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Get Industry-Leading Detection Accuracy with Forney’s HD-EX Flame Detectors

In industrial and power generation sectors, a flame sensor or flame detector is critical for precise monitoring of the burner flame to accurately manage continuous energy production. The use of combustible fuels, such as diesel, natural gas, or refinery gas, make it crucial to the safe operation of high-temperature gas turbines and fired process equipment where the temperature is above 1000 degrees Celsius. Many commercially available flame detectors have several fail points that make them unable to withstand these harsh environments. 

Unlike traditional flame sensors, which can burn out due to harsh conditions or extreme temperatures and lead to unplanned downtime for repair, Forney’s HD Flame Detector combines both Infrared and Ultraviolet optical sensors for the detection of the flames produced in power plants, making it perfect for the power generation, boilers, petrochemicals, and industrial markets.

The use of old or outdated sensors may create a volatile risk (if a flame out condition occurs), leading to severe injuries or irreversible consequences. In this scenario, Forney’s new HD Flame Detector sends a signal to the station to cut off the fuel valves and avoid gas build-up, eliminating the risk of potential explosion or other disastrous consequences. All of this is possible thanks to the HD Flame Detector’s amplifier and high-speed signal processing technology, making it ideal for use in power generation sectors.

These risks represent hundreds of thousands of dollars in damages, equipment repair costs, employee medical bills, and legislation to facility operations in this industry. To help plant operators better mitigate these risks and reduce overall operational costs, Forney’s engineers used the latest detection technology to improve the overall accuracy of flame detection rates, even under the harshest industrial conditions.

What You Need to Know About Forney’s HD and HD-EX Flame Detectors

Forney’s intelligently designed smart Flame Detector offers the highest level of flame discrimination even in multi-burner equipment, thanks to its easy-to-use visual display on mobile phones. The HD and HD-EX models boast the following features to help improve operational efficiency:

  • Product Material – Forney’s HD Flame Detector is made of an engineered polymer housing material, offering strength, creep, and dimensional stability. The HD-EX Flame Detector is made of an aluminum alloy, glass, and epoxy composite material, making it lightweight yet anti-corrosive and better able to withstand harsh conditions. 

  • Dual Optical Sensors – Both HD and HD-EX Flame Detectors are equipped with Infrared (IR) and Ultraviolet (UV) optical sensors accented with a high-speed signal processing amplifier, allowing field supervisors to monitor precise discrimination between multiple radiations. The optical sensitivity of IR is 900 to 1700 nm, and UV is 210 to 390 nm.

  • Connector Type – The HD Flame Detector has a 12-pin quick disconnect connector, making it suitable for hazardous areas, whereas the HD-EX model has a 2 x 6-pin connector that can be used with certified EX entry devices. Both models are designed to receive 24 VDC power and come with a complete Burner Management System. 

  • Use Classifications – The HD Flame Detector is rated for use in NEC Class I, Division II, and 3G hazardous locations to monitor a variety of burners, including gas-fired burners, utility burners, waste fuel burners, and others. The HD-EX Flame Detector is perfect for use in IEC, KS, and 2G hazardous locations. The cable length of both models can be customized to suit different location application requirements. 

  • Connection Interface – The HD Flame Detector comes with 1” NPT (Female) only, whereas the HD-EX Flame Detector comes with 1” NPT, ¾” NPT, M25, and M32 (Female) connection interface, making it suitable for connection to a wide range of equipment. 

  • Connection – Both flame detector models are designed to operate via Bluetooth Technology, supporting wireless management and maintenance of the device via Forney’s mobile app from supported phones or tablets. They can also be connected to a laptop or desktop via an RS-485 communication link for remote monitoring, giving plant operators the freedom to maintain a distance from hazardous areas. (The Forney App can be downloaded from either Apple or Google Play store).

Features HD Flame Detector HD-EX Flame Detector
Material Engineered Polymer Aluminum alloy, glasses, & epoxy
Weight 2.65 Lbs. 7.72 Lbs.
Lens Temp. 1000°F (538°C) 1000°F (538°C)
Connector 12-Pin Connector 2 x 6-Pin Connector
Suitable For NEC Class I, Division II, & 3G areas IEC, KS, ATEX II 2G areas
Ext. In-Line Fuse 1 Amp Fuse 500 mA Fuse
Power Consumption 1.2 Watt 2.9 Watt
Connection Interface 1” NPT (F) only 1” NPT, ¾” NPT, M25, M32(F)
Flame Rating UL94 HB Non-Combustible
Connection Quick Disconnect Use only certified EX devices
Operating Sensor Both IR and UV Both IR and UV
Sensitivity IR – 900-1700nm, UV – 210-390nm IR – 900-1700nm, UV – 210-390nm
Connectivity Wireless Bluetooth Technology Wireless Bluetooth Technology

