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-F in Canada. The updated, streamlined CAP3-F 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!
are generated through voluntary technology adoption.
are generated until the technology becomes a regulatory requirement.
require third party verification which also makes them eligible to trade in Alberta or other jurisdictions.
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 by early implementation.
Instrument Air and Remote Power Combination in CAP3
How It Works
Qnergy (q-ner–gy) is the world’s leading clean technology manufacturer of Stirling energy systems, designing and manufacturing the PowerGen stand-alone power generator. We operate in the stationary power sector providing primary and back-up power as well as combined heat and power in the 1-10kW range. Our products provide low-maintenance power solutions that work reliably with a broad range of heat sources. Our generators contain proprietary Free Piston Stirling Engines (FPSE), an external combustion system. These engines are enclosed, frictionless systems that require no lubrication or repair and are capable of delivering tens of thousands of hours of uninterrupted operation.
And the best part? You have three options to choose from:
CAP3-F: Walk-in shelter with auxiliary equipment space.
CAP3-Nano: Similar to CAP3-M model with increased power of 3,000W capacity.
Advantages:
High reliability and efficiency with no reciprocating engine
H2S sour gas, wellhead and Propane fuel capability
No solar hybrid complexity and extra batteries
Continuous unattended operation
Load -following fuel efficiency
No UPS or oversized battery banks
24/7 remote monitoring
Plug & Play
THREE year engine warranty on CAP3
ZERO oil changes, ZERO maintenance engine
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
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
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 for extended autonomy to facilitate on-off operations
NOTE: Standard battery supplied is 40 Ah. Float Charge is 13.65V and 0.25 A
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
Communications
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 Max Power @ 85°F / 120°F: 5.65kW / 5.1kW.
+365VDC /240VAC
Output A: +365VDC
Output B: 240VAC/50Hz
or 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 SCF/d (15C @ 1 Atmosphere)
Natural Gas (max. ft3/d)
550/935/1300/3964
fuel consumption (15C @ 1 Atmosphere)
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
B149.3-1-5 field approval
This code is for the field approval of gas appliances in Canada and specifically states it does not apply for "a new appliance for which there is an approved Standard".
PowerGen units offered by OilPro comply to this approved Standard.
The Qnergy PowerGen carries the ETL list mark which indicates it was tested by Intertek and found in compliance with accepted national standards including Certifications to CSA STD C22.2 NOS. 14 and 100.
Special field inspection is NOT required for PowerGen operation in Canada.
Alberta
In Alberta, Gas Safety Information Bulletin G-02-01a lists Intertek Testing Services Ltd. as a nationally recognized certification and inspection body with respect to the Safety Codes Act. The Bulletin also states that a special inspection is not intended to be used as a means to accept appliances and equipment when certified products are available.
British Columbia
in BC, Technical Safety BC recognizes the ETL list mark as an approved certification mark for gas appliances in Directive No.: D-G5 051201 2
Dimensions & Transport
PowerGen ships in a carefully designed, export-quality shipping crate which easily fits in a long bed HD pickup truck or on a light flatbed trailer.
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
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)
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
Compressed Air Pneumatics (CAP3)
Watch our video describing the green energy oilfield solution, 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
22 SCFM air output with duplex compressor
Renewables hybridization
Glycol Heat Trace / Waste Heat Recovery
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)
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 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
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:Q: Why is PowerGen fuel use lower than traditional remote power sources?
A: Fuel use. 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. (PowerGens now come in 600, 1200, 1800 and 5650 W sizes)
B: 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 with the Glycol Heat Trace System (GHT) as heat, so for the PowerGen 5650, 14,125-19,775 Watts (48,197- 67,475 BTU/hr) of heat is available to your installation. (All PowerGens except the 600 Watt model are available with the GHT option)
C: Less supporting infrastructure required. Lower propane use and reduced spare battery capacity requirements (PowerGens will float-charge a smaller bank nicely for longer battery life and greater reliability) provide accelerated project payout, improved system reliability, and decreased environmental impact.
Q: Why choose a PowerGen?
A: No Standby power required. 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 can’t provide the optional 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 and reduces the carbon footprint by eliminating the need to truck in custom fuels.
Q: Worried about fuel conditioning costs?
A: There’s no need to be when virtually every gas and oil well makes enough associated gas with energy content sufficient to run the PowerGen. Best of all, depending on caloric value, we only require between about 550-3964 SCF/d to make 600-5650 Watts of power There is no need to guess how long your fuel lasts if it’s available any time, right from the wellhead or from a propane tank. Full autonomy is yours no matter the conditions. That the colder it is, the more efficient a Stirling-type heat difference engines become.
