Systems and methods for detecting discrepancy in a combustion system

A system for determining operating discrepancy a process heater, comprising:

• a processor;
• and,
• memory storing computer readable instructions that, when executed by the processor, operate to:
• receive sensed current operating data within the process heater;
• calculate a delta between the sensed current operating data and an expected current operating data corresponding to the sensed current operating data;
• compare the delta to a predetermined threshold;
• when the delta indicates excess air-flow, determine an amount of the excess air-flow in terms of leakage area within the process heater based at least in part on geometry of the process heater, and an identified draft within the process heater;
• and,
• output a remediation action in response to the delta breaching the predetermined threshold.

A combustion system having burner tip plugging indication, comprising:

• a burner having a burner tip;
• a fuel pressure sensor generating fuel pressure data of a fuel source input into the burner;
• a processor;
• and,
• memory operatively coupled to the processor storing a burner tip monitor as computer readable instructions that when executed by the processor operate to:
• generate a calculated fuel heat release of the burner by executing a fired-systems model of the burner based at least in part on fuel information, a fuel pressure, and burner geometry, and
• compare the calculated fuel heat release of the burner to a measured heat release to generate a burner tip health indication of the burner tip.