Method, apparatus and system for controlling a gas-fired heater

Abstract

The present invention provides a system, method and apparatus for controlling a gas-fired heater connected to a fuel source via a fuel source valve that includes one or more power sources, a temperature sensor, a pilotless igniter disposed within the gas-fired heater, a flame sensor disposed within the gas-fired heater and a controller electrically connected to the one or more power sources, the temperature sensor, the pilotless igniter, the flame sensor and the fuel source valve. The controller turns the pilotless igniter on for a first time period and opens the fuel source valve whenever the temperature sensor indicates that a temperature is less than or equal to a low temperature setting. The controller also closes the fuel source valve whenever the temperature sensor indicates that the temperature is greater than or equal to a high temperature setting or the flame sensor indicates that a flame has gone out.

1 . A system for controlling a gas-fired heater connected to a fuel source via a fuel source valve, the system comprising: 
 one or more power sources;    a temperature sensor;    a pilotless igniter disposed within the gas-fired heater;    a flame sensor disposed within the gas-fired heater; and    a controller electrically connected to the one or more power sources, the temperature sensor, the pilotless igniter, the flame sensor and the fuel source valve, wherein the controller turns the pilotless igniter on for a first time period and opens the fuel source valve whenever the temperature sensor indicates that a temperature is less than or equal to a low temperature setting, and closes the fuel source valve whenever the temperature sensor indicates that the temperature is greater than or equal to a high temperature setting or the flame sensor indicates that a flame has gone out.    
   
   
       2 . The system as recited in  claim 1 , wherein the one or more power sources comprises a battery, a solar panel, a generator or an AC electrical outlet.  
   
   
       3 . The system as recited in  claim 1 , wherein the one or more power sources comprises a battery that is recharged by a solar panel.  
   
   
       4 . The system as recited in  claim 1 , wherein the temperature sensor indicates that the temperature is less than or equal to the low temperature setting by sending a low temperature signal to the controller, and indicates that the temperature is greater than or equal to the high temperature setting by sending a high temperature signal to the controller.  
   
   
       5 . The system as recited in  claim 1 , wherein the low temperature setting and the high temperature setting are set at the temperature sensor or the controller.  
   
   
       6 . The system as recited in  claim 1 , further comprising: 
 a communications interface communicably connected to the controller; or    a fluid level sensor electrically connected to the controller.    
   
   
       7 . The system as recited in  claim 6 , wherein the communications interface is a computer network connection, a modem, a telemetry connection, a telephone line, a wireless communications link.  
   
   
       8 . The system as recited in  claim 1 , wherein the pilotless igniter comprises a hot surface igniter having a silicon nitride heating element.  
   
   
       9 . The system as recited in  claim 1 , wherein the pilotless igniter has a rated temperature of at least 1000° C. at 12 volts.  
   
   
       10 . The system as recited in  claim 1 , wherein the flame sensor is the pilotless igniter.  
   
   
       11 . The system as recited in  claim 1 , wherein gas-fired heater is used at a wellhead, a natural gas or natural gas liquids processing plant, a natural gas or natural gas liquids purification plant, or a petrochemical complex.  
   
   
       12 . An apparatus for controlling a gas-fired heater connected to a fuel source via a fuel source valve, the apparatus comprising: 
 a first connector;    a second connector;    a third connector;    a fourth connector;    a fifth connector; and    a processor connected to the first, second, third, fourth and fifth connectors, such that during operation, the processor receives power from one or more power sources via the first connector, turns on a pilotless igniter for a first time period via the third connector and opens the fuel source valve via the fifth connector whenever a temperature sensor indicates that a temperature is less than or equal to a low temperature setting via the second connector, and closes the fuel source valve via the fifth connector whenever the temperature sensor indicates that the temperature is greater than or equal to a high temperature setting via the second connector or a flame sensor indicates that a flame has gone out via the fourth connector.    
   
   
       13 . The apparatus as recited in  claim 12 , wherein the temperature sensor indicates that the temperature is less than or equal to the low temperature setting by sending a low temperature signal to the processor via the second connector, and indicates that the temperature is greater than or equal to the high temperature setting by sending a high temperature signal to the processor via the second connector.  
   
