“BHELSCAN”

FLAME SCANNER

Presented By
Vishal Laddha
C&I
 INTRODUCTION
•PRINCIPLE PURPOSE OF FLAME SAFEGUARD SUPERVISIORY SYSTEM IS
TO ENSURE THAT IT IS SAFE TO LIGHT THE BOILER AND CONTINUE
BOILER OPERATION.

•IT IS ALSO USED FOR BOILER SHUTDOWN.

•ACCURATE DETECTION OF A FIRE IS ONE OF THE MOST IMPORTANT

TASKS OF FSSS.

•UV, IR AND VISIBLE LIGHT ARE THE DIFFERENT TYPES OF FLAME

SCANNERS.

UV Type : 10 nm to 400 nm
Visible light Type : 380 nm to 740 nm
IR Type: 700 nm to 1 mm
“BHELSCAN” uses visible spectrum for flame sensing.
•AN IDEAL FLAME SCANNER DETECTS A FLAME OF
INTEREST WHILE TOTALLY IGNORING OTHERS AND IS
UNAFFECTED BY CHANGES IN AMBIENT CONDITIONS.

•A FLAME SCANNER IS A SENSOR THAT DETECTS

PRESENCE OF FIRE IN THE BOILER BY ABSORBING THE
LIGHT ENERGY EMMITTED BY THE FIRE.
The microcontroller based flame sensing system is designed primarily for use on
coal fireball and stable oil flame.

It senses the visible light given off by the flame and can recognize a coal/oil
flame by its characteristic fluctuations.

The system consists of a fibre-optic connected scanner head assembly and a

chassis containing electronic signal processing modules. The scanner head assy. is
located at the boiler and the chassis with electronics is mounted in the control
room. The chassis may be located up to 200 metre from the boiler.

The scanner head assy. is normally installed in the wind box assembly
Scanner head

LOG. AMP.

PHOTO VOLTAGE
DIODES TO
CURRENT
CONVERTER

LED
FEEDBACK

FIBER OPTIC
CABLE

4 wire shielded cable to rack

SPECIFICATION

Input signal : 0 to 2mA AC from Head Electronics

Signal : 4 Microcontroller Processor Modules for 1 elevation
2/4 Processor : 2/4 logic detection & fault alarm
Programmable : Pull in, Pull out, Parameters Flicker frequency for oil,
Flicker frequency for coal
Display : 2 ½ digit LED display
Display mode : By Push button selection
Parameter : 4 x 8 bit DIP switch setting
Communication : Serial interface
Enclosure : 19” Rack with 3U size cards
MECHANICAL COMPONENTS
 Stationary part -- “flame scanner guide pipe
assembly”
 removable part--“flame scanner assembly”.

Flame Scanner Guide Pipe Assembly:-

◦ SCANNER HEAD HOUSING
◦ FLEXIBLE METAL HOSE :- Adapts scanner to tilting of
wind box nozzles.
◦ RIGID GUIDE PIPE SECTION:- Fixed to the wind box
and serves as a protective cover/packing gland.
◦ COOLING AIR MANIFOLD:- is screwed onto the guide
pipe
◦ COVER PLATE: closes the wind box opening when
scanner is removed for maintenance.
Flame Scanner Assembly:

•SCANNER HEAD ASSEMBLY:- Comprises of a scanner

head body with the collimator tube, shield, collimating lens,
barrel, mounting plate, compression spring, one end of fiber
optic cable and a plug.

•FLEXIBLE METAL HOSE:- Houses the fiber optic cable

•RIGID PIPE:- Houses the fiber optic cable

•SCANNER HOUSING ASSEMBLY:- houses the scanner head

electronics card which converts visible light signal to
equivalent electrical signal.
 FLAME SCANNER ASSEMBLY:-
FLEXIBLE
METAL
HOSE RIGID
PIPE

SCANNER
HOUSING

SCANNER HEAD
ASSEMBLY
FLAME SCANNER ASSEMBLY:-
SCANNER HEAD
SPACER LENS BODY

PLUG

COMPRESSION FIBER OPTIC

SPRING CABLE
 COOLING AIR REQUIREMENTS:-

Cooling air passes through the guide pipe, the flexible hose and
between the scanner head and housing. The air is discharged into the
furnace by removing any heat picked up from the hot combustion air.
The scanner head should not be exposed to a continuous temperature
above 300°F without cooling air.

Cooling air flow requirements are (per scanner) 55 cfm at 120°F

(Max.).

Air manifold pressure at the scanner guide pipe must be 150mmwc

above furnace pressure.

