Materials System Specification

34-SAMSS-617 Flame Monitoring Systems Instrumentation Standards Committee Members

Awami, Luay Hussain, Chairman Tuin, Rienk, Vice Chairman Dhafeeri, Farhan Taieh Ell, Steven Tal Fadley, Gary Lowell Falkenberg, Anton Raymond Grainger, John Francis Jumah, Yousif Ahmed Khalifa, Ali Hussain Madhi, Fawaz Abdullah Qarni, Mahdi Ali Qaffas, Saleh Abdal Wahab Trembley, Robert James Mahmood, Balal Bogusz, Zbigniew Jozef Dakhil, Tareq Khalil

1 July 2008

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 Scope............................................................ Conflicts and Deviations................................ References.................................................... General Requirements................................... Flame Monitoring Systems............................ Testing........................................................... 2 2 2 3 4 8

Previous Issue: 31 January 2005 Next Planned Update: 1 July 2013 Revised paragraphs are indicated in the right margin Primary contact: Sprague, James Lawrence on 966-3-8746414
CopyrightSaudi Aramco 2008. All rights reserved.

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Document Responsibility: Instrumentation Issue Date: 1 July 2008 Next Planned Update: 1 July 2013

34-SAMSS-617 Flame Monitoring Systems

Scope This specification, together with the purchase order and the Form 8020-617-ENG specification sheets, prescribes the minimum requirements for flame monitoring systems for ignitors and burners used in fired equipment.

Conflicts and Deviations 2.1 Any conflicts between this specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs) Engineering Standards (SAESs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Process and Control Systems Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Process and Control Systems Department of Saudi Aramco, Dhahran.

2.2

References Material or equipment supplied to this specification shall comply with the latest edition of the references listed below, unless otherwise noted. 3.1 Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standard SAES-A-112 Meteorological and Seismic Design Data

Saudi Aramco Materials System Specification 34-SAMSS-821 Control Panel-Outdoor

Saudi Aramco Forms and Data Sheets Form 8020-617-ENG Flame Monitoring Systems

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34-SAMSS-617 Flame Monitoring Systems

3.2

Industry Codes and Standards American National Standards Institute ANSI B1.20.1 ANSI/ISA S82.01 Pipe Threads, General Purpose (Inch) Safety Standard for Electrical and Electronic Test, Measuring, Controlling and Related Equipment - General Requirements Safety Standard for Electrical and Electronic Test, Measuring, Controlling and Related Equipment - Electrical and Electronic Process Measurement and Control Equipment

ANSI/ISA S82.03

European Committee for Electrotechnical Standardization (CENELEC) CENELEC EN 50018 European Committee for Electrotechnical Standardization

International Electrotechnical Commission IEC 529 Degrees of Protection Provided by Enclosures (IP Code)

National Electrical Manufacturers Association NEMA ICS 6 Industrial Control and Systems Enclosures

National Fire Protection Association NFPA 70 4 General Requirements 4.1 Environmental Conditions 4.1.1 Temperature Instruments and control systems shall operate continuously under the following ambient air temperatures without any degradation of the manufacturer's guaranteed performance:
Indoor Air (2) Conditioned 35C (95F) 10C (50F) Outdoor (1)(2)(3) Sheltered 55C (131F) 0C (32F) Outdoor (2)(3) Unsheltered 65C (149F) 0C (32F)

National Electrical Code (NEC)

Maximum Minimum

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Notes: 1) "Sheltered" refers to permanent, ventilated enclosures or buildings, or permanently fixed sunshades with a top and three sides. 2) For instruments which dissipate internal heat and are installed in custom engineered enclosures (e.g., enclosures not included in the original manufacturer's temperature certification), an additional 15C shall be added to the above maximum temperatures. An example, for "indoor air conditioned" installation, the equipment must perform at 35 + 15 = 50C. Similarly, for the "outdoor unsheltered" case, the equipment shall be designed for a maximum operating temperature of 65 + 15 = 80C. 3) For the outdoor installations only, the designer can take credit for forced or passive cooling to eliminate or reduce the 15C heat rise. For example, if vortex coolers are used, the heat removal capacity of the coolers may be subtracted from the generated heat. No more than 15C reduction in temperature will be given as credit. The designer shall substantiate his claim by providing the support data and calculations.

