Flame detection plays a critical role in plant safety by providing early detection of fires and potential hazards. This early detection allows for prompt response, helping to prevent accidents, protect personnel and minimize damage to equipment and facilities. Flame detection technology continues to evolve through advancements in optical sensing technologies. These innovations result in improved accuracy, extended range, enhanced reliability and increased efficiency, thus enhancing overall safety in industrial plants.
Optical flame monitoring basics
Optical flame detectors, including ultraviolet/infrared (UV/IR) and multi-spectrum infrared (MSIR) types, measure radiant energy across multiple spectral wavelengths. Using signal processing algorithms, these detectors analyse radiant energy levels, signal level ratios and the modulation or flicker rate of infrared (IR) energy. These algorithms ensure fast and reliable flame detection while reducing false alarms.
It is important to always select the proper detector to match the radiant emissions expected from the flames to be detected. Since flammable fuels often emit unique spectral signatures, not all detectors are capable of detecting all fuels.
The detection challenges
Despite their effectiveness, conventional flame detectors have had limitations in range, accuracy, installation, maintenance and false alarm immunity. These limitations become more apparent in environments with reflective surfaces, such as stainless steel, and in challenging weather conditions.
Verifying fuel compatibility and ensuring effective range are also challenges. Extended range accuracy reduces the number of detectors needed, simplifying installation, commissioning and day-to-day monitoring, thus lowering long-term costs.
The future optical solution is here now
Recognizing the importance of flame and fire detection for safety, the MSA flame detector engineering team has focused on enhancing detector accuracy and false-alarm immunity to prevent industrial fires. This effort has led to the development of the new MSA General Monitors® FL5000 Multi-Spectrum Infrared Flame Detector (Figure 1). It employs infrared (IR) detectors and an advanced flame-detection algorithm leveraging the intelligence of three sophisticated artificial neural networks (ANN) for signal processing that detects real flame and fire hazards.
Accuracy and false-alarm immunity
With its new intelligence, the FL5000 Detector offers enhanced accuracy and false-alarm immunity. It has the ability to distinguish between real flames and common false-alarm sources found in industrial plants, such as those caused by lightning, sunlight reflection, arc-welding, hot objects and other sources of radiation. The detector’s distance range has been extended to 310ft (95m) for n-Heptane fuel sources, helping to ensure the detection of actual flames before they become full fire events.
Performance and compatibility
The FL5000 Detector’s performance has been Factory Mutual (FM) verified for 22 popular fuel types, making it suitable for a wide variety of industrial applications.
Bluetooth® technology
The FL5000 Detector is the industry’s first optical flame detector with Bluetooth technology. This allows for easy initial configuration set-up and diagnostics via a mobile device using MSA’s exclusive Flame Connect App (Figure 2). In addition to its unique Bluetooth app, the FL5000 Detector features Modbus RS-485 and HART 7 bus communications for integration with automated plant process and comprehensive safety systems.
Built-in reliability
The FL5000 MSIR Flame Detector features Continuous Optical Path Monitoring (COPM), performing an optical and electrical check every two minutes to ensure operational integrity. It includes a built-in heater to maintain optical integrity in various environmental conditions.
Upgrading to next gen technology
Designed with existing users of General Monitors FL4000H MSIR Flame Detectors in mind, upgrading to the FL5000 Detector is seamless. Users can replace the front housing and optical and relay electronics without significant additional work.
Conclusions
MSA Safety’s new FL5000 MSIR Flame Detector represents the future of flame and fire detection technology. It offers improved range, accuracy and reliability, along with industry-first Bluetooth application software, providing true safety peace of mind for process, plant and safety engineers.
For more information, go to https://msasafety.com/FL5000
About the Author
MSA - The Safety Company
Established in 1914, MSA Safety Incorporated is the global leader in the development, manufacture and supply of safety products that protect people and facility infrastructures. Many MSA products integrate a combination of electronics, mechanical systems and advanced materials to protect users against hazardous or life-threatening situations. The company's comprehensive product line is used by workers around the world in a broad range of markets, including the oil, gas and petrochemical industry, the fire service, the construction industry, mining and the military. MSA’s core products include self-contained breathing apparatus, fixed gas and flame detection systems, portable gas detection instruments, industrial head protection products, fire and rescue helmets, and fall protection devices.
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