SMART ALGORITHM TO DETERMINE "STEAM BOILER WATER CONDITION"

Abstract

A technique for determining a boiler water condition includes a boiler controller (aka PSE unit) having a signal processor that implements a boiler control algorithm to receive signaling containing information about sets of N consecutive probe data samples related to a boiler water condition; determine stable average signaling containing information about a stable average by averaging a set of N consecutive probe data samples in the signaling received; determine present stable average signaling containing information about a present stable average by averaging a present set of N consecutive probe data samples in the signaling received; and determine corresponding signaling containing information about the boiler water condition, based upon whether the present stable average is within an allowable limit and a comparison of the present and previous stable average signaling determined.

Claims

1. A boiler controller for determining a boiler water condition comprising: a signal processor configured to receive signaling containing information about sets of N consecutive probe data samples related to a boiler water condition; determine stable average signaling containing information about a stable average by averaging a set of N consecutive probe data samples in the signaling received; determine present stable average signaling containing information about a present stable average by averaging a present set of N consecutive probe data samples in the signaling received; and determine corresponding signaling containing information about the boiler water condition, based upon whether the present stable average is within an allowable limit and a comparison of the present stable average signaling and the stable average signaling.

2. A boiler controller according to claim 1, wherein the signal processor is also configured to determine if the present stable average is within the allowable limit, then increment a stable water counter and rewrite the stable average signaling with the present stable average signaling, else declare a foam condition as the boiler water condition and reset the stable water counter.

3. A boiler controller according to claim 2, wherein the signal processor is configured to repeat for M sets of the N consecutive probe data samples the following: determine if the present stable average is within the allowable limit based upon the comparison of the present stable average signaling and the stable average signaling; and if the present stable average is within the allowable limit, then increment the stable water counter signaling and rewrite the stable average signaling with the present stable average signaling, else declare a foam condition and resetting the stable water counter signaling.

4. A boiler controller according to claim 3, wherein the signal processor is configured to determine if any data sample is out of the allowable limits (+/−) while comparing present average and stable average, then the stable water counter will get reset and will start counting from 0.

5. A boiler controller according to claim 4, wherein the signal processor is configured, once the stable water counter reaches to a count “M”, to set a new foam threshold as a last average data+ an offset.

6. A boiler controller according to claim 5, wherein the signal processor is configured, once the water is stable, to sense the probe for consecutive probe data samples and verify if any crosses the foam threshold before starting the foam algorithm and start a present foam algorithm only if this condition is satisfied.

7. A method for determining a boiler water condition comprising: receiving in a signal processor signaling containing information about sets of N consecutive probe data samples related to a boiler water condition; determining in the signal processor stable average signaling containing information about a stable average by averaging a set of N consecutive probe data samples in the signaling received; determining in the signal processor present stable average signaling containing information about a present stable average by averaging a present set of N consecutive probe data samples in the signaling received; and determining corresponding signaling containing information about the boiler water condition, based upon whether the present stable average is within an allowable limit and a comparison of the present stable average signaling and the stable average signaling.

8. A method according to claim 7, wherein the method comprises, if the present stable average is within the allowable limit, then incrementing a stable water counter, and rewriting the stable average signaling with the present stable average signaling, else declaring a foam condition as the boiler water condition and resetting the stable water counter.

9. A method according to claim 8, wherein the method comprises repeating for M sets of the N consecutive probe data samples the steps of: determining in the signal processor if the present stable average is within the allowable limit based upon the comparison of the present stable average signaling and the stable average signaling; and if the present stable average is within the allowable limit, then incrementing with in the signal processor stable water counter signaling and rewriting the stable average signaling with the present stable average signaling, else declaring a foam condition and resetting the stable water counter signaling.

10. A method according to claim 9, wherein the method comprises configuring the signal processor to determine if any data sample is out of the allowable limits (+/−) while comparing present average and stable average, then the stable water counter will get reset and will start counting from 0.

11. A method according to claim 10, wherein the method comprises configuring the signal processor, once the stable water counter reaches to a count “M”, to set a new foam threshold as a last average data+ an offset.

12. A method according to claim 11, wherein the method comprises configuring the signal processor, once the water is stable, to sense the probe for consecutive probe data samples and verify if any crosses the foam threshold before starting the foam algorithm and start a present foam algorithm only if this condition is satisfied.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0045] The drawing includes the following Figures, not necessarily drawn to scale, including:

[0046] FIG. 1 is a block diagram of a boiler system, according to some embodiments of the present invention.

