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OilPro Oilfield Production Equipment Ltd.

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Product Inventory

PowerGen

What will you with the extra Watts and BTU's efficient design delivers?

PowerGen by Qnergy delivers more power than TEGs or fuel cells, and is priced much lower per Watt in the 300-11,000 Watt range.

We sell PowerGens based on value,but customers return because our system run reliably with minimal effort, and make an environmental case due to its low carbon footprint which gets even better when the units are used as micro CHP (Combined Heat and Power) solution which captures waste heat for on-site freeze protection with the GHT (Glycol Heat Trace) system.

Don't take our word for it: "We have 4 units in field running to date and 3 more within the next month.....The operations team can’t say enough good things about these packages as the runtime is fantastic thanks to Qnergy and OilPro."

PowerGen systems make an immediate economic case. In most Canadian provinces, systems and integrated combinations qualify for significant additional carbon credits replacing pneumatic fuel gas-driven systems with instrument air and/or combined with available electrical systems such as chemical pumps, VRUs (storage tank Vapour Recovery Units), lighting, security etc.

Highlights of the PowerGen system:

  1. Reliable even when fuel quality is poor or has up to 1,000 ppm H2S.
  2. Low maintenance (1-2 hr/year is typical) (filter, glycol maintenance)
  3. Long lifespan (80,000+ hr design life)
  4. Reduce/eliminate venting, flaring
  5. No grid power contract or installation & can be moved.
  6. lower cost/Watt (2-12 x less vs. TEGs or fuel cells)
  7. Hail and theft/vandalism resistant and more reliable vs alternatives
  8. Scalable (plug and play 2 units easily)
  9. Meaningful power = meaningful solutions (up to 5.65 kW/unit)
  10. GHT system c.w programmable temperatures up to 50°C
  11. Integrated capacity and Modbus table for tie-ins with plant MCC systems.
PowerGen works seamlessly with any combustible fuel gas supply like natural gas, propane, ethane, biogas, and associated gas streams. An available 5,650 Watts means you still have power left over to allow for AC heat trace in colder climates with an additional programmable temperature glycol system heat supply of 48,000-60,00 BTU/hr. (2.5-3.5x electrical output)

Applications:

  • flow control
  • metering
  • monitoring
  • lighting
  • site & pipeline ICCP (Impressed Current Cathodic Protection)
  • pneumatic instruments (60-90 low bleed instruments)
  • actuators (low and high power electric and pneumatic)
  • pumps (10 gpm for 1,000-3,000' or  2-5 gpm for 5,000' well)
  • compression power for flowline pressure reduction
  • vapour recovery (VRUs) for smaller tank storage systems
  • analytics
  • heat tracing/ Ruffneck heaters/water tank heating
https://www.youtube.com/watch?v=z2gBf9VqwKE

PowerGen provides critical power in locations where TEGs are being phased out PowerGen Stirling gensets: Designed for rugged and remote operation, the PowerGen provides reliable electrical power supply to the most demanding and mission-critical loads

Certifications/ratings

  • cETLus (UL2200)
  • (CSA C22.2#100 / C22.2#14)
  • IP 54 Enclosure rating

Case Studies

Feature Options available:
  • Sour Gas Service (1,000 ppm H2S capable)
  • Low BTU Value gas (Down to 751 BTU/CuFt)
  • Glycol Heat Trace/Heat Recovery for other onsite systems
  • 3-Phase Motor Drive
  • Fuel Conditioning
  • -40 Cold Start capability (derates 5650 to 4300 Watts)
  • Battery Charging
  • Solar Hybrid Compatible
  • Remote Monitoring by modem or MCC tie-in.
  • Configurable Voltage Outputs (12/24 VAC, 120/240 VDC)
  • Extended Standby
  • Gas Pressure Reduction System (regulators)
  • Impressed Current Cathodic Protection (ICCP)
  • Custom Enclosure Colours
  • Enhanced Security & Lighting

FAQ's

Q:How does PowerGen fuel consumption compare to traditional remote power sources?

A: A 1200 Watt Powergen consumes approximately 1/3 the amount (fewer than 27 liters) of propane than a 500 Watt TEG, which uses about 76 liters (20 Gal/day). This improves costs at installations reliant on propane supply such as telecommunications and signals etc. Recoverable heat on glycol systems can be used to keep enclosures with electronics and batteries in a more efficient temperature range (15°C). We supply 2.5 -3.5x equivalent energy in heat, so 3,000-19,775 Watts of heat is available to your installation. Less frequent propane delivery and reduced spare battery capacity provide accelerated project payout and decreased environmental impact. Who said it had to be a choice?

