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OilPro Oilfield Production Equipment Ltd.

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Product Inventory

PowerGen

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

 

PowerGen Stirling Engines by Qnergy deliver more power & reliability than TEGs or fuel cells, and costs less/Watt in the 300-11,000 Watt range

OilPro distributes and services the PowerGen since CSA/Intertek approval in 2017. PowerGen delivers immediate reliable power and is environmentally friendly with efficient fuel use and micro Combined Heat and Power capability.

Being green doesn't have to put you in the red!

Together with Central Air Equipment in Calgary and OilPro's first proactive BC customer, we built the first ever CAP3 in Canada. The updated, streamlined CAP3 design, now implemented by Qnergy's applications team provides the lowest Total Cost of Ownership solution to reduce methane emissions while providing uninterrupted power and compressed air. We assists producers meet future regulations and reduce Ops/maintenance costs by over 50% and qualify early Alberta adopters for up to 8 years or credit payouts!

PowerGen Qualifies as Alternative Energy Source for Credit Generation in Alberta

Credits:

  1. ..are generated through voluntary technology adoption.
  2. ..are generated until the technology becomes a regulatory requirement.
  3. ..require third party verification which also makes them eligible to trade in Alberta or other jurisdictions.

Attention producers and operators: Don't let capital costs be a barrier to picking the best technology! Independent aggregators are vying for your business. They can provide options ranging from just making your applications to making the entire investment to shared costs/rebates. The latter type usually has risk sharing options to suit, but early adoption (pre Dec. '22) speeds up cash recovery.

A positive ROI is quite common so you are more likely to be adding to your company's bottom line than not by implementing early.

Indexed topics:

Applications:

  • Communication & SCADA
  • Monitoring, Security& Safety
  • Prime Power
  • Renewable Hybrid
  • Well Pad Automation
  • Cathodic Protection(ICCP)
  • Instrument Air and Remote Power Combination in CAP3

How It Works

Qnergy’s Free-Piston Stirling Engine (FPSE) generator transforms virtually any heat source into electricity. Once heat is applied to the FPSE the heat exchangers maintain a temperature differential across the helium-pressurized engine, causing the piston to shuttle back-and-forth.
The oscillating helium drives the linear reciprocating motion of the piston, which by means of an integral linear alternator, directly converts the mechanical motion of the piston into electrical power.
The Qnergy engine has fewer moving parts than traditional kinematic Stirling engines and no direct-contact points that cause wear and require lubrication. The PowerGen engine is ta maintenance-free technology and offers long-life performance, two key features that make it an ideal power source in remote areas.

Advantages:

  1. High reliability and efficiency with no reciprocating engine
  2. H2S sour gas, wellhead and Propane fuel capability
  3. No solar hybrid complexity and extra batteries
  4. Continuous unattended operation
  5. Load -following fuel efficiency
  6. No UPS or oversized battery banks
  7. 24/7 remote monitoring
  8. Plug & Play
  9. THREE year engine warranty on CAP3
  10. ZERO oil changes, ZERO maintenance engine
  11. small footprint, less visibility or usefulness to vandals/thieves

"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 Canada systems and integrated systems like CAP3 qualify for carbon credits.

Highlights of the PowerGen Remote Power Series

Available in 600/1200/1800/5650Watt configurations

Designed for rugged and remote operation, the PowerGen remote power generator provides reliable electrical power supply to the most demanding and mission-critical loads. Based on Qnergy’s no-maintenance and highly reliable PCK series Stirling engines, the generator package works seamlessly with a variety of fuel supplies, including:

  • natural gas
  • propane
  • ethane
  • biogas


Product Application & Engineering for all PowerGens OilPro stocks:

Electrical System

System Output Power See Configuration
Power Max Gauge Wire Interface 6-20 AWG
Cable Gland Input 3/4" Std
Ignition/Standby Battery (std) Sealed AGM Deep Cycle, 12VDC 40Ah
Battery Capacity option up to 160 Ah
Safety E-stop (normally closed)

Fuel System

fuel Type

Dry untreated natural gas from wellhead

Propane, C1-C4

burner pre-mix
ignition direct
gas regulator 2-stage
gas pressure monitor transducer
fuel port 1/2" NPT male

Cooling System

cooling system type closed loop
pump type high efficiency Grundfos® circulating pump
cooling fan type EC fan (2, operating sequentially)
coolant type required Prestone Cor-Guard or equivalent
coolant ratio (OilPro std Canada) 60% glycol/40% water
max coolant volume 4.2 gal / 8.32 litre