Benefits of Forney's HD-EX Flame Detector

1. Improves Work Standard and Safety

Flame monitoring is essential, especially in power generation units, such as gas turbines, boilers, industrial ovens, or kilns. With proper installation and use, the HD-EX flame detector will automatically cut off the gas supply during flame-out conditions, protecting the local environment and minimizing the risk of combustion. Our HD-EX Flame Detector is equipped with wireless technology, which sends remote signals to the monitor through an amplifier, which improves safety by allowing employees to monitor the system from a safe distance away from the heat of the burner and the boiler equipment.

2. Eliminates Unplanned Downtime with Precise Monitoring

Unplanned downtime is detrimental to power generation and manufacturing industries. In fact, nearly 80% of industries have a priority of 0% unplanned downtime, helping to keep the industry profitable with minimal maintenance costs. When your equipment’s flame is unknowingly extinguished or unchecked, it can trigger a catastrophic event in minutes. Thanks to its advanced flame sensing capability with built-in alarm feature, the HD-EX flame detector helps to eliminate unplanned downtime by providing immediate remote notification at the first sign of flame outage.

3. Dual Operating Sensors for Improved Operational Flexibility

Forney’s HD-EX Flame Detector has dual operation sensors to detect flames in both the ultraviolet and infrared spectrums. Whether you’re detecting flames from gas, oil, or coal firing, the HD-EX can integrate with your equipment and operate seamlessly within your existing setup. 

4. Built-in LED Status Faceplate for Easy Monitoring

The integrated LED Status faceplate improves flexibility for field operators. Unlike traditional flame detectors, which need monitoring directly from the station, the HD-EX Flame Detector offers more convenience and remote access by monitoring the status indicator lights on the device faceplate. The easy-to-analyze indicator lights make it possible to confirm at a glance that the system is functioning normally.

5. Compact Size, Lightweight, and Single Head Device

Unlike other traditional or old-fashioned flame detectors, the HD-EX Flame Detector is integrated with all electronic components in a single box (head), connected with a cable to its monitor. The single-head device eliminates the need for installation of multiple components, making installation as simple as mounting the box and connecting a single cable directly to the control system to facilitate remote monitoring. 

6. Advanced Control with the Integrated App

To aid in remote monitoring and maintenance of the flame detector, Forney’s team developed a comprehensive monitoring app that can be used on iPhone or Android devices. From inside the app, operators can change device settings, perform tune-up maintenance, or monitor reports. Access to the app can be limited to named employees or made available to anyone in your organization. 

7. Advanced Bluetooth Technology

To maintain the security and integrity of the HD-EX device, Forney’s engineers utilized the latest in Bluetooth technology for remote access instead of wi-fi. Bluetooth technology helps prevent outside hackers and creates a more stable, secure connection. 

The HD-EX Flame Detector Model

  • Input Power – 24 VDC
  • Steady & Inrush Current – 120 mA and 350 mA
  • Power Consumption & Heat Dissipation – 2.9 Watt and 2.8 Watt
  • Flame Relay – 02 Independent
  • Relay Cycle – > Min 20 x 10e6
  • Wired – RS-485
  • Wireless – Bluetooth (Low Energy)
  • Material – Composite (Aluminum alloy, glasses, and epoxy)
  • Connection Interface – 1” NPT, ¾” NPT, M25, and M32 (Female)
  • Lens Rating – 1000°F (538°C)
  • Degree of Protection – IP66
  • Flame Rating – Non-Combustible
  • Optical Sensitivity – IR (900 to 1700 nm) and UV (210 to 390 nm)
  • Connector – Use only certified HD-EX devices

Ready to Upgrade to the HD-EX Flame Detector?

Your plant can’t afford to risk using unreliable detection equipment that can result in unplanned downtime or dangerous operations. Forney’s HD-EX flame detectors are specifically designed to withstand the harsh environments of power generation plants, and our devices were uniquely designed with the needs of plant operators and managers in mind. 

If your focus is on improving the accuracy and reliability of your flame detection system, then contact your local Forney representative today to discuss our solution options.

About Forney

Forney Corporation has over 93 years of experience manufacturing the safest and most reliable combustion equipment for more than 1,000 power plants in more than 100 countries. The quality and durability of Forney’s state-of-the-art front-end combustion components have been proven by customers in many industries across the globe. Forney igniters, burners, BMS, flame detectors, dampers, and duct burners have provided efficiencies and cost savings for plant operators in electric utilities, chemical processing, pulp & paper, and cement industries.