EP1000301B1 - Burner systems - Google Patents

Burner systems Download PDF

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Publication number
EP1000301B1
EP1000301B1 EP98936492A EP98936492A EP1000301B1 EP 1000301 B1 EP1000301 B1 EP 1000301B1 EP 98936492 A EP98936492 A EP 98936492A EP 98936492 A EP98936492 A EP 98936492A EP 1000301 B1 EP1000301 B1 EP 1000301B1
Authority
EP
European Patent Office
Prior art keywords
detection apparatus
fault detection
combustion chamber
oxygen
monitoring
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP98936492A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP1000301A1 (en
Inventor
Christopher Roger c/o I.E.C.S. HEANLEY
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Webb Mark St John
Original Assignee
Webb Mark St John
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Webb Mark St John filed Critical Webb Mark St John
Publication of EP1000301A1 publication Critical patent/EP1000301A1/en
Application granted granted Critical
Publication of EP1000301B1 publication Critical patent/EP1000301B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/18—Systems for controlling combustion using detectors sensitive to rate of flow of air or fuel
    • F23N5/184—Systems for controlling combustion using detectors sensitive to rate of flow of air or fuel using electronic means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/24—Preventing development of abnormal or undesired conditions, i.e. safety arrangements
    • F23N5/242—Preventing development of abnormal or undesired conditions, i.e. safety arrangements using electronic means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2221/00—Pretreatment or prehandling
    • F23N2221/10—Analysing fuel properties, e.g. density, calorific
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2223/00—Signal processing; Details thereof
    • F23N2223/08—Microprocessor; Microcomputer
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00—Measuring
    • F23N2225/04—Measuring pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00—Measuring
    • F23N2225/08—Measuring temperature
    • F23N2225/10—Measuring temperature stack temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00—Measuring
    • F23N2225/08—Measuring temperature
    • F23N2225/13—Measuring temperature outdoor temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2233/00—Ventilators
    • F23N2233/06—Ventilators at the air intake
    • F23N2233/08—Ventilators at the air intake with variable speed
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2235/00—Valves, nozzles or pumps
    • F23N2235/02—Air or combustion gas valves or dampers
    • F23N2235/06—Air or combustion gas valves or dampers at the air intake
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2235/00—Valves, nozzles or pumps
    • F23N2235/12—Fuel valves
    • F23N2235/16—Fuel valves variable flow or proportional valves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/003—Systems for controlling combustion using detectors sensitive to combustion gas properties