Communication

Ethernet RJ 45
Protocol Modbus RTU
internet infrastructure TCP/IP
remote Data Viewer Qnergy SmartView®
discrete I.O's configurable
inputs (dry contact) x6 (16-20 AWG)
outputs (relay) x8 (16-20 AWG) (max 250V/1A)

 

Configurations available in each PowerGen, 600/1200/1800/5650 Watt

Series configuration output phase angle connection
Standard

120/240VAC

split phase

Output A: 120 VAC 60Hz

Output B: 120 VAC 60Hz

A: 0°

B: 180°

3 Wire:

L1, L2 &

Common/Neut.

Optional Configurations Available

A

± HVDC

(±332 to ±365)

Output A: +HVDC

Output B: -HVDC

A: 0°

B: 180°

3 Wire:

+ve, -ve &

Common

B

120 / 240 VAC

2 Phase

Output A: 120 VAC 60Hz

Output B: 240 VAC 50/60Hz

A: 0°

B: 0°

3 Wire:

L1, L2 & Common/

Neut.

C

240V / 480V

Split Phase

Output A: 240 VAC 50/60Hz

Output B: 240 VAC 50/60Hz

A: 0°

B: 0°

3 Wire:

L1, L2 & Common/

Neut.

D

± HVDC /

120 VAC

Output A: +HVDC

Output B: 120 VAC 60Hz

A: 0°

B: 0°

3 Wire:

+ve, L2 &

Common

E

± HVDC /

240 VAC

Output A: +HVDC

Output B: 240 VAC 50/60Hz

A: 0°

B: 0°

3 Wire:

+ve, L2 &

Common

Fuel Operational Specifications

(Contact us regarding use of any not-standard gaseous fuels (C1-C4))

Model

  ft3/d fuel consumption

600/1200/1800/5650

fuel consumption Natural Gas (max. ft3/d) 550/935/1300/3964
fuel consumption Propane (max. gal/d) 4.3/7.2/10/44.4
fuel P range natural gas (psi/kPa) 3-50 / 20.7-344.7
fuel P range Propane (psi/kPa) 2-10 /  13.8-68.9
Wobbe Index min/max 832/1470 BTU/ft3
Caloric Value min/max 751/1215 BTU/ft3

Emissions

NOx @5% O2 30.0 ppm 66 mg/kWh
COx @5% O2 45.0 ppm 60 mg/kWh
VOC -- Negligible, lean combustion

HRU (Heat Rejection Unit) Operational Specifications

Thermal Heat Rejection

maximum

available

x2.5-3.5 of

Electric Power Output equivalent

Environmental Condition Specifications

Sound Max dBa < 75 dBA @ 1m
ambient T continuous operation, OilPro stock min/max

-40°C to +40ºC /

-40°F to + 104°F

Ambient T (Startup), OilPro Std stock minimum -40°C
Altitude derating

5% derate every 1,000 ft (above 5,000 ft)

5% derate every 304.8 m (above 1524 m)

Certifications/ratings

Dimensions

Glycol Heat Trace Module

Benefits:

  • Over 50,000 BTU/HR of heat available
  • No external power supply required
  • User selectable return temperature
  • Ultra-reliable rotary-vane circulating pump
  • Independent glycol reservoir
  • Full monitoring and control
  • Ideally suited for remote locations

Glycol Heat Trace

The Glycol Heat Trace (GHT) feature collects waste heat from the Stirling engine cooling system and its exhaust for uses like heating fuel lines, tanks or other components.

How it works:

A plate heat exchanger separates engine coolant from the GHT medium. The GHT glycol  circulates using a rotary vane pump on a variable speed motor. The PowerGen monitors the supply and return temperatures of the GHT media and adjusts operation to match the heat load and meet the return temperature set point. The GHT feature can be disabled with the winter/summer toggle switch.

GHT Module Specifications:  Imperial/metric
Minimum Return Setpoint Temperature 77 F/ 25 C
Maximum Return Setpoint Temperature 131 F / 55 C
Maximum 1/2" tube length 1500 ft / 457.2 m
Flow Rate

0.5-2.2 gpm /

1.89-8.33 lpm

Fluid Reservoir - working volume 1.5 gal / 5.68 litres
Fluid Reservoir - expansion volume 0.5 gal / 1.89 litres
Heat Trace Interface 1/2" NPT female
Coolant Filter

100 mesh SS /

100 micron

Glycol Content Range 50-60%

We recommend Prestone CorGuard glycol  60/40 coolant for optimal performance in the primary circuit, and uninhibited 60/40 ethylene glycol in the GHT circuit for optimal systems reliability.

