ATEX, IECEx, FM-Ex, EAC-Ex)
• Approvals: DVGW, AGA, FM, EAC, SIL 2/3 and cULus
• Customized versions by HEGWEIN Engineering

Benefits

• Highest operational and functional safety
• High availability
• Flexible burner designs:
• Straightforward installation and commissioning
• Reliable long-term spare parts availability:
  • Electrical and mechanical components can be replaced separately

• High turn down ratio
• Different sizes from 15 kW to 4.5 MW available
• Available with integrated ionization flame monitor and ignition transformer or burner control, thus no additional electrical installation and cabling effort
• Robust and easy to maintain: all electrical and mechanical components easily replaceable
• Gas burner for zone 1/21 and zone 2/22 available (ATEX and IECEx)

Applications

• For industrial combustion plants, thermal processes, combustion chambers, boilers, furnaces, reactors, etc.
• All processes in intermittent operation and continuous operation

Gas fired Ignitors

In association with our principals, AIMS offers gas ignition burner solutions for industrial use in accordance with currently applicable regulations and on the basis of technical expertise gained from more than 70 years of experience.

Flexible product variants make it possible to configure burners suitable for a wide range of industrial applications. Both standard devices and customised and application specific special solutions guarantee a high degree of quality.

Features

• Tight and long ignition flame
• Compact modular design
• Integrated spark transformer, flame monitor or burner control unit
• Reliable spare parts availability
• Optimal electromagnetic compatibility
• Straightforward installation and commissioning
• Various ignition burner series with different options available
• Gas ignition burner with heat release up to 10 MW in accordance with NFPA
• Explosion protection – Zone 1/21 and Zone 2/22 (ATEX, IECEx, FM-Ex)
• Approvals* GW, AGA, FM, EAC, SIL2/3 and cULus
• Customised versions on request

Benefits

• High availability
  • Highest operational and functional reliability
  • Electrical and mechanical components can be replaced separately

• Flexible gas ignition burner design
  • Customer-specific/plant-specific solutions
  • Fuel flexibility
  • Optical flame monitor can be integrated
  • Configurable flame monitor safety time
  • High degree of protection for different ambient conditions
  • Standard tube lengths from 240 to 18000 mm (available in 10 mm increments), tube split available optionally
  • Broad range of applications in industrial combustion technology, e.g. in chemical, petrochemical and thermal process plants, as well as in power plants

Flare Flame / Pilot Monitoring

E²T Quasar 2

Continuous Duty Flare Monitoring and Detection Instruments

Advanced Energy’s E²T Quasar 2 instruments provide continuous monitoring and detection of pilot flame and flared gases from flares.

• Flame detection up to 400 m
• Detection of hydrocarbon and hydrogen flames
• Pilot and flaring signal level mA output
• Modular optoelectronic package for easy access and service

Overview

The  E2T Quasar 2 is available in two models, the Quasar 2 M8100-EXP and Quasar 2 M8100-EXP Advanced. The base system provides basic flare pilot monitoring capabilities and the advanced system includes an intensity mA output. The advanced unit’s setpoint feature can also be used for staged flares.

Target alignment is accomplished via the targeting port and signal intensity LED bar displays amplitude in combination with a stable heavy-duty, swivel M-4 mount. Custom electronics adapt to target movement, varying luminosity, and most climate conditions.

Benefits

• Install a reliable and accurate flare pilot monitoring system without service interruption
• Use the high-resolution optical system and various spot sizes to position the system up to 1/4 mile (400 m) away from the monitored flare stack
• Adjust the alarm delay circuit to eliminate false alarms from temporary loss of signal due to intermittent flames, adverse weather, and wind
• Monitor pilot flame detection and flaring status signals with the intensity mA output (Advanced version only)

Features

• Configurable product to meet a wide range of client flare types and monitoring requirements
• Five optics options with targeting port for alignment (available in 37.5:1, 60:1, 75:1, 150:1, and 300:1)
• Status lights: green (flame) and red (no flame)
• Housing is stainless steel (316 L), 114 mm tube diameter, IP 66
• Additional features are available to meet a wide range of flare types, monitoring requirements, and budgets

Typical Applications

• Elevated flares – e.g. steam assisted, air assisted, and gas assisted
• Ground flares – e.g. burn pit flares and ground flare arrays
• Off-shore flares
• Staged flares

Video link:

https://youtu.be/L2G4kDYlXwQ

FlareSpection:

Infrared Camera System for Continuous Pilot Flame and Flare Stack Monitoring

FlareSpection provides real-time, pilot flame, flare monitoring, and flaring status necessary for safety, environmental protection, and governmental compliance

• Continuous, remote, and automatic monitoring of pilot flames and flared gases
• High-resolution (640 x 480 pixels) thermal imaging camera combined with high magnification optics, provides unmatched spatial resolution and superior image quality
• Advanced software to enable automated and seamless integration with a plant’s distributed control system (DCS)
• Explosion-proof, stainless-steel enclosure designed for hazardous areas
• Alternative or secondary backup system to conventional thermocouples can be installed and repaired without shutting down the plant

Overview

The FlareSpection™ system provides extremely clear and reliable flare image and pilot flame monitoring of multiple flare tips. FlareSpection optimizes plant operations, improves safety, and ensures regulatory compliance. It enables you to remotely and automatically confirm flare operation and detect differences in flare stack heat signatures.