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 remote start/stop be done via communication?
A: Yes, using Modbus TCP you have extensive control and monitoring of the PowerGen. TA discrete input starts and stops the PowerGen.
Q: Do I require an additional FEB board?
A: The Front End Board (FEB) is standard on the PowerGen and includes a number of discreet IO's for customer use. The FEB has terminals for field termination.
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 monitoring. 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. PowerGen and CAP Modbus registers can be read from the PowerGen IP.
Q How does the PowerGen integrate with existing UPS systems?
A:The PowerGen gives the ability to get more out of all existing battery systems due to its ability to float charge, significantly increasing battery life and allowing relatively smaller battery banks to provide more reliable power.
12VDC start battery: We can provide a system to monitor this battery system and turn on the PowerGen when it gets low (mounted in PowerGen), OR Customers can trickle charge this battery from their system, OR We can supply a small solar panel on top the PowerGen to trickle charge our start battery.
Generator start: We can provide a system to monitor a battery bank and turn on the PowerGen when a solar system can’t keep up. We can mount this in an outdoor rated panel. (Please let us know if you requrie CSA certification).We are familiar with most existing hardware, and can advise on AGS (Auto Generator Start) integration.
Q: What about cost?
A: A hardware store genset seems 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. (There is a reason fuel cell systems are hybrid systems!)
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?
A: 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?
A: 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?
A: 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.
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:
Use Serial numbers, show in tab 2.7 of cost workbook
Break down into as much detail as possible.
Costs can be grouped, use notes tab and refer to the quote
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
For packages such as VRU only use single Serial No., such as that on control panel.
For all projects:
In GHT emission quantification Excel file and cost workbook, use Facility ID and Petrinex LSD for locations where projects are implemented
Facilities must be Active Status in AER. Shut in and suspended facilities not eligible except SCVF (Surface Casing Vent Flow) projects
Gas analysis of facility/LSD where project is implemented must be provided if not using CCI-set default values
All cells and calculations in MSExcel file must be connected\
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
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)
PowerGen 1200/5650 Two models available: PowerGen 5650 PowerGen 1200 Considering the minimal maintenance (1-2 hrs annually on the air intake filter, glycol levels and pump checks, and no engine maintenance), you'll see these units pulling ahead on the economics from year 2-2.5 on vs. traditional gensets with combustion engines.
Optional Adders: 1. Glycol Circulation System 2. -40 C temperature Option (Note: the -40%u00B0C package not required if unit is inside a building that is kept above -20%u00B0C) 3. 5-Year Spares Kit: 4. SmartView - All New Orders: (Includes 12 months free monitoring, cellular modem, booster and mtg. hardware) **After 12-month SmartView trial: - (includes all software and firmware upgrades, software support, unlimited login) ** to be paid by end user direct to Qnergy.
Details on both units: 1,200 Watt Model (see info on 5,650 model below) Dry Natural gas or Propane fueled Closed loop cooling system
Configurations available: Variety of 120 VAC/ 240 VAC, and 12/24 VDC combinations. See: https://oilpro.ca/wp-content/uploads/2018/05/PowerGen-5650-1200-Brochure-Final.compressed.pdf
Communication RJ45 Ethernet Modbus RTU Protocol SmartView Data viewer Configurable I/O's 8 x (16-20 AWG) (Max 250 V/1A) Outputs (Relay)
Fuel Consumption: 673-935 Cubic feet/day of gas heat value from 751 BTU/cuft to 1,215 BTU/cuft wellhead gas Note: capable of buring up to 1,000 PPM H2S
5,650 Watt Model Dry Natural gas or Propane fueled Closed loop cooling system
Configurations available: Variety of 120 VAC/ 240 VAC, and 12/24 VDC combinations. See: https://oilpro.ca/wp-content/uploads/2018/05/PowerGen-5650-1200-Brochure-Final.compressed.pdf
Communication RJ45 Ethernet Modbus RTU Protocol SmartView Data viewer Configurable I/O's 8 x (16-20 AWG) (Max 250 V/1A) Outputs (Relay)
Fuel Consumption: 1,433-3,964 Cubic feet/day of gas heat value from 751 BTU/cuft to 3,382 BTU/cuft wellhead gas Note: capable of burning up to 1,000 PPM H2S
Additional heat available: 2.5 to 3.5 x power output available as hot glycol for heat tracing
Dimensions, weight, foundation requirements: 69.4" Long x 28.1 Wide x 57.2 High (Note HRU/radiator can be mounted remotely from engine/generator) 866 lbs dry weight concrete pad foundation: 3' x 6' on tamped gravel base
Certifications for both units ETL C and US UL 2200 CSA C22.2#100/C22.2#14 ISO 9001.2015 (target certification: 2018)
For more detailed information and links to case studies and actual user applications, go to: http://remotepowergen.com/
CAP3-NanoLTS air package will operate under the following technical specifications: • Redundant Air Compressors • Integrated Air Dryer with over 25 deg C dew point suppression • Air available to site: Up to 3 scfm @ Up to 140 PSI. Higher air flows available at lower pressures. • Auxiliary AC Power: up to 3000 W at 240 or 120 VAC at a continuous flow rate of 3 scfm. • If using Glycol Heat Trace (GHT) module, available power will be reduced.
