Overview:
The enhanced generator system is a complete mechanical and control package that tightly integrates fewer and much more intelligent components into an elegant package. It raises the level of steam generator efficiency, reliability, and combustion emissions.

System Features:

• Each generator panel has its own high performance Allen-Bradley control processor and color LCD operator interface display. Each generator is stand-alone and is fully functional and not affected by control failures in other units.
• System incorporates smart digital instrumentation and electrical actuation devices for high accuracy and reliability.
• Stable and precise control coupled with innovative passive flue-gas recirculation system enabled ultra low NOx level of less than 7 ppm.
• Sophisticated and flexible control system performs full on-line steam quality and efficiency calculations. Complete system data management is also done.
• Precise air rate control is performed using blower motor variable frequency drive and stack excess oxygen transmitter. Air rate modulation performs closed loop control of stack excess oxygen. No variable vanes or louvers are used.
• Main gas controls consisting of; safety valves of dual electro-hydraulic actuated ball valve system, FM approved for gas safety service, and normally open bleed solenoid; characterized ball valve with modulating electric actuator for rate control; and multi-variable transmitter for fully compensated orifice gas measurement.
• In the same way, the enhanced generator system can also incorporate control and metering of a waste gas stream for extra heat usage and waste disposal. The waste stream is blended and burned with the main gas stream to provide complete incineration of these components.
• Water rate controls using orifice meter with smart DP transmitter, and characterized control valve with electric modulating actuator. Water rate is modulated to provide closed loop steam quality control.
• Fuel oil rate controls using Micro-Motion coriolis meter, and characterized ball valve with electrical modulating actuator.
• Very low steam generator pressure loss and high capacity is available using optional parallel path splitflow water and steam loops.
• Full actuation and control of pilot gas assembly allows fully automatic generator startup.
• The Advanced generator system can interface to centralized feedwater pumps system or control onboard water pump.

Safety Features:

• Independent flame fail management using FM approved flame safety controller.
• Air flow sensing using blower VFD feedback diagnostics, purge air velocity sensor, and stack gas O2 transmitter. Pre and post purge timers are embedded in the PLC system and cannot be adjusted by the operator.
• More precise tube failure detection using water input and steam output mass balancing.
• Position feedback on safety valves assures out of position failure detection. No valves can be forced out of control during operation.
• Safety valves incorporate robust electro-hydraulic ball valve system, not guillotine valves for reliable shutoff and long life.
• Always fully automatic control at programmed setpoints for steam quality, excess O2, fuel, and gas rates.
• Detection of signal loss from all devices triggers alarm and shutdown.
• Generator controls are remotely controllable if it is desired to keep personnel away from equipment.
• The advanced generator system has full reset and restart operation. “One button start”. Once commanded to start, the generator system will automatically perform all sequencing to full run operation. The unit requires no further attention.

Reliability Features:

• Corrosion resistant fiberglass enclosures for control and variable frequency drive equipment.
• Periodic safety testing is much faster due to fewer and smarter instruments. The full suite of safety checks for the advanced steam generator system typically take only 4 hours.
• Smart digital instrumentation hold stable calibration and have no moving parts to wear providing very long life.
• No air louvers or shutters to adjust or wear.
• All electric actuation, no pneumatic compression, drying, filtering, distribution, regulation, positioning, and actuation equipment to maintain.
• System has offline maintenance mode that allows flexible actuation of valves and blower for testing and servicing.