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The use of old or outdated sensors may create a volatile risk (if a flame out condition occurs), leading to severe injuries or irreversible consequences.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.
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:
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.
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.
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.
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.
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.
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.
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
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.
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.