Inline Pilot Flame Detection via Coaxial Sensor Integration
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Solution Overview
Problem
Existing pilot systems for oil and gas processing suffer from low accuracy and sensitivity in flame detection, particularly in harsh environmental conditions, and are prone to premature shutdown due to factors like icing, clogging, and improper ignition adjustments, leading to unreliable operation.
Innovation Solution
An inline pilot system with a coaxially disposed flame sensor electrode and a novel near-field ionization method, where multiple parallel tubular-shaped flames combust around the electrode, creating a rich ion field for improved detection and stabilization, with integrated ignition and flame detection capabilities within the pilot nozzle assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flame rectification systems use externally mounted flame sensor rods and ground electrodes, then the system structure is simple, but the flame detection accuracy and sensitivity are low under harsh environmental conditions
Solution Approach 1:
The patent combines the flame sensor rod and ground electrode into a single integrated assembly mounted within the pilot nozzle. The flame sensor rod is positioned coaxially with the pilot fuel outlet, and the ground electrode is integrated into the nozzle structure, eliminating the need for separate external mounting components and improving detection reliability.
Solution Approach 2:
The patent introduces a ceramic insulator as an intermediary component between the flame sensor rod and the pilot fuel outlet. This ceramic material provides electrical insulation while allowing thermal conduction, enabling the flame sensor to detect ionized gases from the pilot flame while maintaining structural integrity and preventing electrical shorting.
2Reliability
If flame sensor rods are externally mounted, then installation is easy, but they are prone to loosening due to temperature extremes and vibration
Solution Approach 1:
The flame sensor rod and ground electrode are integrated into the pilot nozzle assembly as a single unit, eliminating separate mounting hardware that could loosen. The sensor rod passes through the ceramic insulator and is secured within the nozzle structure, making it resistant to thermal expansion and vibration while maintaining electrical isolation.
3Measurement precision
If wind and environmental factors shift the flame away from the externally mounted sensor rod, then flame detection efficiency is reduced, but the system configuration remains simple
Solution Approach 1:
The flame sensor rod is positioned coaxially with the pilot fuel outlet within the nozzle assembly, ensuring that the sensor is always in the optimal position to detect the pilot flame regardless of external wind or environmental conditions. This integrated positioning eliminates the need for external adjustment mechanisms.
4Reliability
If enclosed combustion applications divert the pilot flame away from the flame sensing rod, then premature shutdown occurs, but the existing system structure is maintained
Solution Approach 1:
The flame sensor rod, ground electrode, and pilot fuel outlet are integrated into a single nozzle assembly with coaxial alignment. This internal configuration ensures that the sensor remains positioned within the pilot flame path even in enclosed combustion applications, preventing premature shutdown while maintaining a compact structure.
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 system provides robust and durable flame detection and maintenance, enhancing reliability under adverse conditions, allowing operation across a wide range of fuel pressures and improving flame anchoring and detection sensitivity.
Implementation Method 1
Flame rectification relies on ionized gas formed during combustion, which may carry a small current
Implementation Method 2
An alternating current is applied to the sensor so that when a flame is present the current flows from the sensor through the flame to a ground. Because the flame rod or sensor is smaller than the ground electrode, an alternating current (AC) applied to the flame sensor flows primarily in one direction and the AC current is rectified to a pulsating direct current (DC), or rectified current.
Data Source
AI summary
A novel inline pilot assembly and method of flame detection for use with combustion applications for oil or gas processing is provided wherein the pilot assembly includes a pilot novel assembly with a unique placement of fuel and induction holes to improve flame stability, promote flame anchoring near the diffuser, and discourage the pilot flame front from migrating forward away from the diffuser.