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OilPro Oilfield Production Equipment Ltd.

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Product Inventory

PowerGen

PowerGen by Qnergy delivers more power than TEGs or fuel cells, and is priced much lower per Watt.

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

We provide power solutions to anyone requiring critical remote power solutions in response to AEP (Alberta Environment and Parks) regulations to create offsets usable under CCIR (Carbon Competitiveness Incentive Regulation) for advanced environmental compliance. Our energy efficient PowerGen series helps producers comply with costly California Energy Commission-administered LCFS (Low Carbon Fuel Standard) in advance of Canadian implementation. Highlights of the PowerGen system:
  1. Reliable even when fuel quality is poor or contains H2S.
  2. Low maintenance (1-2 hr/year is typical) (air filter, glycol maintenance mostly)
  3. Long lifespan (80,000+ hr design life, and units are now running 13 years continuously at NASA labs)
  4. Reduce venting, flaring
  5. No grid power contract or install wait, can be moved.
  6. lower cost/Watt (2-10x less vs. TEGs)
  7. Hail and theft/vandalism resistant and more reliable vs. solar
  8. Scalable (plug and play)
  9. Meaningful power = meaningful solutions (5- 7.5 HP/PowerGen)
  10. Well-suited to 4+ well pads or truck-out/LACT unit power
The generator package works seamlessly with a variety of fuel supplies, including natural gas, propane, ethane, biogas, and multiple 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 controllable glycol system heat supply of 48,000-60,00 BTU/hr. PowerGen supplies flexible power and BTU's.

Applications:

  • flow control
  • metering
  • monitoring
  • lighting
  • site cathodic protection and pipeline ICCP
  • pneumatic instruments (60-90 low bleed instruments)
  • actuators
  • pumps (10 gpm for 1,000-3,000' or  2-5 gpm for 5,000' well)
  • compression power for flowline pressure reduction
  • analytics
  • heat tracing/ Ruffneck heaters/water tank heating

PowerGen provides critical power in locations where TEGs are being phased out PowerGen Series Stirling engine gensets: Designed for rugged and remote operation, the PowerGen remote power generator provides reliable electrical power supply to the most demanding and mission-critical loads. With only 1 hour annual maintenance and highly reliable PCK series Stirling engines, the generator package can work seamlessly with a variety of fuel supplies, including natural gas, propane, ethane, biogas, and multiple associated gas streams.

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
  • 3-Phase Motor Drive
  • Fuel Conditioning
  • Extreme Low Temperature Module
  • Three Stage Battery Charging
  • Hybrid Compatible
  • Remote Monitoring
  • Configurable Voltage Outputs
  • Extended Standby
  • Gas Pressure Reduction System
  • Heat Recovery
  • Impressed Current Cathodic Protection (ICCP)
  • Custom Enclosure Color
  • Enhanced Security/Lighting

FAQ's

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: For the in-depth version, visit https://www.spaceflightinsider.com/space-centers/glenn-research-center/it-keeps-going-and-going-stirling-engine-test-sets-long-duration-record-at-nasa-glenn/, which explains NASA’s experiment with the FPSE which has been running continuously since 2003. Only maintenance of monitoring instruments and component inspections have interrupted the continuous duty of this engine. 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 https://www.youtube.com/watch?v=r77z4zsTT64 . 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 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 gas being burned to electricity and heat. This is achieved with the use of an air-assisted on-board system-powered blower which is 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 70-80% range. Converting energy on site using gas available on-site fuel is extremely efficient. When you consider that fuels such as gasoline, diesel or processed gas can ultimately result in an overall energy conversion rate in the 10-20% range at the driven wheel of an automobile 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 -30C 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

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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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POWERGEN-RESIDENTIAL-HYBRID

Hybridized PowerGen - Solar - Battery package. Includes:
Power Control System and Battery Charging interface,
Control and Monitoring interface. Power interface module
to be co-located within […]

Product Details

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POWERGEN-TAMPER PROOF LATCH

Compression Latch
Oversized to match Heavy Duty PowerGen enclosure.
Specifically designed to match seal compression for tight factory-fit seal.
OilPro recommends a minimum of 6 latches per […]

Product Details

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POWERGEN-TAMPER PROOF LATCH-KEY

Compression Latch-key
Tamper-proof industrial-strength triangular 7 mm key to operate the compression latch
Specifically designed to handle torque required for compression for tight factory-fit […]

Product Details

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