 

 

Applications:

  • flow control
  • metering
  • monitoring
  • lighting
  • site & pipeline ICCP (Impressed Current Cathodic Protection)
  • pneumatic instruments (60-90 low bleed instruments)
    • https://www.youtube.com/watch?v=phQsPhm1dO8
  • 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

 

PowerGen provides critical power in locations where TEGs are being phased out

Compressed Air Pneumatics (CAP3)

Qnergy Instrument Air solutions are designed to displace the methane emission of pneumatic devices.

The Compressed Air Pneumatic (CAP3) includes:

  • 11 scfm continuous air output at 100 psi (60+ scfm available and 145+psig options)
  • Low maintenance robust duplex compressors
  • Integrated air dryer
  • HMI for local data review and control
  • Eliminates “wet-gas” pneumatic issues
  • Gas flow measurement for mitigation reporting
  • Eligible for emission offset carbon credits
  • Gas Conditioning Unit (GCU), protects against liquids in gas inlet
  • Smartview remote monitoring

Pneumatic devices powered by pressurized natural gas are widely used in the natural gas industry for process control and chemical injection. These devices vent spent gas directly into the air threatening the clean fuel advantages of natural gas. Qnergy’s innovative low-maintenance CAP3 solution efficiently combusts the normally vented methane, while economically providing reliable electric power and clean, dry instrument air.

-40° C/F cold start capable models: CAP3F & M:

Off-grid options available with both CAP3F & M

  1. 22 SCFM air output with duplex compressor
  2. Renewables hybridization
  3. Glycol Heat Trace  / Waste Heat Recovery
  4. Dry Air Receiver


Compressed Air as a Service (CAaaS)

Eliminate methane emissions with no CapEx using a simple and proven solution

The Problem

  • The energy industry faces unprecedented pressure to reduce operational methane emissions
  • Facilities have many small emission sources from pneumatics
  • Most solutions are costly and require complex planning, installation and maintenance to work reliably
  • Available solutions are labour intensive, unreliable and untested

The Solution

CAaaS is a simple utility-style agreement with an activation fee and pay-as-you-go for metered air and electricity

  • extensively proven in the field
  • flexible offering that minimizes cost of ownership
  • simple to install and operate with minimal complexity or maintenance
  • Perfect fit for remote sites with existing pneumatics
  • Generates emissions offset credits to pay for this service in Alberta (additional credits available in other provinces, please ask)

The CAP3 (Compressed Air Pneumatics) concept

For a deeper understanding, download the CAaaS whitepaper 

PowerGen N+ Solutions

Qnergy’s power interface package allows for paralleling multiple power sources with flexible AC and DC output options

Benefits

  • Scalable for 5,10 and 15kW Power requirements
  • seamless backup battery integration
  • increased system reliability
  • Fuel consumption optimization (Propane or Natural Gas)
  • Can readily be hybridized with renewable energy sources like PV & Wind. (We make renewables reliable)
  • Reduced maintenance and cost of ownership
  • Dispatchable generation
  • IOT connectivity

PowerGen 5.65 kW Stirling advantage vs Traditional internal combustion engines:

  • Maintenance-free 80,000 hr engine life (no oil changes, no field rebuilds)
  • Efficient, low-emission combustion (100x lower than EPA CO and NOx limits)
  • Wide operating temperature range (-40°C to +40°C)
  • Load-following engine (no load banks or wet stacking issues)
  • SmartView web-based monitoring system

N+1 Standby Redundancy

Intelligent auto transfer switch dispatches the standby generator for critical N+1 power applications.

Off-Grid Telecom

Rack-mounted, high performance power system with integrated battery trays and load distribution. Ideal for prime power or standby grid backup power extension.

Parallel Generation

Scalable multi-generator system for power application above 10kW. The power interface package provides customizable AC and DC output power levels.

PowerGen Solar Hybrid Solutions

Qnergy’s solar hybrid system leverages the PowerGen Stirling engine to supplement photovoltaic power creating the most reliable off-grid power system.

