Ir infrared flame sensor

Types of IR Flame Sensors

Infrared (IR) flame sensors are devices that detect flames based on the emission or reflection of infrared radiation. They are used in various industrial applications, power plants, and firefighting systems. These sensors offer flame detection and play a crucial role in fire prevention and safety. Depending on the design and detection principle, there are several types of infrared flame sensors:

• Single-Channel IR Flame Sensors:

  The photo detector and the optical filter that absorbs all but the infrared wavelengths are in the single-channel design. The sensor needs to detect the flame's temperature and can do so by measuring the infrared radiation it emits. These sensors are mostly used for flame detection in industrial furnaces and ovens.

• Multi-Channel IR Flame Sensors:

  Multi-channel IR flame sensors have more than one photo detector and a rotating optical filter with multiple wavelength bands. The filter rotates through a series of wavelength bands to determine if a flame is present at a specific wavelength. These sensors provide flame detection in hazardous areas like oil refineries, chemical plants, and petrochemical facilities.

• Scanners:

  Scanners have optical systems that scan a plane to detect flames. The optical system can be a mirror, lens, or any device that can see through an area. Scanners can detect multiple flames in a single plane or the same flame in multiple planes. Many types of industrial furnaces and boilers, which can have many simultaneous flames, use scanners for flame detection.

• Infrared Gas Flame Sensors:

  Infrared gas sensors measure a gas's infrared absorption at specific wavelengths, which can indicate the presence of a flame. Gas flames, such as natural gas or propane, show characteristic absorption patterns in the infrared spectrum, helping these sensors detect and monitor gas flames in various applications, including boilers and furnaces.

  These flame sensors show absorption spectra at different wavelengths for various gases. They provide information about the presence and concentration of gas flames.

  These flame sensors have applications in industrial processes where gas flames are present, such as burners and stoves. They contribute to safety by detecting the flame status of gas-powered equipment and helping to prevent leaks or unintentional gas release.

Function and Features

The various features of IR flame sensors aid in their quick response to identifying flames. They have become crucial for safety in industrial and commercial settings. Here are the main attributes of an IR flame sensor:

• Multi-wavelength detection

  Some IR flame detectors use multiple-wavelength detection to identify more than one wavelength of radiation from a flame. It improves flame discrimination, increasing accuracy by blocking out false alarms from non-flame sources.

• Optical path length

  The function of an IR flame sensor depends on the optical path length within which the sensor can detect flame radiation. In most cases, the optical path length is determined by the type of detector and application. Flame sensors with longer path lengths can detect flames from an extended range, making them suitable for large industrial plants.

• Robustness

  Flame sensors have robust and durable constructions that can withstand harsh applications. They work under extremely high temperatures and pressures in industrial settings. Moreover, they are resistant to corrosion and can detect flames in caustic atmospheres.

• Heating elements

  Heating elements are important for preheating the flame sensor. They help eliminate mist, condensation, and frost on the detector head. In return, the heating elements improve the flame sensor's detection capability in foggy or colder environments.

• Visual indicators

  A good flame sensor should have visual indicators such as LED lights. They show the operator's status of the device, along with any detected flame patterns. The indicators improve response time to alarms and overall system safety.

• Optical Lens Cleaning

  Optical lens cleaning systems automatically remove dirt and residue from the lens. They enable flame detectors to maintain accurate detection in dirty environments. The cleaning systems use water spray, air, or a combination of both to clear the lens.

• Communications interface

  IR flame sensors have communications interfaces like Modbus, HART, and FF that allow data transfer between sensors and control systems. The data includes flame detection information, sensor status, and alarm conditions. Users can remotely monitor and manage sensors, improving response to potential hazards.

• Certification

  Flame sensors have various certifications, such as ATEX, UL, and IECEx, which show compliance with industry standards. They provide assurance that the sensors meet the required safety and performance specifications for flame detection in various industries.

Usage Scenarios of IR Infrared Flame Sensor

IR flame sensors have various applications in different industries. They are used in the following scenarios：

• Burners: The IR flame sensor plays a vital role in ensuring safe burner operations. In most cases, the sensor detects the presence of flames in fuel burners. If there is no flame due to some explosion or a rapid drop in temperature, the sensor immediately shuts down the burner, preventing further fuel leakage.
• Ovens: Infrared flame sensors are common in industrial ovens. They ensure efficient and safe oven operation by detecting and monitoring the presence of flames. When the oven reaches the desired temperature, the sensor closes the gas valve. The sensor also shuts down the burner in case of a flame failure, preventing excess gas from leaking into the oven.
• Boilers: Flame sensors are crucial components in boiler systems. They enhance the operator's safety by detecting the presence of flames in the boiler. The IR sensor shuts down the burner in case of a flame failure, preventing potential boiler explosions and leaks.
• Stirred tank reactors: The IR flame sensor promotes safe and effective operations in stirred tank reactors. It makes sure there are no reaction mixtures with an explosive atmosphere. The flame sensor quickly detects any flames and shuts down the reactor in case of a flame presence.
• Heat exchangers: Infrared flame sensors are used in industrial heat exchangers to detect flames in the heating sections. The sensor increases an exchanger's safe operation by monitoring flame presence and protecting it from excessive heat or potential fires.
• Process industries: These flame sensors are common in process industries like petrochemical, oil & gas, and chemical manufacturing. They are widely used to detect and monitor flames in various equipment, such as burners, reactors, and furnaces. The sensor increases the safety measures in these industries since they are prone to fires and explosive atmospheres.

How to Choose an IR Infrared Flame Sensor

When choosing flame sensors for sale, it is important to consider a number of factors to ensure that the sensor will meet specific application needs. One of the most important factors to consider when selecting a flame sensor is its environmental condition. This factor will influence the sensor's durability and the type of flame sensor to be used. For instance, if the sensor is to be used outside, an ultraviolet flame sensor would be a perfect choice because it can withstand harsh conditions. On the other hand, an IR sensor can be used in an indoor application. Furthermore, sensor applications in areas with explosive or hazardous conditions should be placed in a flame sensor housing where they won't be affected by external conditions.

Another factor to consider is the sensor's response time. A quick response time will detect flames in real time and avoid hazardous conditions. When sensor response time increases, it leads to more significant damage and loss of life. Sensor range is another factor to consider. When the flame is too far to reach, a sensor with a longer detection range should be used. Sensor output should be considered too. Sensors with the ability to integrate with multiple systems should be used. Sensors that meet NEMA and IP standards should be considered too. These standards ensure that the sensors are compatible with flame detection systems and are capable of withstanding environmental conditions.

When choosing a flame sensor for an application, it is crucial to ensure that the sensor can properly detect the flame in a given application. Taking the size of the sensor and mounting requirements into consideration will make the sensor come up with proper flame sensor placement. The cost of the sensor should be considered too. While more expensive sensors will offer better features, cheap sensors can be used to save money.

Q and A

Q: What is the purpose of a flame sensor?

A: A flame sensor's primary function is to detect the presence of flames and prevent situations that could lead to explosions or fires. The sensor accomplishes this by observing the emitted radiation and notifying the control system if there is a flame.

Q: Why is IR flame detection preferred over other flame detection methods?

A: Infrared flame sensors are preferred because they are less affected by environmental conditions like smoke, visible light, or water. They can detect flames from a considerable distance and provide a high level of certainty in flame detection.

Q: What are the types of IR flame sensors?

A: There are three main types of infrared flame sensors: dual-band, triple-band, and near-infrared. Each type has its unique characteristics and is used in various applications.

Q: What is the working principle of an IR flame sensor?

A: The infrared flame sensor detects the presence of a flame through the emission of infrared light. A fire emits infrared radiation, and the flame sensor picks up this radiation, signaling the presence of a flame.