Process Probe Heater Shutoff for Flameout Protection
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Solution Overview
Problem
Existing combustion process analyzers face risks of explosion due to high-temperature sensors in the combustion zone and require additional hardware like flame arrestors or scanners, which increase complexity and cost, while existing methods to address flameout conditions may inhibit measurement access and accuracy.
Innovation Solution
A process combustion transmitter with a probe having a measurement cell heated above the fuel's flashpoint, featuring electronic circuitry that automatically disengages the heater once sufficient process heat is maintained, eliminating the need for a flame scanner and potentially reducing the necessity for a flame arrestor by ensuring the measurement cell cools passively during a flameout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flame arrestor is added over the diffuser to quench explosions, then safety is improved, but measurement lag increases and system complexity increases
Solution Approach 1:
The patent removes the flame arrestor component from the system entirely. Instead of adding protective hardware, the solution extracts the hazard by cooling the measurement cell below the flashpoint when flameout is detected, eliminating the need for flame arrestors and their associated complexity and measurement lag.
Solution Approach 2:
The patent introduces a gaseous buffer (nitrogen or other inert gas) as an intermediary substance. When flameout is detected, this gas is directed to the measurement cell to displace unburned fuel and create a protective atmosphere, serving as a mediator between the hazardous combustion environment and the sensitive measurement cell.
2Measurement precision
If the measurement cell is heated above flashpoint for measurement, then measurement capability is improved, but explosion risk increases during flameout
Solution Approach 1:
The patent implements dynamic temperature control of the measurement cell. The cell is heated above flashpoint during normal operation for measurement capability, but automatically cooled below flashpoint when flameout is detected. This dynamic adjustment of operating conditions allows the system to maintain measurement capability while eliminating ignition risk during hazardous conditions.
Solution Approach 2:
The patent applies preliminary anti-action by detecting flameout conditions and immediately cooling the measurement cell below the flashpoint before any potential ignition can occur. This preemptive cooling action prevents the harmful effect of ignition before it can happen, rather than relying on post-ignition mitigation.
3Reliability
If a gaseous buffer is created to protect the measurement cell, then safety is improved, but additional hardware and system cost increase
Solution Approach 1:
The patent makes the existing nitrogen supply system multi-functional. The nitrogen line serves both its original purpose and the additional function of creating a protective gaseous buffer in the measurement cell during flameout. This eliminates the need for separate protective hardware while providing comprehensive safety.
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
This solution provides enhanced flameout protection without additional hardware, reducing system complexity and cost, while maintaining measurement accuracy and accessibility, and allows for broader application in hazardous environments.
Implementation Method 1
The process probe includes a heater configured to heat the measurement cell to the operating temperature
Implementation Method 2
a temperature sensor, and to the heater. The electronic circuitry is configured to disengage power to the heater once process combustion heat is sufficient to maintain the measurement cell at the operating temperature as indicated by the temperature sensor indicating the probe has reached a heater shutoff threshold
Implementation Method 3
once process combustion heat is sufficient to maintain the measurement cell at the operating temperature
Data Source
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AI summary
A process combustion transmitter (10) is provided. The transmitter (10) includes a process probe (12) extendible into a flow of process combustion exhaust. The process probe (12) has a measurement cell (36) with an operating temperature that is above a flashpoint of process combustion fuel. The process probe (12) includes a heater (38) configured to heat the measurement cell (36) to the operating temperature. Electronic circuitry is coupled to the measurement cell (36) and to the heater (38). The electronic circuitry is configured to disengage power to the heater (38) once process combustion heat is sufficient to maintain the measurement cell (36) at the operating temperature and thereafter to maintain the heater (38) in a de-energized state.