4.1.2

Contaminants Installations shall be designed for operation in an environment with contaminant levels as defined in the Ambient Air Quality Section of SAES-A-112.

4.1.3

Humidity Indoor humidity design basis shall be 20% to 80% relative humidity. Outdoor design basis shall be 5% to 95% relative humidity (noncondensing).

4.2

Engineering Units All dimensions and measurements shall be in the International System of Units (SI), and may be followed by the equivalent value in English units between brackets. When not critical, the equivalent dimensions and measurements may be rounded off to their nearest practical value.

Flame Monitoring Systems 5.1 System Design The flame monitoring system shall consist of flame scanner(s), a receiver unit (sometimes called an amplifier or control unit) with the appropriate flame status output contacts, and the interconnecting wiring. The system shall be selfchecking and failsafe. The flame monitoring system shall provide output signals for the safe start-up and shutdown of ignitors/burners.

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5.2

Flame Detection Principle 5.2.1 The flame detection principle shall be proposed by the Vendor and shall be suitable for the particular fuel being fired. The principle proposed shall discriminate clearly between radiation from the burner or ignitor flame being supervised and radiation from adjacent flames or furnace walls under all possible operating conditions. If flame rods are specified, the receiver shall use a rectification type system for detection.

5.2.2 5.3

Failsafe and Self-Testing Requirements 5.3.1 The flame monitoring system shall be failsafe; i.e., any type of fault, such as power supply failure, component failure, disconnected ground connection, etc., will cause the flame output relay to de-energize immediately. Flame scanners that may not fail safe, including all UV phototube sensors, shall include a self-checking shutter mechanism that will periodically cut-off flame radiation to the scanner. Flame scanners that fail safe may use alternate means for self checking. The flame receiver shall be provided with a self-checking system which recognizes the "no flame" signal from the scanner during self-testing. Failure of any self-checking facility or a sensing of flame during the selftest shall de-energize the flame output relay. The flame output relay shall remain energized during the self-checking time. The cycle time of the self-check function shall be two seconds or less and specified on Instrument Specification Sheet.

5.3.2

5.3.3

5.3.4 5.3.5 5.4

Sensitivity Adjustments 5.4.1 Flame monitor shall be provided with means for sensitivity adjustment to achieve the following functions: 5.4.2 To enable selective discrimination between flames of different fuels; and, To avoid detecting flames from adjacent burners.

Sensitivity adjustments shall be provided with a scale for verifying, adjusting, and recording the sensitivity settings.

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5.4.3

Flame scanner shall be selectively sensitive to the type of flame radiation specified, and shall not respond to interference from radiation sources other than flames. This discrimination shall be based on frequency components rather than signal intensity. The flame monitor shall not indicate "flame present" when one or more of the following radiation sources is present and there is no flame: Electric sparks (from high energy ignitors 10 kV/60 Hz) X-Ray or Gamma-Rays (from local NDT weld testing) Incandescent lamp (100 watts, 60 Hz); Fluorescent lamp (60 watts, 60 Hz); or Daylight (3000 lux).

5.4.4

5.4.5

If complete immunity to the above radiation sources is not possible, Vendor shall specify the applicable exceptions and include provisions or precautions to be taken to ensure proper operation of the system.

5.5

Output Signals 5.5.1 The flame monitor system shall provide the following output signals (for each flame scanner) from the receiver chassis: 5.5.2 Flame Present/Flame Out signal via relay contacts; Flame intensity analog meter or test jacks at the receiver chassis; Flame intensity analog output for remote indication; Self-checking/system fault light or LED indication and contact output.

All contact outputs shall be single-pole double-throw rated at 0.5 A, 120 V AC, non-inductive.