[0047] FIG. 2 is a diagram of a flow chart for implementing steps A through H, according to some embodiments of the present invention.

[0048] In the Figures, similar parts are labeled with similar reference numerals. Moreover, not every part is labelled with a reference numeral and lead line in every Figure, so as to reduce clutter in the drawing.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1

[0049] By way of example, and according to some embodiments of the present invention, FIG. 1 shows a steam boiler system generally indicated as 10 having a steam boiler 12 arranged or configured in relation to a probe 14 with a probe element 14a and a probe sensor 16 with probe sensing circuitry 16a, as well as a boiler controller 20 for implementing a boiler control algorithm for controlling the steam boiler 12. The boiler controller 20 may include, or form part of, a PSE unit, e.g., consistent with that set forth herein. By way of example, the boiler controller 20 may include a signal processor 20a arranged in relation to a memory circuit or component 20b and a counter circuit or component 20c for implementing DOM and stable water counting functionality. Associated signaling S may be exchanged between the boiler controller 20 and the probe sensing circuitry 16a, e.g., as shown in FIG. 1. The boiler controller 20 may also include other circuits or components generally indicated as 20d, e.g., including input/output circuitry or components, data and control bus circuitry or components, as well as other circuitry or components to implement the signal processing functionality disclosed herein. Further, in the boiler controller 20 all of the circuits or components 20b, 20c, 20d are understood to be suitably coupled together for providing a suitable signaling exchange to/from the signal processor 20a for implementing the signal processing functionality disclosed herein.

Algorithm to Overcome Prior Art Foam Algorithm Limitations

[0050] The present invention takes into account and implements a new boiler control algorithm generally indicated as 30 in FIG. 2 having steps A through H, which includes a water stability check, a dynamic water quality check and a consecutive water level drop check, e.g., consistent with that set forth below:

[0051] A. Turn on the PSE unit.

Water Stability Check

[0052] B. If the boiler's probe 14 is in an in-water condition, the boiler controller 20 in the steam boiler system will start a counter like counter 20c (see FIG. 1) for counting to a Delay on Make (DOM) count and will turn the boiler ON upon reaching the DOM count. By way of example, in operation the steam boiler system 10 may include the boiler controller 20 configured to implement the new boiler control algorithm to receive probe sensing signaling containing information that the boiler's probe 14 is immersed in the boiler's water, and provide controller signaling to start the counter 20c to count to the DOM count. Upon reaching the DOM count, the boiler controller 20 will provide controller signaling to turn the steam boiler 12 ON. The DOM count is a counter or number, e.g. that is predetermined depending on the particular boiler application and may by set in the boiler controller 20, e.g., as one skilled in the art would appreciate.

Dynamic Water Quality Check

[0053] C. Once the steam boiler or burner 12 is ON, “N” consecutive probe data samples will be averaged and will be set as a stable average. By way of example, in operation the boiler controller 20 may be configured to implement the new boiler control algorithm to provide control signaling to actuate the probe sensor 16 and sense the probe 14, receive probe data signaling from the probe sensor 16 containing information about the “N” consecutive probe data samples, and provide further control signaling to store consecutive probe data signaling containing information about the “N” consecutive probe data sample, e.g., in the memory 20b (FIG. 1). Further, the boiler controller 20 may also be configured to receive memory signaling containing information about the “N” consecutive probe data samples (e.g., stored in the memory 20b (see FIG. 1)), process the memory signaling to determine stable average signaling containing information about the stable average, and store the stable average signaling in the memory 20b as a set stable average.

[0054] D. Next “N” consecutive data samples will then be averaged and will be compared with the set “Stable average”. If the present (i.e., next) stable average is within an allowable limit(s) (or variation), then increment a stable water counter 20c and rewrite the stable average with the present stable average. By way of example, in operation the boiler controller 20 may be configured to implement the new boiler control algorithm, e.g., consistent with that set forth in step C, to sense the probe 14 and determine next “N” consecutive data sample signaling containing information about the next “N” consecutive data samples, which may then be stored in memory 20b. Moreover, the boiler controller 20 may be configured to implement the new boiler control algorithm to provide control signaling to receive memory signaling containing information about the next “N” consecutive probe data samples (e.g., stored in a memory 20b), process the next “N” consecutive probe data samples to obtain next stable average signaling containing information about the next stable average, compare the next stable average to the set stable average (e.g., stored and received back from in the memory 20b), and determine if the next stable average is within the allowable limit. If the boiler controller 20 determines that the next (i.e., present) stable average is within the allowable limit, then the boiler controller 20 provides control signaling to increment the counter 20c for stable water counting, rewrite the stable average signaling with the next stable average signaling, e.g., which may be stored in the memory 20b. The boiler controller 20 may also be configured to determine corresponding signaling containing information about the steam boiler water condition, e.g., based upon whether the present stable average is within an allowable limit and a comparison of the present stable average signaling and the stable average signaling. The corresponding signaling may take the form of, or may include, control signaling to continue to implement the new boiler control algorithm to further monitor or evaluate the steam boiler water condition, e.g., including to shut down the boiler system consistent with that set forth herein. By way of further example, the “allowable limit” may include, or take the form of, an allowable standard deviation, e.g., which may be determined depending on the boiler application. The scope of the invention is not intended to be limited to any particular allowable limit, e.g., small boiler applications may have one allowable limit, large boiler applications may have another allowable limit, and intermediate boiler applications may have still another allowable limit, as one skilled in the art would appreciate.

