Flare Pilot Flame Rod Assembly Ionization Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current flame monitoring technologies in high-temperature pilot burners face challenges in responding quickly to flame existence in extreme environmental conditions, such as high winds and moisture, leading to potential failures and false positives.

Innovation Solution

A flame rod assembly with a high-temperature ceramic insulator and a signal cable designed for rapid self-drying, capable of withstanding temperatures from -40 to 1100°C, incorporating a hermetic seal and high-temperature brazing, and utilizing a multi-mode ionization device for instantaneous detection and ignition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional flame monitoring technology is used in high-temperature pilot burners, then the system can detect flame existence, but the response time is slow and false positives occur in extreme environmental conditions

Engineering Contradiction:

Improveflame detection accuracyVSAvoidresponse time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces conventional mechanical/thermal flame sensing mechanisms with an ionization-based detection system. The flame rod assembly uses ionization to detect flame presence, providing instantaneous response without the delays associated with thermal inertia in conventional systems. This substitution of detection mechanism directly addresses the slow response time and false positive issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters of the detection system by using ionization current measurement as the detection parameter rather than thermal parameters. This parameter change enables instantaneous detection of flame existence while the hermetic seal and quick-drying insulator maintain system reliability in moisture-prone environments, eliminating false positives.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If the flame rod operates in high-temperature environments up to 1100°C, then the system can maintain operation in flare applications, but moisture and rain cause failures

Engineering Contradiction:

Improveoperating temperature rangeVSAvoidmoisture and rain impact

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent employs a hermetic seal around the flame rod assembly, creating a protective barrier that prevents moisture and rain from reaching electrical components. This sealing mechanism allows the system to operate in high-temperature environments while immunity to moisture-induced failures is maintained through the hermetic barrier.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent utilizes the high-temperature environment, which normally promotes moisture evaporation, to its advantage by implementing a quick-drying insulator. The insulator's design allows rapid moisture evacuation, converting the harmful effect of moisture exposure into a beneficial quick-drying characteristic that prevents electrical failures while maintaining high-temperature operation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If a hermetic seal and quick-drying insulator are implemented, then moisture resistance is improved, but device complexity increases

Engineering Contradiction:

Improvemoisture resistanceVSAvoidassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the hermetic seal and quick-drying insulator into an integrated flame rod assembly. By combining these protective features into a single unified structure rather than separate components, the system achieves enhanced moisture resistance while minimizing the increase in device complexity through functional integration.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution ensures reliable, long-term operation with reduced false positives and rapid response times, maintaining performance across extreme temperatures and weather conditions, providing a competitive advantage in the flare and flare pilot market.

Implementation Method 1

Ionization flame rod technology may indicate an existence of a flame virtually instantaneously

Methodology Applied

Scientific EffectIonization: Ionisation

Implementation Method 2

The insulator may be made of any suitable insulating material, such as ceramic

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

The insulator material may be cast with a specific geometry and attached to a flame rod at the end connections via a high temperature coupling with brazing or welding

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS8986000B2Flare pilot detection and ignition system

Publication Date: 2015.03.24 HONEYWELL INTERNATIONAL INC

AI summary

A system having a flame rod assembly for operation in a high temperature pilot burner. The assembly is designed for operation in temperatures from about −40 to 1100 degrees C. The system may operate in inclement weather involving high speed winds and significant amounts of moisture and rain to hurricane storm force levels and rates. The system incorporates an electrical apparatus which may provide flame sensing and ignition via the flame rod assembly incorporating a quick drying insulator around a rod of the assembly to ensure proper operation of the electrical apparatus.