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The Mk7 E.G.A

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EGA Trim

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ScreenshotsAutoflame Training, 2011Mk7 EGA (Technical Training)

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Combustion Management Systems

• Sampling and display• O2, CO2, CO, NO

and SO2 or NO2

• Exhaust temperature

• Combustion efficiency

• 3 parameter trim• O2, CO2, CO

• Limits• O2, CO2, CO, NO

and exhaust gas temperature

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Combustion Management Systems

Stand alone/trim functionEmissions levels can be accessed via:

• 10.4” Touch screen display

•Micro Modulation unit

•Six 4-20mA signals

•Data Transfer Interface (DTI & CEMS monitoring)

•PC (personal computer)

•BMS (building management system)

•PLC

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Combustion Management Systems

1. Improve combustion

2. Increase efficiency

3. Reduce fuel consumption

4. Reduce Cost- up to 2% has been recorded

5. The most important reason-

IMPROVED SAFETY

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Combustion Management Systems

1. E.G.A. 3 parameter trim

• O2, CO2 and CO

• Trims because of fluctuations in ambient conditions

2. Variations in stack pressure or barometric conditions or small changes in gas pressure/BTU content

• Minute corrections to the air damper

• Or minute corrections to the fan speed drive

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Combustion Management Systems

SENSOR SERVO

SECOND SETPOINT FACILITYEXTERNAL MODULATION

SWITCH

EXTERNAL

BOILER

DRIVECH.5SPEEDVARIABLE FLAMEOR

DRAFTFORCED AUX.

SERVO

CH.4AIR AUX.

SERVOSERVO

CH.3CH.2U.V

LOAD OR

OIL

AIRPRESSURE

PRESSURESENSOR

OIL

CH.1

FUEL

PRESSURESENSOR

GAS

GAS

HIGH/LOW GASPRESSURE PROVING

VALVE PROVING

SENSOR

PROBESAMPLING

CH.6

FLUE

VARIABLESPEED DRIVE

EXTERNAL

T.D.S.PROBE

FEEDWATERVALVE

STEAMSENSOR

CAPACITANCEPROBES

TEMP.SENSOR

TEMP.SENSOR

SURFACEBLOWDOWN

BOTTOMBLOWDOWN

FEEDWATERSERVO

OUTSIDETEMP. SENSOR

SENSOR SERVO

SECOND SETPOINT FACILITYEXTERNAL MODULATION

SWITCH

EXTERNAL

BOILER

DRIVECH.5SPEEDVARIABLE FLAMEOR

DRAFTFORCED AUX.

SERVO

CH.4AIR AUX.

SERVOSERVO

CH.3CH.2U.V

LOAD OR

OIL

AIRPRESSURE

PRESSURESENSOR

OIL

CH.1

FUEL

PRESSURESENSOR

GAS

GAS

HIGH/LOW GASPRESSURE PROVING

VALVE PROVING

SENSOR

PROBESAMPLING

CH.6

FLUE

VARIABLESPEED DRIVE

EXTERNAL

T.D.S.PROBE

FEEDWATERVALVE

STEAMSENSOR

CAPACITANCEPROBES

TEMP.SENSOR

TEMP.SENSOR

SURFACEBLOWDOWN

BOTTOMBLOWDOWN

FEEDWATERSERVO

OUTSIDETEMP. SENSOR

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Combustion Management Systems

Problems with O2 trim

1. If only O2 is measured and trimmed on then there is no measurement as to what the CO or NOx readings are

2.O2 readings seem correct but what is actually happening?

•Changes in ambient conditions can cause the CO to rise significantly (>>100ppm) even though the O2 reads well- O2 trim does not correct

•Leaks through the boiler- small gaps in the boiler shell (around joints) can lead to increased air being induced into the boiler

•Higher O2 readings from atmosphere so the system starts to trim, even though the combustion may be fine

•Combustion becomes unstable and dangerous

•CO levels (>>500ppm), higher NOx levels, O2 readings correct

•Actual combustion O2 readings around 0-0.5%- very dangerous!!