Q: Why choose a PowerGen?

A: Traditional power supplies like solar, internal combustion, chemical and TEGs can’t guarantee reliable supply/are battery dependent; can produce harmful emissions; require custom fuels; and don’t allow the further benefit of waste heat availability for glycol heat tracing. PowerGen’s emissions are incinerator-like due to a controlled air-assisted external combustion system. Best of all, the capability to use any gaseous fuel available at the wellhead (including up to 1,000 ppm H2S) ensures supply while reducing the carbon footprint as it eliminates the need to truck in custom fuels.

Q: Are you worried about fuel availability?

A: There’s no need to be when virtually every gas and oil well in Canada makes enough gas or associated gas with a BTU content we can use to run the PowerGen. Best of all, depending on BTU’s/Cu.Ft, we only require between about 1,500 -4,000 Cu.Ft/ day to provide up to 5,650 Watts of power. There is no need to guess how long your fuel lasts if it’s available any time, right there at the wellhead or from a Propane pig or bullet. Full autonomy is yours no matter what the conditions, and remember that the colder it gets the more efficient a heat difference engine like the PowerGen’s becomes.

Q: Where do I use the PowerGen?

A: PowerGen is designed to make your existing renewables reliable, or to replace diesel generators, Solar, ThermoElectric Generators (TEGs) and fuel cells. Use it anywhere you need power and heat, close to the grid or far away from it. At service needs of 1-2 hrs/year, the PowerGen can be maintained and kept running anywhere power is critical to operations and communications.

Q: Can PowerGen be monitored?

A: PowerGens are connected to the factory to relay its own operating parameters only. However it’s also fitted with Modbus capabilities for SCADA connectivity to your existing system. We provide free cellular monitoring for the first year and give you the option for subsequent years. Qnergy, PowerGen’s parent company is well-versed in remote operations as is evident from its involvement with a number of NASA’s Mars missions.

Q: What do PowerGens cost?

A: Know that PowerGens have the lowest cost/Watt of any competing remote power system out there. Additional packages for lower temperature, additional heat recovery and extra low temperature operations allow you to pick the system best suited for your site, with straight-forward pricing for all options.

Q: Will OilPro integrate the PowerGen with my site-specific needs?

A: OilPro specializes in coordinating Engineering, Project Management and Construction of skid packages which can include everything from rectifiers to instrument air to battery charging, straight site power, sweetening systems, gas compression, chemical pumps and heat distribution for tanks or flowlines etc. to integration with on-site fuel supply and MCC buildings and other production equipment. A general area classification provides lots of leeway in terms of site placement. OilPro takes a brand-agnostic approach to whatever requires power at your site. We will integrate PowerGen with any Qnergy vetted inverter, charger, compressor, pump, motor or electrical system you require. Once a Site Survey is done, we can coordinate with your preferred integrator or be your one-stop general contractor, whichever suits your project business model best.

Q: Can PowerGen be trailered, boxed, or otherwise housed?

A: A suitable trailer can support the roughly 1,200 lb PowerGen nicely to provide steadfast off-grid power for mobile applications from site monitoring, lights, data gathering and general communications. However mounting on concrete, piles or rig mats is also easily accomplished, as is integration on a more elaborate skid. As PowerGen’s cabinet is designed to be placed outside already there is no need to enclose it again. The -20°C versions can be partially enclosed if desired, leaving the radiator portion outside the building while contributing to heat inside the building if desired. The -40°C version of the PowerGen can provide 1200 to 5650 Watts continuously for at least its design life of 80,000+ hrs with some test units now outlasting their own monitoring equipment with continuous runs of approximately 13 years at the time of this writing!

Q: What happens internally if the air intake was to suck in an air/gas mixture?

A: Powergen is tuned to operate lean- access fuel of around 3.5-4% O2. Adding fuel into the intake air will in turn reduce the oxygen content, causing a rise in the flame temperature until it becomes too rich, causing incomplete combustion and high levels of carbon monoxide. The Powergen monitors its engine head temperature and will lower the burner rate when the head over-heats. Therefore there is no risk to the hardware. In all cases the flame remains inside the combustion chamber and is not capable of traveling upstream beyond the quenching plate (perforated plate behind the burner deck). Burner chamber volume is sized so that the flame cannot exit and travel down the sealed exhaust ducting, therefore no exposed flame. Supporting illustration:

Q: Can this generator as a whole ignite external flammable gases?