[0055] E. The boiler controller 20 in the steam boiler system 10 may be configured to implement the new boiler control algorithm to repeat at least step D for “M” sets of data samples.

[0056] F. If any data sample is out of the allowable limits (+/−) while comparing present average and stable average during the step D, then the stable water counter 20c will get reset and will start counting from 0. By way of example, in operation the boiler controller 20 may be configured to implement the new boiler control algorithm to determine if any next (i.e., present) stable average is out of the allowable limits (+/−) while comparing the next stable average signaling and the set stable average signaling during the step D; and if so, then the boiler controller 20 may be configured to provide control signaling, e.g., to reset the stable water counter 20c to start counting from 0.

Consecutive Water Level Drop Check

[0057] G. Once the stable water counter 20c reaches to a count “M”, the last average data+ an offset will be set as a new foam threshold. By way of example, in operation the boiler controller 20 may be configured to implement the new boiler control algorithm to receive stable water counter signaling containing information that the stable water counter 20c reached the count “M”, and provide foam threshold signaling containing information about the last stable average data sample plus an offset to set as the foam threshold, e.g., which may be stored in the memory 20b. The scope of the invention is not intended to be limited to any particular so-called offset, e.g., small boiler applications may have one offset. large boiler applications may have another offset, and intermediate boiler applications may have still another offset, as one skilled in the art would appreciate. Moreover, the count M is a counter or number, e.g. that is predetermined depending on the particular boiler application and may by set in the boiler controller 20, e.g., as one skilled in the art would appreciate.

[0058] H. Once the water is stable, the probe 14 will sense, e.g., three consecutive probe data samples and verify if any crosses the foam threshold before starting the foam algorithm. The present foam algorithm will start only if this condition is satisfied. By way of example, in operation the boiler controller 20 may be configured to implement the new boiler control algorithm and provide control signaling to actuate the probe sensor 16 to sense the some consecutive number of probe data samples (e.g., 3), receive consecutive probe data sample signaling containing information about the consecutive probe data samples, process the consecutive probe data sample signaling, compare the consecutive probe data sample signaling to foam threshold signaling containing information about the foam threshold to verify if the consecutive probe data crosses the foam threshold, e.g., before starting the foam algorithm of the new boiler control algorithm. The scope of the invention is not intended to be limited to any particular so-called foam algorithm. The scope of the invention is intended to include, and embodiments are envisioned using, foam algorithms that are both now known in the art, and later developed in the future.

TABLE-US-00001 TABLE The following is a table showing field validation reports: Software - Field Validation Report Client Part Customer Sr. No Name Date Number Location feedback 1 Client 1 Date 1 153827 Client 1 Works well. NO Address issues found 2 Client 1 Date 1 153827 Client 1 Works well. NO Address issues found 3 Client 2 Date 1 153827 Works well. NO issues found 4 Client 3 Date 2 153827 All Units are 5 Client 3 Date 2 153827 working good 6 Client 3 Date 2 153827 7 Client 3 Date 2 153827 8 Client 1 Date 3 153827 Client 1 Works well. NO Address issues found 9 Client 3 Date 4 153927 All units are 10 Client 3 Date 4 153927 working good for 11 Client 3 Date 4 153927 client 3 12 Client 3 Date 4 153927 13 Client 3 Date 4 153927 14 Client 3 Date 4 153927 15 Client 3 Date 4 153927 16 Client 3 Date 4 153927 17 Client 3 Date 4 153927

The Scope of the Invention

[0059] It should be understood that, unless stated otherwise herein, any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein. Also, the drawing herein is not drawn to scale.

[0060] Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention.