Materials System Specification
34-SAMSS-617 31 January 2005
Flame Monitoring Systems
Instrumentation Standards Committee Members
Al-Awami. L.H., Chairman
Tuin, R.R., Vice Chairman
Al-Dakhil, T.K.
Al-Dhafeeri, F.T.
Al-Khalifa, A.H.
Al-Madhi, F.A.
Alqaffas, S.A.
Bogusz, Z.J.
Ell, S.T.
Fadley, G.L.
Falkenberg, A.R.
Gawargy, N.E.
Grainger, J.F.
Jumah, Y.A.
Mahmood, B.
Qarni, M.A.
Trembley, R.J.
Saudi Aramco DeskTop Standards
Table of Contents
1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 General Requirements................................... 3
5 Flame Monitoring Systems............................. 4
6 Testing............................................................ 8
Previous Issue: 31 December 2002 Next Planned Update: 1 August 2008
Revised paragraphs are indicated in the right margin Page 1 of 9
Primary contact: Jim L. Sprague on 874-6414
Document Responsibility: Instrumentation 34-SAMSS-617
Issue Date: 31 January 2005
Next Planned Update: 1 August 2008 Flame Monitoring Systems
1 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.
2 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.
2.2 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.
3 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
3.2 Industry Codes and Standards
American National Standards Institute
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Document Responsibility: Instrumentation 34-SAMSS-617
Issue Date: 31 January 2005
Next Planned Update: 1 August 2008 Flame Monitoring Systems
ANSI B1.20.1 Pipe Threads, General Purpose (Inch)
ANSI/ISA S82.01 Safety Standard for Electrical and Electronic Test,
Measuring, Controlling and Related Equipment
- General Requirements
ANSI/ISA S82.03 Safety Standard for Electrical and Electronic Test,
Measuring, Controlling and Related Equipment
- Electrical and Electronic Process
Measurement and Control Equipment
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 National Electrical Code (NEC)
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 Outdoor Outdoor
Conditioned (2) Sheltered (1)(2)(3) Unsheltered (2)(3)
35°C 55°C 65°C
Maximum (95°F) (131°F) (149°F)
10°C 0°C 0°C
Minimum (50°F) (32°F) (32°F)
Notes:
1) "Sheltered" refers to permanent, ventilated enclosures or buildings, or permanently fixed
sunshades with a top and three sides.
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Document Responsibility: Instrumentation 34-SAMSS-617
Issue Date: 31 January 2005
Next Planned Update: 1 August 2008 Flame Monitoring Systems
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 15°C shall be added to the above maximum temperatures. An
example, for "indoor air conditioned" installation, the equipment must perform at 35 + 15 =
50°C. Similarly, for the "outdoor unsheltered" case, the equipment shall be designed for a
maximum operating temperature of 65 + 15 = 80°C.
3) For the outdoor installations only, the designer can take credit for forced or passive cooling to
eliminate or reduce the 15°C 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
15°C 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 (non-
condensing).
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.
5 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 self-
checking and failsafe. The flame monitoring system shall provide output signals
for the safe start-up and shutdown of ignitors/burners.
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.
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Document Responsibility: Instrumentation 34-SAMSS-617
Issue Date: 31 January 2005
Next Planned Update: 1 August 2008 Flame Monitoring Systems
5.2.2 If flame rods are specified, the receiver shall use a rectification type
system for detection.
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.
5.3.2 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.
5.3.3 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 self-
test shall de-energize the flame output relay.
5.3.4 The flame output relay shall remain energized during the self-checking
time.
5.3.5 The cycle time of the self-check function shall be two seconds or less
and specified on Instrument Specification Sheet.
5.4 Sensitivity Adjustments
5.4.1 Flame monitor shall be provided with means for sensitivity adjustment to
achieve the following functions:
- To enable selective discrimination between flames of different fuels;
and,
- To avoid detecting flames from adjacent burners.
5.4.2 Sensitivity adjustments shall be provided with a scale for verifying,
adjusting, and recording the sensitivity settings.
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.
5.4.4 The flame monitor shall not indicate "flame present" when one or more
of the following radiation sources is present and there is no flame:
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Document Responsibility: Instrumentation 34-SAMSS-617
Issue Date: 31 January 2005
Next Planned Update: 1 August 2008 Flame Monitoring Systems
- 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).
5.4.5 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:
- 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.
5.5.2 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 The allowed variations shall not influence the flame monitor operation or
sensitivity.
5.6.3 The flame monitoring system's performance and reliability shall not be
affected by short power supply interruptions (10 milliseconds).
5.6.4 The flame output shall not be energized, even momentarily, when the
power is applied if no flame is present.
5.6.5 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
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Document Responsibility: Instrumentation 34-SAMSS-617
Issue Date: 31 January 2005
Next Planned Update: 1 August 2008 Flame Monitoring Systems
labeled by any of these agencies: UL, FM, CSA, or European third-
parties 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.
5.7.2 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.
5.7.3 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.
5.7.4 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.
5.7.5 The construction of the scanner shall permit easy access to the optical
system to facilitate cleaning and maintenance.
5.7.6 The design and construction of all items shall meet the requirements of
ANSI/ISA S82.01 and ANSI/ISA S82.03.
5.7.7 All threaded pipe connections shall be tapered per ANSI B1.20.1.
5.8 Performance
5.8.1 Flame-on response time: Time elapsed between flame establishment and
flame detection (output relay switching) shall be 4 seconds or less.
5.8.2 Flame-out response time: Time elapsed between flame extinguishment
and flame-out detection (output relay switching) shall be 4 seconds or
less.
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.
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Document Responsibility: Instrumentation 34-SAMSS-617
Issue Date: 31 January 2005
Next Planned Update: 1 August 2008 Flame Monitoring Systems
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 Testing Requirements
6.1.1 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.
6.1.2 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
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Document Responsibility: Instrumentation 34-SAMSS-617
Issue Date: 31 January 2005
Next Planned Update: 1 August 2008 Flame Monitoring Systems
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.
Revision Summary
31 January 2005 Revised the "Next Planned Update". Reaffirmed the contents of the document, and
reissued with minor changes.
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