In other words, should you treat the PowerGen as open flame equipment, which impact its location on the site due to spacing requirements of this type of equipment? Answer: The Qnergy PowerGen 5650 has an enclosed combustion chamber that is fully encapsulated within heat exchangers in such a way that there is no exposed heated surface hot enough that could cause pre-ignition to external air-borne flammable natural gas. In terms of ingress of external air-borne gas via the exhaust system into the combustion chamber, we have a positive pressure combustion chamber which, when the unit is operating, prevents any ‘unintended’ flammable gas access to the combustion chamber. To help you with locating the PowerGen on your site, we have further clarification from Alberta's Energy Regulator: "Given how the Sterling engine operates, with an enclosed combustion chamber and no possible way for a flame front to exit the unit if an air/gas mixture is drawn in, I conclude that it operates more like an internal combustion engine rather than flame type equipment." (June 25, 2018)

Q: The PowerGen is capable of burning sour fuel gas with up to 1,000 ppm H2S; Will we be required to do dispersion modelling?

Answer: Section 7.12(1) of (Alberta Energy Regulator) AER Directive 060 requires dispersion modelling if the H2S content is greater than or equal to 10 mol/kmol (your 1000 ppm would be 1 mol/kmol) or one tonne per day.  PowerGen doesn’t trigger either of these, so dispersion modelling would not be required by Directive 060. Note that our free-standing height is only 54 inches, so it would be possible for the emissions to be very undispersed if someone was standing nearby. OilPro recommends consideration is given to determine whether the operator might want some sort of setback distance so that a person couldn’t stand too close to the exhaust. The heat of the exhaust will provide some lift and may act like an effective stack height, taking the plume up into the air, to then disperse more as it travels downwind. The Air Quality Objective for SO2 is 172 ppb, so the dispersion would need to be taken from the original concentration of about 1,000,000 ppb (1,000 ppm) resulting from the original 1,000 ppm of H2S, down to 172 ppb.  Dispersion is quite effective, so this is probably not difficult to achieve (comparatively much larger sources still dilute to levels below 172 ppb), but if required it is recommended to model the scenario to be sure of each case. Bottom line: no, AER requirements do not require a model of the gas stream of this low H2S concentration and rate.

Q: What makes the Free Piston Sterling Engine (FPSE) last so long without maintenance?

Answer: This in-depth version, explains NASA’s experiment with the FPSE running continuously since 2003. In brief: The FPSE is designed to have no contact between moving parts. There are no contacting bearings or seals which eliminates wear items. Secondly the hot-end metallurgy, weld procedures and assembly methods were carefully chosen for their durability. Any engineer will tell you that the best designs are usually the simplest. The FPSE is no exception. The engine contains helium gas, which is heated at one end, and as the helium expands it forces a piston away from the hot end and into an oscillating cycle. Indirect action between this piston induces movement of a secondary piston which incorporates a linear alternator that generates electrical output. There is no rotary motion, no crank, just back and forth movement, enabled by internal springs called flexure plates, which resemble the small discs found in 45 RPM vinyl records. The flexure plates are designed around a material fatigue life beyond that of the required operating life of the engine. The engine design life is in the order of 10-20 years to match NASA’s mission durations in the 17-year range, but speculations indicate these engines can last beyond 20 years. We’ll only know for sure in 2023.

Q: Why should we consider the PowerGen a clean technology when it burns hydrocarbons?