After shutting down the unit, scanner cooling air must be maintained
until furnace conditions are such that the scanner assembly cannot
overheat.
ELECTRICAL COMPONENTS:-
 The electrical components of the BHELSCAN system are
contained in the scanner housing assemblies and the card
rack assembly.
 A photo diode located in each scanner housing assembly
converts visible light (flame signal) observed by the
scanner head into an electrical equivalent signal.
 The scanner housing output signal is an AC current signal,
which is sent to the card rack assembly for processing.
 In the card rack assembly, each current flame signal is
converted into a voltage flame signal. The voltage flame
signal is then separated into intensity and frequency
components.
 An intensity signal indicates the magnitude of the flame
brightness on 2½ digit LED display(Range is 0-100%).
 A fault signal is established if the intensity component is
less than its minimum preset limit or greater than its
maximum preset limit. If a fault signal is established, a
fault LED is lit and flame signal cannot be established for
that corner. Hence oil flame or coal flame lights will not
come ON.
 DESCRIPTION OF MODULES:-
Flame scanner card rack assembly consists of the following modules:
1. Flame processor module- 4 Nos.
2. 2/4 output module - 1 No.
3. Power supply unit - 1 No.

There are two semiconductor fuses rated for 63mA are available in the
flame processor motherboard to protect the DC supply to scanner head
electronics.

DO NOT REMOVE ANY MODULE WITH POWER ON

The front facia of this module consists of a 7-segment display, 9 status LEDs and
one Push Button
 Figure - 6B
BHELSCAN – GENERAL ARRANGEMENT
 Figure - 7B
BHELSCAN –FLAME PROCESSOR MODULE

AC gain
pot.(Coal)

Intensity Coal freq. AC gain

pull in Set value pot.(Oil)

Intensity Oil freq.

pull out Set value
2/4 Module

 This receives digital signals corresponding to “Flame 1 ON”

from all 4 flame processor module.

 If two or more than two “Flame 1” inputs are available, 2/4

Module signals presence of fireball.

 However , for fireball indication in DCS , corresponding feeder

“ON” bit is taken in an AND Gate along with the above
mentioned 2/4 Logic.
 Figure - 8B
BHELSCAN –2/4 MODULE

2/4 Relay

Fault Relay
Figure - 9B
BHELSCAN –POWER SUPPLY MODULE (FRONT VIEW)

Figure - 9C
BHELSCAN –POWER SUPPLY MODULE (REAR VIEW)
Power Supply Module

 This will work in 110V AC or 230V AC as given in the

nameplate

1. +15 V DC
2. –15V DC
3. +5.0V DC

 All the above DC outputs are over voltage and short

circuit protected. There is a fuse available in the power
supply motherboard, whose rating is 2 Amps
 ◦ System Operation Test (FAULT)
1. Disconnect the signal wire - intensity display by
flashing 100%.
2. During furnace OFF- display ‘00’ to indicate the dark
furnace condition.
3. If any power supply wire is cut or any short circuit in
the signal wire to ground- display will show ‘00’
flickering.
4. When Power supply +15Vdc fuse blown - flashing
100%.
5. When Power Supply -15Vdc fuse blown –Any Value
There are 4 DIP switches (8 bits) are available to set the following data
in binary form to the microcontroller.

S.NO TYPICAL PRESENT

. VALUE VALUE
1. Pull in value (PI) 40% 40%
2. Pull out value (PO) 30% 20%
3. Coal frequency set value 5Hz 3Hz
(F1)
4. Oil frequency set value 30Hz 25Hz
(F2)

The digital outputs of flame1 (coal) and flame2 (oil) status are fed to
the 2/4 output module. A 4-20 mA current output is available to
represents the intensity of the flame.
 Dip Switch Setting Procedure

Locate S1 DIP switch - Set ‘40’

DIP switch position: 8 7 6 5 4 3 2 1
Setting status: OFF OFF ON OFF ON OFF OFF OFF
 Calibration of Scanner Head Electronics:-

Gain and Offset Adjustment:

The following equipment will be required :

a. Digital voltmeter (DVM)

b. 1 mA dc current source (1 V dc in series with a resistor; 1k)
c. 1 μA dc current source (1V dc in series with a resistor; 1M)
d. Small soldering pencil
Disconnect the positive lead of the photodiode.
Simulate a photodiode input by connecting the 1 mA dc current
source to the photodiode terminals.
Connect the digital volt meter between signal “C” and common “D”
terminals on the electronics card.
Turn the scanner power supply “on” and adjust potentiometer R101 to
provide a reading of 0.000 V.

Replace the 1 mA dc current source with a 1 μA source.

Adjust potentiometer R103 to provide a reading of 1.000 V
Dark Furnace Bias Adjustment :

Completely block all light.

Connect a digital voltmeter between the signal C and common D
terminals on the electronics card.
The power supply switch should be turned on.
Adjust potentiometer R113 so that the DVM reads approximately
2.1V.
Maintenance And Trouble Shooting
Scanner Head :
•The scanner head should be inspected periodically and cleaned, if
necessary.
Fibre optic cable:
•The collimator shield and the lens on the end of the fibre-optic
cable should also be inspected periodically for cleanliness.
Electrical components:
•The electronic modules do not require periodic maintenance.
•If AC power is not ON.
•If DC supplies are not ON.
•In flame processor module, fault lamp should be OFF.
•In 2/4 flame module, the fault lamp should be OFF.
•Do not insert or pull out any module from the connector when
power is ON.
THANK YOU….