Benefits

  • Hybrid design blends the advantages of solar energy with those of Stirling reliability
  • 24/7, year-round off-grid power
  • Smaller PV panel footprint
  • Smaller battery bank with longer life (no deep cycling)
  • Reduced engine fuel consumption vs TEGs and reciprocating engines
  • Decreased operating costs (less maintenance and downtime)

PowerGen Stirling Advantage

  • Maintenance free 80,000 hr engine life (no oil changes, no field rebuilds)
  • Efficient, low-emission combustion (100x lower than EPA CO and NOx limits)
  • Wide operating temperature range (-40°C to +40°C)
  • Load-following engine (no load banks or wet stacking issues)
  • SmartView web-based monitoring system

Under normal conditions, the PV array supplies power through the system’s battery bank.  The PowerGen engine sits in standby, monitoring the battery health.  In extended durations of poor solar availability, the PowerGen intelligent control system will start the engine and charge the batteries.  In cold northern climates, the waste heat of the PowerGen system is harvested to maximize system performance to:

  • Heat propane tanks to keep fuel flowing in frigid temperatures
  • De-ice communication towers
  • Increase battery efficiency and prevent freezing.

PACIFIC NORTHWEST CASE STUDY

A pipeline operator was tasked with installing a cathodic protection station in a remote
area. Although high voltage utility lines were available nearby, the cost to extend and
transform the power for this small station was prohibitive. Due to the challenging weather
conditions in this region, an off-grid solar system itself would be costly due to the size of the PV array and large battery bank needed to provide reliable power in the cold, dark winter months.
Pairing a more reasonably sized off-grid solar system with the PowerGen 5650 increased the reliability and value of the system. The generator eliminates deep discharge cycles
on the battery, preventing accelerated aging. Using fewer batteries that last longer not only
saves capital but reduces the environmental waste associated with disposal. With the intelligent control system, the engine only runs when required, optimizing fuel consumption. This system adapts to changing weather conditions ensuring efficient power production, while the maintenance-free engine drives operational savings.

Explosion Proof

Qnergy’s PowerGen EXP brings the remote power reliability of the PowerGen’s Stirling engine to on and offshore applications that require hazardous operating certifications.  The PowerGen’s ability to operate independently of solar exposure means reliable power is provided regardless of the weather or season, all with a smaller footprint than comparable solar arrays.

BENEFITS

  • Supplied in standard intermodal container
  • Plug and play design
  • Optimized for shipping on and offshore
  • Certified for installation in ATEX and IECEX hazardous locations
  • Provides 500 W to 15 kW of AC and DC power
  • Positive pressure system rated for –40 to +40°C environments
  • Reduced engine fuel consumption
  • Decreased operating costs (less maintenance and downtime)

POWERGEN STIRLING ADVANTAGE

  • Maintenance free 80,000h engine life (no oil changes, no field rebuilds)
  • Efficient, low-emission combustion (100x lower than EPA CO and NOx limits)
  • Wide operating temperature range
  • Load-following engine (no load banks or wet-stacking issues)
  • SmartView web-based monitoring system
  • Ability to burn unprocessed gas with low BTU requirements (600-3000BTU)
  • Reliable power regardless of the weather or cloud coverage

The PowerGen EXP is flexible and customizable to fit all your power needs ranging from
500 W to 15 kW. The footprint is adaptable to accommodate both small unmanned platforms and large multi-well platforms.

 PowerGen and CAP3 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: What about Micro Combined Heat and Power?

The GHT, Glycol Heat Trace loop recovers waste heat from the engine and exhaust and turns it into a programmable return temperature loop of up to 1500' for your wellsite heat tracing or heating needs. Energy is conserved and put to work to ensure reliable fuel gas availability to critical site components on the coldest days.

Q: What 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 and the CAP3 systems 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.

Furthermore, the newest generation of CAP3 systems now come with integrated, GHG emissions mitigation reporting directly to your desktop with 24/7/365 access.

Q: What about cost?

A: A  hardware store genset is definitely cheaper, but when it comes to continuously reliable critical power there is no equal in the 300 to 11,000 Watt range. Know that PowerGens have the lowest cost/Watt of any competing remote critical power system. Combine that with the additional heat recovery and proven trouble-free extra low temperature operation capability and PowerGen can't be beat. (no more frozen fuel gas systems with GHT, no more impossible starts in -40 temperatures, no more TEG condensation buildup and no more fuel cell core replacements)

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.

MTIP, PowerGen and CAP3

For Alberta Producers working with MTIP (Methane Technology Implementation Program) to assist with ESG standards, reduce cost of compliance and stay competitive, the following will be helpful. The program is administered by Carbon Connect International.

Their website will guide you through the application and eligibility steps.