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Combustion Management Systems

Parameter 74

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Combustion Management Systems

Combustion Map

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Limits of CombustionLimits of Combustion

0

1

2

3

4

5

6

7

25% 50% 75% 100%

O2commissionedO2 offset

Absolute

0

20

40

60

80

100

120

140

160

25% 50% 75% 100%

COcommissionedCO offset

Absolute

0

10

20

30

40

50

60

25% 50% 75% 100%

NOcommissionedNO offset

Absolute

0

100

200

300

400

500

600

700

25% 50% 75% 100%

TempcommissionedTemp offset

Absolute

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Mk7 sampling screen

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Combustion Management Systems

45 DEGREES

INCORRECT CORRECT

SAMPLE TUBESAMPLE TUBE

PROBEPROBE TubingTubing•Maximum length- 10mMaximum length- 10m

•Diameter- 2mmDiameter- 2mm

•No lower pointsNo lower points

Probe positioning•450 angle into flue

•Check for leaks

•1.5” BSP socket

•Error 20- tube blockage

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Combustion Management Systems

E.G.A. Positioning•10m to sampling probe

•Cool environment (410F – 1040F (50C – 400C))

•Exhaust gases- where do they go?

•Re-calibrates on contaminated gases

External environmental enclosure (ENC1008)•Non-standard ambient conditions

•Extreme environments

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Sample InSample In

Thermocouple I/PThermocouple I/PSample InletSample InletPinch Valve (3)Pinch Valve (3)

NO CellNO Cell

CO/NO BypassCO/NO BypassPinch Valve (1)Pinch Valve (1)

SOSO22 Cell Cell

SOSO22 Pinch Valve (2) Pinch Valve (2)

CO CO CellCell

OO22 CellCell

PumPumpp

SOSO22 Pump Pump

FanFanPressure SwitchPressure SwitchDrain SolenoidDrain Solenoid

Vacuum SwitchVacuum Switch

LED BankLED Bank

COCO22 Cell Cell

Chiller BlockChiller Block

FilterFilter

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The Mk7 E.G.A

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Options• 12- E.G.A. setup

• Monitoring only• Trim functionality• E.G.A. not optioned

• 19/20/21- upper offset limits % O2, CO2: ppm CO

• 22/23- lower offset limit % O2, CO2

• 25/26/27- absolute value % O2, CO2: ppm CO

• 28- trim threshold

• 36- sensor selection for NO, SO2, NO2 cells

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Combustion Management Systems

Parameters• 4- allows readings to settle during commissioning• 8- wash out period• 9- auto commission time• 11- air flush time• 12- CO included for trim function• 13- air damper movement during auto commission• 14- fuel valve movement• 16- time between E.G.A. self calibrations

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Combustion Management Systems

Parameters (continued)• 17- number of trims before error• 18- air damper movement during operation• 24- E.G.A. calibration time• 25- time interval between samples• 26- number of samples per trim cycle• 27- minimum operating temperature• 28- maximum operating temperature

• 44- O2 window for no further trim

• 45- CO2 window for no further trim

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• Serial cable link between PC and E.G.A.• DOS based program• Usable with Windows XP (Technical Bulletin

#14)• Press F1 for help menu on the program• Pinch valve configuration

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1. O2 range adjustable, e.g. 4mA (0%) – 20mA (20.9%)

2. CO2 range adjustable3. CO range adjustable, e.g. 4mA (0ppm) – 20mA

(999ppm)4. NO range adjustable5. SO2 range adjustable6. Exhaust gas temperature7. Efficiency/nett/gross8. Input for ambient air temperature9. Air temperature input, e.g. 4mA (320F(00C)) – 20mA

(7000F(3720C))10. E.G.A. unit air temperature ambient11. Smoke density auxiliary input/output

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Error code on MM display• 01- no communications to the EGA

• Check wiring• Is the system grounded?

• 20- pump failure• Sampling blockage- check inlet to

E.G.A.• Isolation of each section

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Error code on MM display• 21- O2 cell failure

• Check voltages• Re-calibration• Are there any leaks on the tubing (pinch

valves)?

• O2 cell reads 20.9% • Check all the tubing is airtight• Is the sample tube blocked?• Air solenoid?• Leak on flue?

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Levels of repair/service1- Minor repair/service

• Cleaning, testing and re-calibration• New pump, tubing plus cells if required

2- Significant repair• Plus replacement of damaged components,

cells, e.t.c.

3- Service exchange• Replacement of E.G.A. for a fully repaired,

tested and calibrated unit

4- Beyond Economical Repair (BER)

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The New Mk7 EGA

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Mk7 EGA – Sampling Screen

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Mk7 EGA – Sampling Screen

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Mk7 EGA – Setup Screen

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Mk7 EGA – Setup Screen

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Mk7 EGA – Cell Status Screen

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Mk7 EGA – Settings Screen, Operating Mode

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Mk7 EGA – Settings Screen, Operating Mode

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Mk7 EGA – Settings Screen, Calibration Code

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Mk7 EGA – Fault History

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