5.6

Electrical Requirements 5.6.1 Flame Monitoring equipment shall be suitable for operation at 120 V AC, 60 Hz. The voltage may vary from 106 V minimum to 127 V maximum. Frequency may vary 2 Hz. 5.6.2 5.6.3 The allowed variations shall not influence the flame monitor operation or sensitivity. The flame monitoring system's performance and reliability shall not be affected by short power supply interruptions (10 milliseconds).
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5.6.4 5.6.5

The flame output shall not be energized, even momentarily, when the power is applied if no flame is present. Electrical components or devices which may produce arcs, sparks or high temperatures and which are intended for operation in locations classified as hazardous under NFPA 70, Article 500, shall be listed or labeled by any of these agencies: UL, FM, CSA, or European thirdparties certified with the full requirements of CENELEC EN 50018.

5.7

Construction 5.7.1 The flame monitoring receiver shall be suitable for panel or rack mounting in an outdoor, electrically nonclassified area. If the purchase order includes a local panel for mounting the flame receiver system, it shall meet requirements of 34-SAMSS-821. Enclosures specified to be weatherproof and dust-tight shall conform to NEMA ICS 6, Type 4 or IEC 529, Degree of protection IP 56, and shall be suitable for the electrical area classification as required by the Instrument Specification Sheet. The scanner housing shall be provided with an air purge connection or separate air purge fittings shall be provided. The manufacturer shall specify the quality, pressure, and flow rate of the air required for purge. The viewing window shall be designed to prevent high temperature gases, soot, dust and moisture from entering the scanner housing. All components in the scanner shall be firmly attached to the housing and withstand vibration of at least 1 G over a range of 5 to 60 Hz. The construction of the scanner shall permit easy access to the optical system to facilitate cleaning and maintenance. The design and construction of all items shall meet the requirements of ANSI/ISA S82.01 and ANSI/ISA S82.03. All threaded pipe connections shall be tapered per ANSI B1.20.1.

5.7.2

5.7.3

5.7.4 5.7.5 5.7.6 5.7.7 5.8

Performance 5.8.1 5.8.2 Flame-on response time: Time elapsed between flame establishment and flame detection (output relay switching) shall be 4 seconds or less. Flame-out response time: Time elapsed between flame extinguishment and flame-out detection (output relay switching) shall be 4 seconds or less.
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5.9

Installation Fittings The flame scanner mounting shall permit accurate positioning of the scanner toward the flame zone being monitored and shall also provide the necessary temperature isolation.

5.10

Interconnecting Cable Vendor shall specify the type and permissible maximum length of cable which can be installed between the scanner and the receiver unit without affecting the rated performance, failsafe or self-checking operation of the system. The Vendor shall also specify the maximum allowable cable resistance and capacitance as well as cable shielding/screening requirements.

5.11

Instrument Marking 5.11.1 Each separate unit (flame scanner, receiver unit, and auxiliary equipment) shall be provided with a permanently attached stainless steel tag showing the following information: Tag Number Manufacturer and Model number Serial Number (if applicable) Purchase Order Number

5.11.2 All terminals for external wiring shall be identified with polarity symbols, and the words "input", "output", "power supply" or relay contact symbol, as applicable. 6 Testing 6.1. The Vendor shall provide detailed test procedures with the flame monitoring system for: Initial flame signal measurement test. Initial lightoff check for proved ignitor. Ignitor turndown test. Hot refractory interference tests. Ignition spark pickup test. Response to other radiation source test. Final flame signal with hot combustion chamber test.

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6.2

The Vendor shall provide evidence of satisfactory radio frequency interference (RFI) susceptibility testing of the flame monitoring system in accordance with the following criteria: RF sources such as hand-held transceivers operating at 5 W, in the 150 to 170 and 450 to 470 MHz bands and at a distance of one meter, shall not cause a fault, incorrect output of flame relay, or a flame output signal disturbance of more than 1% of range when keying or transmitting.

1 July 2008

Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document and reissued with editorial changes.

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