   
       14 . The apparatus as recited in  claim 12 , further comprising: 
 a signal conditioner disposed between the processor and the second connector or the fourth connector;    a buffer disposed between the processor and the third connector or the fifth connector;    a voltage regular disposed between the first connector and the processor;    a sixth connector connected to the processor for a communications interface;    a seventh connector connected to the processor for a fluid level sensor;    a reset switch connected to the processor; or    a status indicator connected to the processor.    
   
   
       15 . The apparatus as recited in  claim 12 , wherein the processor comprises two or more microprocessors that different logic and have one or more isolated inputs with current limit protection.  
   
   
       16 . The apparatus as recited in  claim 12 , wherein the apparatus is sealed except for the first, second, third, fourth and fifth connectors.  
   
   
       17 . A method for controlling a gas-fired heater connected to a fuel source via a fuel source valve, the method comprising the steps of: 
 turning a pilotless igniter on for a first time period and opening the fuel source valve whenever a temperature is less than or equal to a low temperature setting; and    closing the fuel source valve whenever the temperature is greater than or equal to a high temperature setting or a flame sensor indicates that a flame has gone out.    
   
   
       18 . The method as recited in  claim 17 , further comprising the steps of: 
 receiving a low temperature signal from a temperature sensor whenever the temperature is less than or equal to the low temperature setting; and    receiving a high temperature signal from a temperature sensor whenever the temperature is greater than or equal to the high temperature setting.    
   
   
       19 . The method as recited in  claim 17 , fturther comprising the step of setting the low temperature setting and the high temperature setting at a temperature sensor or a controller.  
   
   
       20 . The method as recited in  claim 17 , wherein the fuel source valve is not opened until a second time period has elapsed after the pilotless igniter was turned on.  
   
   
       21 . The method as recited in  claim 17 , further comprising the step of transmitting operational data to a remote location.  
   
   
       22 . The method as recited in  claim 17 , further comprising the step of disabling the fuel source valve and the pilotless igniter during a start up or low voltage condition.  
   
   
       23 . The method as recited in  claim 17 , further comprising the step of closing the fuel source valve whenever the flame sensor indicates that the flame was not created and the igniter is off.  
   
   
       24 . The method as recited in  claim 23 , further comprising the step of transmitting an alarm signal.  
   
   
       25 . The method as recited in  claim 23 , fturther comprising the step of turning the pilotless igniter on for the first time period and opening the fuel source valve after a third time period has elapsed since the fuel source valve was closed.  
   
   
       26 . The method as recited in  claim 17 , further comprising the step of turning the pilotless igniter off (if it is on) and closing the fuel source valve (if it is open) whenever a system interrupt is detected.  
   
   
       27 . The method as recited in  claim 26 , wherein the system interrupt comprises a low voltage, a low fluid level, a processor failure, a reset button or a flame out.  
   
   
       28 . A computer program embodied on a computer readable medium for controlling a gas-fired heater connected to a fuel source via a fuel source valve, the computer program comprising: 
 a code segment for turning a pilotless igniter on for a first time period and opening the fuel source valve whenever a temperature sensor indicates that a temperature is less than or equal to a low temperature setting; and    a code segment for closing the fuel source valve whenever the temperature is greater than or equal to a high temperature setting or a flame sensor indicates that a flame has gone out.    
   
   
       29 . A control kit for a gas-fired heater connected to a fuel source via a fuel source valve, the kit comprising: 
 a battery;    a temperature sensor;    a pilotless igniter for installation within the gas-fired heater;    a flame sensor for installation within the gas-fired heater;    a controller having a first connector for the battery, a second connector for the temperature sensor, a third connector for the pilotless igniter, a fourth connector for the flame sensor and a fifth connector for the fuel source valve, wherein the controller is configured to turn the pilotless igniter on for a first time period and open the fuel source valve whenever the temperature sensor indicates that a temperature is less than or equal to a low temperature setting, and close the fuel source valve whenever the temperature sensor indicates that the temperature is greater than or equal to a high temperature setting or the flame sensor indicates that a flame has gone out.    
   
   
       30 . The kit as recited in  claim 24 , further comprising: 
 a solar panel; and    a charging connector on the controller for the solar panel such that the solar panel is used to recharge the battery.