Apparatus and method for detecting furnace flooding

Patent metadata

Field	Value
Publication number	US-10378765-B2
Application number	US-201715718481-A
Country	US
Kind code	B2
Filing date	Sep 28, 2017
Priority date	Apr 24, 2017
Publication date	Aug 13, 2019
Grant date	Aug 13, 2019

Abstract

A method includes identifying a first steady-state gain associated with a relationship between a characteristic of a furnace and a setpoint used by a controller that is configured to control the characteristic of the furnace, The first steady-state gain is identified using data collected when the furnace is not suffering from flooding.
The method also includes identifying a second steady-state gain associated with the relationship during operation of the furnace. The method further includes comparing the first and second steady-state gains and identifying actual or potential flooding of the furnace based on the comparison.

First claim

What is claimed is:

1. A method comprising:
identifying a first steady-state gain associated with a relationship between a characteristic of a furnace and a setpoint used by a controller that is configured to control the characteristic of the furnace, the first steady-state gain identified using data collected when the furnace is not suffering from flooding;
identifying a second steady-state gain associated with the relationship during operation of the furnace;
comparing the first and second steady-state gains; and
identifying actual or potential flooding of the furnace based on the comparison.

2. The method of claim 1 , wherein:
the second steady-state gain is identified using data collected when the controller is operating in a closed-loop mode to control the characteristic of the furnace; and
the controller is configured to receive measurements from one or more sensors and generate one or more actuator control signals when operating in the closed-loop mode.

3. The method of claim 1 , wherein:
the setpoint comprises a temperature setpoint;
the characteristic of the furnace comprises a flow rate of fuel gas into the furnace; and
the controller is configured to control the flow rate of fuel gas into the furnace based on the temperature setpoint.

4. The method of claim 1 , wherein the second steady-state gain is identified using data collected after one or more perturbations in the setpoint.

5. The method of claim 4 , wherein:
the setpoint comprises a temperature setpoint; and
the one or more perturbations in the setpoint comprise one or more changes in the temperature setpoint.

6. The method of claim 1 , wherein the second steady-state gain is identified repeatedly during the operation of the furnace.

7. The method of claim 1 , further comprising:
in response to identifying actual or potential flooding of the furnace, at least one of: generating an alert, altering the operation of the furnace, and stopping the operation of the furnace.

8. An apparatus comprising:
at least one processing device configured to:
identify a first steady-state gain associated with a relationship between a characteristic of a furnace and a setpoint used by a controller that is configured to control the characteristic of the furnace, using data collected when the furnace is not suffering from flooding;
identify a second steady-state gain associated with the relationship during operation of the furnace;
compare the first and second steady-state gains; and
identify actual or potential flooding of the furnace based on the comparison.

9. The apparatus of claim 8 , wherein the at least one processing device is configured to identify the second steady-state gain using data collected when the controller is operating in a closed-loop mode to control the characteristic of the furnace.

10. The apparatus of claim 8 , wherein:
the setpoint comprises a temperature setpoint; and
the characteristic of the furnace comprises a flow rate of fuel gas into the furnace.

11. The apparatus of claim 8 , wherein the at least one processing device is configured to identify the second steady-state gain using data collected after one or more perturbations in the setpoint.

12. The apparatus of claim 11 , wherein:
the setpoint comprises a temperature setpoint; and
the one or more perturbations in the setpoint comprise one or more changes in the temperature setpoint.

13. The apparatus of claim 8 , wherein the at least one processing device is configured to identify the second steady-state gain repeatedly during the operation of the furnace.

14. The apparatus of claim 8 , wherein the at least one processing device is further configured to:
in response to identifying actual or potential flooding of the furnace, at least one of: generate an alert, alter the operation of the furnace, and stop the operation of the furnace.

15. A non-transitory computer readable medium containing instructions that when executed cause at least one processing device to:
identify a first steady-state gain associated with a relationship between a characteristic of a furnace and a setpoint used by a controller that is configured to control the characteristic of the furnace, using data collected when the furnace is not suffering from flooding;
identify a second steady-state gain associated with the relationship during operation of the furnace;
compare the first and second steady-state gains; and
identify actual or potential flooding of the furnace based on the comparison.

16. The non-transitory computer readable medium of claim 15 , wherein the instructions that when executed cause the at least one processing device to identify the second steady-state gain comprise:
instructions that when executed cause the at least one processing device to identify the second steady-state gain using data collected when the controller is operating in a closed-loop mode to control the characteristic of the furnace.

17. The non-transitory computer readable medium of claim 15 , wherein:
the setpoint comprises a temperature setpoint; and
the characteristic of the furnace comprises a flow rate of fuel gas into the furnace.

18. The non-transitory computer readable medium of claim 15 , wherein the instructions that when executed cause the at least one processing device to identify the second steady-state gain comprise:
instructions that when executed cause the at least one processing device to identify the second steady-state gain using data collected after one or more perturbations in the setpoint.

19. The non-transitory computer readable medium of claim 18 , wherein:
the setpoint comprises a temperature setpoint; and
the one or more perturbations in the setpoint comprise one or more changes in the temperature setpoint.

20. The non-transitory computer readable medium of claim 15 , wherein the instructions that when executed cause the at least one processing device to identify the second steady-state gain comprise:
instructions that when executed cause the at least one processing device to identify the second steady-state gain repeatedly during the operation of the furnace.

21. The non-transitory computer readable medium of claim 15 , further containing instructions that when executed cause the at least one processing device to:
in response to identifying actual or potential flooding of the furnace, at least one of: generate an alert, alter the operation of the furnace, and stop the operation of the furnace.

22. The non-transitory computer readable medium of claim 15 , wherein the instructions that when executed cause the at least one processing device to identify the first and second steady-state gains comprise:
instructions that when executed cause the at least one processing device to perform closed-loop model identification using data collected when the controller is controlling the characteristic of the furnace.

Assignees

• Honeywell Int Inc

Inventors

• Stewart Gregory E
• Foslien Wendy K

Classifications

• F23N5/242 Primary

  using electronic means · CPC title

• F23N2900/00

  Special features of, or arrangements for controlling combustion · CPC title

• F23N5/187

  using electrical or electromechanical means · CPC title

• F23N5/18

  using detectors sensitive to rate of flow of air or fuel · CPC title

• F23N1/042

  using electronic means · CPC title