World Leaders in Combustion Management Solutions Module Gas Setup Introduction The Mk7 E.G.A Cell...
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World Leaders in Combustion Management Solutions http://www.autoflame.com/ Module Gas Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Autoflame Training, 2011 Mk7 EGA (Technical Training)
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Transcript of World Leaders in Combustion Management Solutions Module Gas Setup Introduction The Mk7 E.G.A Cell...
World Leaders in Combustion Management Solutions
http://www.autoflame.com/
Module
Gas
Setup
Introduction
The Mk7 E.G.A
Cell Status
Further Information
Settings
EGA Trim
Limits
Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
ScreenshotsAutoflame Training, 2011Mk7 EGA (Technical Training)
World Leaders in Combustion Management Solutions
http://www.autoflame.com/
Module
Gas
Setup
Introduction
The Mk7 E.G.A
Cell Status
Further Information
Settings
EGA Trim
Limits
Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
Screenshots
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
World Leaders in Combustion Management Solutions
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Module
EGA Trim
Setup
Introduction
The Mk7 E.G.A
Cell Status
Further Information
Settings
EGA Trim
Limits
Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
Screenshots
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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Module
EGA Trim
Setup
Introduction
The Mk7 E.G.A
Cell Status
Further Information
Settings
EGA Trim
Limits
Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
Screenshots
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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Module
EGA Trim
Setup
Introduction
The Mk7 E.G.A
Cell Status
Further Information
Settings
EGA Trim
Limits
Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
Screenshots
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
World Leaders in Combustion Management Solutions
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EGA Trim
Limits
Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
Screenshots
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
World Leaders in Combustion Management Solutions
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Module
EGA Trim
Setup
Introduction
The Mk7 E.G.A
Cell Status
Further Information
Settings
EGA Trim
Limits
Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
Screenshots
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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Module
EGA Trim
Setup
Introduction
The Mk7 E.G.A
Cell Status
Further Information
Settings
EGA Trim
Limits
Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
Screenshots
Combustion Management Systems
Parameter 74
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Introduction
The Mk7 E.G.A
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Combustion Management Systems
Combustion Map
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Sampling
The Mk7 E.G.A
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Introduction
The Mk7 E.G.A
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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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Introduction
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Combustion Management Systems
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EGA Trim
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Introduction
The Mk7 E.G.A
Good Practice
Troubleshooting
Software
Screenshots
Mk7 sampling screen
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Setup
Sampling
The Mk7 E.G.A
Cell Status
Further Information
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Introduction
The Mk7 E.G.A
Good Practice
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Screenshots
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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Introduction
The Mk7 E.G.A
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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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Introduction
The Mk7 E.G.A
Good Practice
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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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Introduction
The Mk7 E.G.A
Good Practice
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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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