Eligible for MTIP applications are:

  • Upstream oil and gas operators with:
  • Facilities located in Alberta and subject to Section 8 requirements set out under Alberta Energy Regulator Directive 60
    Facilities which are either:
    • Part of an aggregate facility as defined in the Technology Innovation Emissions Reduction (TIER) Regulation, OR
    • Facilities that are not regulated under TIER

Incentive details:

  • Incentives are approved up to 50% of the total eligible project cost
  • Maximum incentives are $ 1M CAD per operator
  • Minimum incentive is $ 10k
  • Funding is approved on a first come, first served basis
  • Payments will only be made to operators

Eligible project types as they relate to PowerGen applications:

  • Pneumatic Devices
    • Pneumatic Devices Electrification (including instruments, actuators, VFD’s, motors, chemical injection pumps)
    • Instrument gas to instrument air conversion
  • Hydrocarbon storage tanks
    • Hydrocarbon storage tank vapour recovery unit (gas can be sent to the PowerGen fuel gas inlet)
  • Compressor vent gas use and destruction
    • (gas can be sent to the PowerGen fuel gas inlet)
  • Others and non-routine:
    • Surface casing vent gas flow and gas migration (gas can be sent to the PowerGen fuel gas inlet)
  • Casing gas:
    • Casing gas destruction (gas can be sent to the PowerGen fuel gas inlet)
    • Casing gas conservation (gas can be sent to the up to 5 HP compressor connected to the PowerGen and/or gas can be sent to the PowerGen fuel gas inlet)

Program details:

  • Only retrofit projects are eligible
  • Project timeline maximum is 6 months
  • Operator or service provider acting on behalf of operator can apply
  • Fund stacking is allowed
    • i.e. combination of MTIP with Emissions Reduction Fund
      • CCI recommends applying for ERF 1st and then MTIP.
      • If the project is not currently on the list of MTIP eligible project types and is an elimination project, you do not need to submit an Eligible Technology Application for MTIP.
      • Once your project receives approval from the ERF technical assessment, you can proceed directly to an MTIP application and select ‘ERF Approved Elimination Project’ from the project type list.

Claiming carbon credits as well as MTIP funding is not permitted

  • Projects that receive funding through MTIP and would like to retain associated environmental attributes can do so by reversing MTIP funding prior to June 2021 (interest free)

Reasons to participate:

  • Go beyond compliance in a changing regulatory environment
  • Streamlined and easy process for applying and fund payment
  • No third party verification required
    •  

Tips to get your PowerGen or CAP3 project on a fast track:

  1. Use Serial numbers, show in tab 2.7 of cost workbook
  2. Break down into as much detail as possible.
  3. Costs can be grouped, use notes tab and refer to the quote
  4. If there are questions about cost eligibility reach out to technical reviewer for clarification or reference “Project Cost Summary – Eligible and Ineligible” on CCI Portal
  5. For packages such as VRU only use single Serial No., such as that on control panel.
  6. For all projects:
    1. In GHT emission quantification Excel file and cost workbook, use Facility ID and Petrinex LSD for locations where projects are implemented
    2. Facilities must be Active Status in AER. Shut in and suspended facilities not eligible except SCVF (Surface Casing Vent Flow) projects
    3. Gas analysis of facility/LSD where project  is implemented must be provided if not using CCI-set default values
    4. All cells and calculations in MSExcel file must be connected\
    5. Project must met abatement cost threshold ($50/Tonne CO2 Lifetime)

Project specific tips:

  • Pneumatic Devices:
    • Vent rate of each device with corresponding references must be provided in the GHT Excel file
    • Air to Gas volumes
  • Hydrocarbon Storage Tanks
    • Tanks must be currently venting. Flare base case is not eligible
    • Gas analysis of the tank itself (not the well) done after Jan.1 2019 must be provided and used for GHG calculations
  • Casing Gas
    • A proof of casing gas volume must be provided
    • Wells must be currently venting

Questions about MTIP and ERF eligibility? Contact us at [email protected], or go directly to [email protected]

Use a PowerGen to electrify your field and qualify for GHG credits.

The Alberta emissions offset protocol for pneumatic electrification specifically identifies Stirling engines as an eligible form of alternative energy for credit generation on greenfield sites.

Projects where a new electrified device are eligible when supplied with alternative electricity generation. (Alternative electricity methods include the PowerGen's waste heat and Stirling engine electricity generation capabilities as qualified sources)

Visit this page for more information.

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