Definitions

  • the present invention relates to burner systems, e.g., boiler systems, and more particularly to fault detection apparatus for a burner system as hereinafter defined.
  • Fuel usually in gaseous form, is supplied to a combustion chamber where it is burnt in a controlled manner, usually in air likewise supplied to the chamber.
  • the fuel supply is commonly regulated by a valve and the air supply by a damper control linked to a fan, with regulation of both supplies being used to control the heat being generated. As soon as control is lost for whatever reason, an explosion becomes a distinct possibility.
  • the integrity of the gas/air ratio control mechanism is typically only checked by: a) a low air pressure alarm which is set to trigger if the pressure falls below the minimum pre-set level prior to and after ignition (often set at minimum); and b) micro-switches which prove the integrity of the linkages or actuator motor only prior to ignition. These switches are frequently found to be set course to prove actuation only, not to prove the conditions have been precisely met. Some switches are integral within the driving servo motor and are therefore not able to prove the integrity of the linkage; quadrants; damper or valve.
  • the low pressure switch will typically only be activated if the air supply is lost altogether, (e.g. burner fan failure).
  • the air supply is lost altogether, (e.g. burner fan failure).
  • the air supply is lost altogether, (e.g. burner fan failure).
  • a burner with a 5-1 turn-down ratio i.e. 20% to 100% of maximum heat
  • only 20% of the required air could be supplied at high fire, without the burner 'locking out'. This is a not infrequent occurrence, and results in high emissions of oxides of nitrogen, carbon monoxide, unburned fuel, damage to the tubes as well as a potential for a serious accident.
  • US patent 4915613 (assigned to Honeywell, Inc.) discloses method and apparatus which monitor fuel pressure in a heating system where a controller controls activation of the fuel valves.
  • a fuel pressure limit signal is provided to the controller for determining if the fuel pressure crosses predetermined thresholds. In order to avoid nuisance shut downs, the fuel pressure limit signal is ignored by the controller for a predetermined interval after the controller has actuated a fuel valve. The predetermined interval is selected to prevent nuisance shut-downs as a result of responding to pressure transients in the fuel main.
  • a burner system is defined as comprising a burner and combustion chamber for burning fluid fuel in oxygen-containing gas, both of which are supplied to the burner.
  • the combustion products exit the combustion chamber through a flue.
  • fault detection apparatus for a burner system as hereinbefore defined, comprising means for monitoring the supply of fluid fuel (eg natural gas, propane or butane) to the combustion chamber; means for monitoring the supply of oxygen-containing gas to the combustion chamber; means for comparing readings from the monitoring means with reference values; and means for generating a signal in dependence on the comparison made.
  • fluid fuel eg natural gas, propane or butane
  • the system provides a way of evaluating the relative proportions of the components (fluid fuel and oxygen-containing gas) undergoing combustion by monitoring the effective quantities per unit time of both as actually supplied to the combustion chamber, rather than believed to have been supplied to the combustion chamber.
  • the effective quantity relates to the number of moles of useful component supplied, although when dealing with gaseous supplies at the same temperature and pressure, the effective quantity is simply related to the volume supplied.
  • the reference values may be determined by taking readings from the monitoring means when optimum burner conditions are established. It is relatively easy to ascertain when such conditions are achieved using a multi-gas flue analyzer to ensure complete combustion and the correct excess air has been established.
  • a given burner system fitted with standard supply lines may have predictable characteristics which enable the reference values to be pre-set, obviating the need for in situ determinations to be made.
  • the instantaneous readings from the monitoring means match the reference values, indications will be all is well and that no further action need be taken, other than to continue monitoring the supplies. If, however, the instantaneous readings from the monitoring means are different to the reference values, a signal is generated, perhaps either to warn the operator of potential danger or to override the operation of the combustion apparatus, eg inhibit ignition or shut down the combustion apparatus during operation. The signal may even simply warn of a departure from optimum combustion efficiency.
  • the burner system may further comprise valve means for regulating the flow of fluid fuel into the combustion chamber, in which case the fluid fuel supply monitoring means is located downstream of the valve means.
  • the burner system may further comprise valve means for regulating the flow of oxygen-containing gas into the combustion chamber, in which case the oxygen-containing gas supply monitoring means is located downstream of the respective valve means.
  • the monitoring means are located in the burner, immediately adjacent the burner head where the fuel and oxygen containing gas mix prior to combustion.
  • the readings from the monitoring means accurately reflect the ratio of fuel to oxygen-containing gas being supplied to the combustion chamber.
  • the monitoring means are sensing what is actually being supplied to the combustion chamber, not what is believed to be supplied to the combustion chamber.
  • At least one of the monitoring means may comprise a sensor for sensing the pressure of the respective supply.
  • the pressure sensor may be utilized during purge to identify increased back pressure which might result, for example, from fouled heat transfer surfaces in the boiler or a flue blockage.
  • purge pressure sensor signals could be used to identify other malfunctions such as induced draft damper control or induced draft fan operation. Fouling or faults would be detected by comparison of the ambient air pressure and back pressure as measured by the pressure sensor during purge.
  • At least one of the monitoring means may comprise a flow sensor.
  • the flow sensor may prove useful in situations where pressure variance may be too small to measure flow rate accurately.
  • the fault detection apparatus may further comprise a temperature sensor for sensing the temperature of the oxygen-containing gas, and means for compensating for the temperature variations prior to the comparison being made.