A: This comes down to what Ory Zik, CEO of Qnergy calls “Carbon Literacy”, which involves taking into account a system’s overall lifetime carbon footprint. There are four reasons the PowerGen should be considered to have a lower carbon footprint versus alternate remote site critical power generation systems. First is the lifetime carbon footprint. We must take into account the total lifetime carbon footprint of an engine. The FPSE was declared by NASA to be “the most reliable generation technology in history”. The FPSE requires minimal scheduled maintenance and component replacement/service. No oil changes and fewer visits to PowerGen sites mean less carbon-intensive maintenance. This is why the PowerGen compares favourably versus internal combustion engines but als compared to fuel cells, both of which require replacement of major components at regular intervals. Second is the efficiency, either stand-alone but also in a CoGen (or Micro Combined Heat and Power or CHP) application. Consider the PowerGen’s ability to control combustion at a near-perfect stoichiometric ratio once installed, regardless of the fuel gas quality used. This means there is an extremely efficient conversion of the energy in the  burned gas top electricity + heat. This is achieved with an air-assisted on-board system-powered blower adjusted to match the burner’s need for air with the BTU’s available in the fuel gas. In colder climates Co-Generation plays a role in applications where a continuously maintained process temperature is important. The PowerGen provides additional carbon footprint reductions by using its own waste heat to circulate hot glycol on site. This raises the PowerGen’s overall efficiency from the roughly 20-30%+ range into the 70-90% range. Converting energy on site using gas available on-site fuel is extremely efficient. Once one considers fuels such as gasoline, diesel or processed gas can ultimately result in an overall energy conversion rate as low 10-20% at the driven wheel after all the losses throughout the processing and distribution networks, decentralized power generation makes a lot of sense. Similar losses apply to centrally generated and distributed electricity networks, regardless of the means used to generate power, due to line losses in distribution. Third is the reduced reliance on backup battery storage. The Powergen, due to its significant power output compared to conventional remote power sources like ThermoElectric Generators (which, like the FPSE are a very reliable form of heat engine, but only due to their relatively short conductive path, end up converting only 6% of that heat into electricity) and fuel cells (Which can be both fuel dependent and have a limited, expensive, key component lifespan), means fewer backup batteries are required because the PowerGen can help recover drained onsite energy storage more quickly. As the charge rate is much higher, lower reserves are required. Solar and wind power require even more battery backup due to their intermittent and seasonally variable nature. We all know that our car batteries eventually die, with a typical lifespan of 2-5 years. Reducing the amount of required backup power causes a significant reduction in the carbon footprint of the overall system PowerGen is part of. PowerGen customers are also using the Glycol Heat Trace (GHT) option to keep batteries within their most efficient temperature range, further extending battery life and reducing the need for additional backup in low temperature operations. Fourth is that the PowerGen shines at times when everything else on a site starts to fail. The PowerGen becomes more efficient the colder the ambient temperatures are, which happens to coincide with PowerGen customer’s greatest reliance on continued operation of their facilities. During the prolonged cold spell of the 2019 Polar Vortex which saw temperatures dip into the -40°C bracket, OilPro’s PowerGen customers reported how pleased they are that many cold-related site visits related to freeze-up problems were eliminated due to the system’s increased reliability. Fewer emergency shut-downs mean fewer unscheduled site visits, which means fewer hydrocarbons burned calling in men, trucks, steaming equipment for unscheduled visits.

Background

About Sterling Engine Technology:

The original kinematic Stirling machine, developed over 200 years ago by Rev. Robert Stirling, did not attain significant technical or commercial success until the latter half of the 20th century. An increased focus on this technology over the last 50 years has led to significant recent breakthroughs in terms of operating concepts and supporting technologies. The principal “Stirling advantage” is that it is a closed-cycle external combustion engine, meaning the heat source is outside the engine and the inside of the engine can be sealed. Stirling engines also make use of a regenerative heat exchanger that allows them to re-use their heat. This regeneration feature is what makes the Stirling cycle efficient, in addition to allowing it at the same time to be powered by virtually any heat source (e.g., oil, gas, solar, wood, coal, nuclear, and other combustible material)

Certifications:

ISO 9001 Certification (May 2018)

PG-1.2/5.65KW-24DC-120/240AC-GAS

PowerGen by Qnergy delivers more power than TEGs or fuel cells, priced much lower.What will you with the extra Watts and heat available?

Product Details

POWERGEN-COLD-OPT-5YR SPARE (PG-7703)

POWERGEN-COLD-OPTION-5YR SPARE PARTS

Product Details

POWERGEN-GHT MODULE INSULATING BLANKET

Insulation blanket for GHT system.
Improves heat retention in the PowerGen Glycol Heat Trace system.
- At ambient temperature of -40%u00B0C, approximate heat loss estimated to be 72W vs […]

Product Details

POWERGEN-MICRO UTILITY GAS HEATER-60,000 BTU/HR[V1033]

Size: 12.75"OD x 4'-0" lg.
c/w the following equipment:

• heater shell nominal water capacity: approx. 21 us gal.

• Removable Coil consisting of: (6) - 2" tubes, (2) 2"CL.600 […]

Product Details

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