Sparkless Pilot Igniter Using Resistance-Based Flame Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing sparkless ignition systems for piloted burners require flame rods or thermocouples to detect pilot flames, which are costly, prone to maintenance issues, and can be unreliable due to temperature quenching and corrosion, especially in harsh environments like remote wellheads.

Innovation Solution

A sparkless pilot flame igniter that uses a hot surface igniter assembly energizable with a DC source, where the resistance of the igniter element is measured before and after ignition to determine the presence or absence of a flame, eliminating the need for flame sensors like thermocouples or flame rods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If flame rods or thermocouples are used to detect pilot flames, then flame detection capability is provided, but device complexity and maintenance requirements increase

Engineering Contradiction:

Improveflame detection reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the ignition element and flame detection function into a single integrated hot surface igniter assembly. The same heating element that ignites the pilot flame also serves as the flame sensor, eliminating the need for separate flame rods or thermocouples. This merging reduces device complexity while maintaining reliable flame detection through resistance measurements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hot surface igniter assembly performs multiple functions: it acts as both the ignition source and the flame detection sensor. By making the igniter element universal (serving dual purposes), the patent eliminates the need for separate dedicated flame sensing components, thereby reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If flame rods are used for flame detection, then flame sensing capability is achieved, but maintenance requirements increase due to carbon formation and corrosion

Engineering Contradiction:

Improveflame sensing reliabilityVSAvoidmaintenance frequency

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The igniter element serves its own dual function as both ignition source and flame sensor without requiring separate maintenance for flame sensing components. The resistance-based detection method eliminates carbon formation and corrosion issues associated with flame rods, as the measurement is made through the heating element itself rather than through a separate sensor surface.

Inventive Principle:

Principle #25Self-service

3Reliability

If thermocouples are used to sense pilot flame temperature, then flame detection is provided, but cost and susceptibility to temperature quenching increase

Engineering Contradiction:

Improveflame detection capabilityVSAvoidtemperature quenching sensitivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the thermal-based thermocouple detection method with an electrical resistance-based measurement system. Instead of using thermocouples that are physically susceptible to temperature quenching and require thermal contact with the flame, the system measures electrical resistance changes in the hot surface igniter element, substituting a mechanical/thermal sensing approach with an electrical measurement approach that is not affected by temperature quenching.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 a reliable, cost-effective, and maintenance-free ignition system that can operate in harsh conditions without the need for flame sensors, ensuring consistent flame detection and reducing operational costs and complexity.

Implementation Method 1

a hot surface igniter assembly which is energizable with a DC source... produces heat by induction sufficient to ignite the pilot fuel

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

The operation of the igniter is controlled by measuring a control parameter related to the resistance of the hot surface igniter element, and using the change in the value of the control parameter prior to and after ignition to sense the presence or absence of a flame

Methodology Applied

Scientific EffectResistive temperature detection: Electrical Resistance

Data Source

PatentUS10527285B2Sparkless igniters and methods for pilot ignition

Publication Date: 2020.01.07 SUREFIRE PILOTLESS BURNER SYST LLC

AI summary

Sparkless igniters for pilot services comprising hot surface igniter elements, and methods for operating these igniters without the use of flame rods or thermocouples. The electrical resistance of the hot surface igniter element is measured and used to control the operation of the igniters using a suitable burner management system. The measured electrical resistance may also be manipulated to yield a control parameter for use in the burner management system. The igniters are designed to prevent quenching of the hot surface elements by the fuel-air mixture. The igniters optionally permit easy swap out of hot surface igniter elements.