  • the volume of a fixed amount of gas at constant pressure varies with temperature, and hence temperature variations will effect the actual amount of gas delivered to the combustion chamber.
  • a plurality of reference values could be provided, with different reference values being used at different temperatures.
  • the oxygen-containing gas is air, and thus the temperature sensor may be mounted to sense ambient conditions.
  • the signal generated in dependence on the comparison made is further dependent on the magnitude of any difference between the reference values and the readings from the monitoring means.
  • One embodiment of the present invention is designed to provide a configured, measured response to departures from safe operating conditions, permitting early identification of maintenance needs without an unscheduled shutdown if possible.
  • the signal generating means may thus provide a range of signals depending upon the perceived seriousness of the difference between actual readings and reference values. In the most serious situation (perhaps indicative of a potential explosion), the signal could effect automatic and immediate shut down of the combustion apparatus; in less serious situations, the signal could activate an alarm with a view to initiating a routine maintenance check.
  • the fault detection apparatus may further comprise means for monitoring the flow of combustion by-products (flue gas) exiting the combustion chamber.
  • the flue gas monitoring means may enable more accurate comparisons to be made by providing a way of checking the relative amounts of fuel and oxygen-containing gas supplied to the combustion chamber.
  • the flue gas monitoring means may be a pressure transducer.
  • the pressure transducer may, in combination with the pressure sensors already mentioned, enable pressure drops across the combustion chamber to be detected. Any such pressure drop may be indicative of e.g. a blockage somewhere in the system, leading to a further safety control.
  • the fault detection apparatus may further comprise means for sensing the temperature of combustion by-products (flue gas) exiting the combustion chamber, means for predicting the temperature of combustion by-products (flue gas) exiting the combustion chamber based on the calorific value of the fuel/oxygen containing gas supplied, means for comparing the sensed and predicted temperatures and producing an output in dependence upon the comparison made. If, for example, the sensed and predicted temperatures differed by more than a predetermined amount (perhaps indicative of fouling of either the fireside or water side heat transfer surfaces or loss of heat transfer fluid), the output may include controlled shut down of the system. With such apparatus, it should be borne in mind that "cold start" readings may differ significantly from “steady state” readings.
  • the fault detection apparatus may further comprise means for regulating the supply of oxygen-containing gas in dependence upon a comparison between the supply of oxygen-containing gas as monitored and a predetermined level of supply.
  • the regulating means may produce a measured response in fan motor speed in order to increase or decrease the supply of oxygen-containing gas to restore the supply to the predetermined level, e.g., to maintain the required supply of combustion air for any given gas pressure.
  • the fan motor speed typically controlled by an ac variable speed drive which may readily be regulated by a proportional integral derivative function within the ac drive.
  • An alternative if on ac drive is not used is to provide a position trim with feedback to the combustion air damper servo motor.
  • a method of detecting a fault in a burner system comprising: monitoring the rate of fluid fuel supply to the combustion chamber; monitoring the rate of oxygen-containing gas supply to the combustion chamber; comparing monitored readings with reference values; and generating a signal in dependence upon the comparison made.
  • Figure 1 shows schematically a burner system embodying the present invention.
  • a burner or boiler system 10 comprises a combustion chamber 12 having gaseous fuel supply line 14 and air supply line 16. Valve 15 regulates the flow of fuel into the combustion chamber 12 and fan and damper 17 regulate the supply of air to the combustion chamber 12. The by-products of burning the fuel at burner 18 are vented through flue 20 and heat generated by combustion is absorbed by boiler heat exchanger 22.
  • Fault detection apparatus comprises a first pressure sensor 24 in the air supply line 16, downstream of the fan and damper 17; and a second pressure sensor 26 in the fuel supply line 14, downstream of the valve 15.
  • the pressure sensors are readily available components, typically of silicon diaphragm design, and measure pressures typically in the range 100 to 3500 pascals, with a range output of 4 to 20 mA or 0 to 10 volts).
  • the pressures P 1 and P 2 sensed respectively by sensors 24, 26 are fed to micro-processor 30, together with a temperature indication T 1 of the air supply which is provided by temperature sensor 28.
  • the micro-processor 30 stores a range of reference pressure values across a range of temperatures which are indicative of optimum combustion conditions. The values may have been determined when the burner was being commissioned using a flue gas analyzer to ascertain the pressures in the supply lines at a given temperature which give rise to a fuel/air mixture required for complete combustion.
  • the micro processor 30 compares them with the pressure readings sensed by sensors 24, 26, and produces a measured response 32 in dependence upon the results of the comparison. The comparison is made by direct comparison of the reference values and sensed readings.
  • the measured response 32 is graded as follows:
  • a combustible-gas detector 40 spaced from the burner 18, detects for combustible gases in the plant room 42.
  • the detector may be of the well known and proven electro catalytic type, in which two beads, one active and the other a compensator, form one half of a Wheatstone bridge configuration).
  • the output D 1 of the detector 40 is received by micro-processor 30 which assess whether the level is close to or above a lower explosive limit. If flammable gas is detected close co or above the lower explosive limit, the micro-processor 30 isolates power and gas supply to the boiler instantly.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Regulation And Control Of Combustion (AREA)
  • Feeding And Controlling Fuel (AREA)
  • Control Of Steam Boilers And Waste-Gas Boilers (AREA)
  • Air Supply (AREA)
EP98936492A 1997-08-01 1998-08-03 Burner systems Expired - Lifetime EP1000301B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB9716151 1997-08-01
GBGB9716151.7A GB9716151D0 (en) 1997-08-01 1997-08-01 Boiler systems
PCT/GB1998/002183 WO1999006768A1 (en) 1997-08-01 1998-08-03 Burner systems