Designed with optimized spectral ranges, a high-resolution thermal imaging camera, and high magnification optics, this system continuously monitors through moisture, heavy rain, and fog from hundreds of meters away. Its certified explosion-proof housing enables the system to be located in hazardous areas. You can also confirm pilot flame and flare presence, detect plant performance deviations, and set alarms using the system’s advanced software.

Benefits

• Detect multiple pilot flames and flares simultaneously and continuously, ensuring safe and compliant flare monitoring
• Reliably monitor pilot flames and flares with minimal false alarms, increasing plant uptime
• Accurately monitor from hundreds of meters away, giving great flexibility to choose the remote flare monitoring system’s location
• Install in hazardous plant areas thanks to explosion-proof housing (certified)
• Avoid costly regulatory fines and unscheduled downtime
• Continue plant operation if thermocouples fail, long-term remote monitoring system can serve as a backup to conventional thermocouple monitoring
• Be immune to factors such as flame movement, varying luminosity, and adverse climatic conditions
• Easily connect to the plant’s DCS via protocols, such as Modbus and OPC, as well as connections to pilot ignitors via traditional I/O relay modules

Features

• High-resolution thermal imaging camera combined with high magnification optics provides high-resolution image of pilot flames and flares
• ATEX, IECEx, US, and Canada certified explosion-proof housing
• Stainless-steel enclosure with an integrated sighting tube to prevent dust and dirt on the window
• Easy installation and maintenance from remote mounted location
• Rugged, adjustable mount and base provides stable alignment of the system to pilots and flares (no periodic adjustments required)
• Advanced software to log performance, record video, and set up alerts for measurements that may fall outside of the plant’s preset limits
• Image, event, and alarm logs stored for audits

Typical Applications

• Flare monitoring

Video link:

https://youtu.be/Zv5I5NlNHbk

Video & Thermal Imaging system for furnace monitoring

FurnaceSpection

Infrared Camera System for Continuous Reformer Tube Monitoring and Temperature Measurement Inside Furnaces

Advanced Energy’s FurnaceSpection system provides real-time continuous temperature measurement to identify process abnormalities inside high-temperature furnaces in refining, metals, and glass production processes. It measures the temperature of product, refractory, and heat transfer surfaces inside natural gas-fired furnaces.

• Accurate 640 x 480 focal-plane array thermal imaging camera with sensitivity of 0.06°C
• Boroscope optics filtered at 0.85 μm wavelength to view through combustion gas and flames
• Rugged IP66, air or water cooled (SD), protective enclosure
• Standard (SD) with auto-retraction and Mobile (MB) versions available
• Radiometrically calibrated

Overview

The FurnaceSpection™ system helps you quickly and accurately identify process abnormalities to prevent unplanned outages. Monitor and control process temperature uniformity through streaming images and powerful software that is also ideal for analysis and historical trending. Digital and analog outputs are available to broadcast images of your plant’s local network.

For petrochemical reformers, FurnaceSpection ensures tubes perform optimally and helps extend their life cycles. In metal annealing applications, use FurnaceSpection cameras to reduce cycle times and improve quality and process repeatability.

In addition to standard (SD) and mobile (MB) versions, customized solutions are available to meet specific application needs.

Benefits

• Monitor and control process temperature uniformity through real-time streaming images
• Identify process abnormalities before they develop into problems and unplanned outages
• Reduce cycle times and improve quality and process repeatability
• Measure temperature of product, refractory, and heat transfer surfaces
• Record and analyze data to optimize processes

Features

• Advanced software with simultaneous acquisition from multiple cameras and advanced analytics
• Complete system integration with installation support
• Stainless steel lens with air cooling or optional water cooling (SD)

Typical Applications

• Reformer monitoring
• Annealing furnaces
• Dome and blast furnace
• Glass melting furnace

Video link

https://youtu.be/d4o6IFcLTLk

BoilerSpection MB

Mobile Infrared Camera for Clear Inspection of Boiler Tubes and Furnace Walls

Advanced Energy’s BoilerSpection MB imaging system utilizes special mid-wave infrared detectors to see through flames. This unique feature means BoilerSpection MB can provide the clearest and most stable through-flame images in boilers, furnaces, kilns, or incinerators.

• Completely digital and IP-addressable camera system
• Built for mobile use
• Utilizes standard connections for viewing and recording real-time images
• Spectral wavelength: ~3.9 µm narrow bandpass filter
• Measurement range: 500 to 1600°C (932 to 2912°F)

Overview

Inspect your furnace within minutes. The BoilerSpection™ MB imaging system includes everything you need and is easy to set up.

BoilerSpection MB enables you to quickly and accurately identify process abnormalities for optimal combustion and heat transference. You can direct cleaning operations, regulate fuel and air flow, reduce emissions, decrease fuel consumption, speed up boiler light off, and improve safety. It includes a standard video (BNC) output to use with legacy video equipment.

Benefits

• Pinpoint problems before they cause outages
• Inspect build-up of ash/slag on boiler tubes
• Diagnose burner flame conditions
• Measure temperature across entire image
• Record and analyze data to optimize combustion processes

Features

• Special mid-wave infrared detector
• Mobile or semi-permanent through-flame imaging inside power boilers, furnaces and incinerators
• Compatible with BoilerSpection continuous monitoring solution

Typical Applications

• Monitoring coal-fired boilers