Publications (2)

Publication Number Publication Date
EP1000301A1 EP1000301A1 (en) 2000-05-17
EP1000301B1 true EP1000301B1 (en) 2001-11-21

Family

ID=10816737

Family Applications (1)

Application Number Title Priority Date Filing Date
EP98936492A Expired - Lifetime EP1000301B1 (en) 1997-08-01 1998-08-03 Burner systems

Country Status (7)

Country Link
EP (1) EP1000301B1 (zh)
CN (1) CN1265729A (zh)
AT (1) ATE209319T1 (zh)
AU (1) AU731892B2 (zh)
DE (1) DE69803294T2 (zh)
GB (1) GB9716151D0 (zh)
WO (1) WO1999006768A1 (zh)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4119845A1 (en) 2021-07-14 2023-01-18 Pittway Sarl Method and controller for operating a gas burner appliance
EP4170236A1 (en) 2021-10-19 2023-04-26 Pittway Sarl Method for pressure monitoring a pressure-dependent process and pressure sensor

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10114405B4 (de) * 2001-03-23 2011-03-24 Ebm-Papst Landshut Gmbh Gebläse für Verbrennungsluft
US6722550B1 (en) * 2003-05-09 2004-04-20 Illinois Tool Works Inc. Fuel level indicator for combustion tools
CN1308621C (zh) * 2005-01-06 2007-04-04 桂林电子工业学院 以重油为燃料的工业熔炉燃烧状态的测算方法
CN102022735A (zh) * 2010-11-24 2011-04-20 北京建龙重工集团有限公司 一种防燃气回火或脱火的方法和装置
CN102788364B (zh) * 2011-05-20 2014-08-27 林荣郎 燃烧机的炉压监控方法及其装置
DE102013110199A1 (de) * 2013-09-16 2015-03-19 Fev Gmbh Vorrichtung und Verfahren zur Versorgung eines Verbrennungsmotors mit einem konditionierten Verbrennungsgas
MY192652A (en) 2016-02-19 2022-08-29 Haldor Tops?E As Over firing protection of combustion unit
US11428407B2 (en) 2018-09-26 2022-08-30 Cowles Operating Company Combustion air proving apparatus with burner cut-off capability and method of performing the same

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1571906A (en) * 1977-11-22 1980-07-23 British Gas Corp Air fuel gas ratio controls for burners
US4915613A (en) 1989-01-25 1990-04-10 Honeywell Inc. Method and apparatus for monitoring pressure sensors
IT1242025B (it) * 1990-11-30 1994-02-02 Jacorossi Spa Apparecchiatura per la regolazione del rapporto combustibile/ comburente nei generatori di calore, in particolare per impianti di uso civile.
JP3008614B2 (ja) * 1991-12-06 2000-02-14 松下電器産業株式会社 給湯機
JPH06241446A (ja) * 1993-02-22 1994-08-30 Osaka Gas Co Ltd ガスバーナ用安全装置
FR2723630B1 (fr) * 1994-08-11 1996-09-20 Seet Procede et dispositif de reglage automatique d'un bruleur a gaz pour chaudiere
US5605452A (en) * 1995-06-06 1997-02-25 North American Manufacturing Company Method and apparatus for controlling staged combustion systems
JPH0960867A (ja) * 1995-08-28 1997-03-04 Sumitomo Metal Ind Ltd 異常バーナ検出方法

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4119845A1 (en) 2021-07-14 2023-01-18 Pittway Sarl Method and controller for operating a gas burner appliance
WO2023285345A1 (en) 2021-07-14 2023-01-19 Pittway Sarl Method and controller for operating a gas burner appliance
EP4170236A1 (en) 2021-10-19 2023-04-26 Pittway Sarl Method for pressure monitoring a pressure-dependent process and pressure sensor
WO2023066712A1 (en) 2021-10-19 2023-04-27 Pittway Sarl Method for pressure monitoring a pressure-dependent process and pressure sensor

Also Published As

Publication number Publication date
GB9716151D0 (en) 1997-10-08
ATE209319T1 (de) 2001-12-15
AU731892B2 (en) 2001-04-05
AU8546998A (en) 1999-02-22
EP1000301A1 (en) 2000-05-17
DE69803294T2 (de) 2002-07-25
DE69803294D1 (de) 2002-02-21
WO1999006768A1 (en) 1999-02-11
CN1265729A (zh) 2000-09-06

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