CAP3-NanoLTS air package will consist of the following: • Footprint CAP3-NanoLTS: 28"W x 28"L x 61"H @ 450 Lbs • Electric heater • Exhaust fan • Dryer Type: Desiccant Heatless - Regenerative • 2 Gallon Air Tank • Dry tank system • Supplied with transfer switch for external back-up power • Flow monitoring and summary directly to the HMI display • Micro PLC / 7" HMI with UV rated Cover • Flow monitoring and summary directly to the HMI display • Modbus communication
Electrical Supply & Install • Connection of Simplex IA Package Power • Connection of 5.6 kW Generator 240V/120V • Compressor Distribution panel c/w 7" HMI • Transfer switch for an external backup generator • 2 x Oil-less low maintenance Air Compressor • 1x Filter/Dryers
PowerGen Sweet Gas Conditioning Unit (GCU) Ideal for sweet fuel gas applications. Unit includes electric heat tracing insulation blanket HLSD LSH to send SmartView warning to assigned operators LSHH to shut unit down prior to flooding fuel gas train (regulator, mixing valve, blower)
Designed for use with the entire PowerGen Remote Power products line. It is designed to protect this highly reliable remote power system from entrained liquids in the gas stream. The GCU allows for liquid and solid contaminates to be removed from the inlet fuel line before entering the PowerGen's fuel delivery system. The GCU features 2 liquid level sensors that will indicate when liquids are present and ultimately, shut in the PowerGen fuel system if liquid levels exceed the GCU capacity. The GCU also employs the use of electric heat trace, powered by the PowerGen, to install at any pressure drop locations upstream of the PowerGen. This will reduce the chance of liquids freezing and condensing within the fuel delivery line.
Benefits: Max. Pressure of 100 psi 1/2" NPT inlet ASME/ CRN certified 3 USG capacity 40' of heat trace supplied Remote monitoring ready Manual 1/2" drain Supports MODBUS TCP/IP monitoring Operable at -40 deg. C Factory installed, or field retrofit capable Mounts to PowerGen cabinet by gas inlet connection, does not require additional foundation
Qnergy - Compressed Air Pneumatics Skid Package including PowerGen 5650 (-40 deg C)
The CAP3-M skid air package for pneumatic operation at wellpads and production facilities. CAP3 is the most reliable solution in the marketplace. Coupled with the 100% duty-rated PowerGen, the Stirling based generator provides continuous power (24/7/365) to all electrical components included in this skid package. We are confident the CAP3-M skid air package provides reliable Instrument Air for Pneumatics as well as power for your specific loads.
1. GENERAL INFORMATION - CAP3-M Pneumatic devices vent spent gas directly into the air reducing the clean fuel advantages natural gas offers. The Compressed Air Pneumatics (CAP3-M) skid package is designed for rugged and remote operation in any climate condition, from desert to tundra to mountaintop. The low-maintenance CAP3-M system combusts the normally-vented methane at much greater efficiency than any internal combustion engine, while economically providing reliable electric power and clean dry instrument air for pneumatic devices. The CAP3-M skid is built around the PowerGen working seamlessly with a range of fuel supplies, including; natural gas, Propane, Ethane or associated gas streams. The CAP3-M skid package is built to meet strict quality standards. The integrated components and controls are all designed to maximize the customer's ability to control and monitor their skid air package while minimizing maintenance and monitoring related site visits.
2. COMPRESSED AIR PNEUMATICS SKID (CAP3-M) 2.1. Technical Information The CAP3-M skid air package will operate under the following technical specifications: • Oil-less, low maintenance Duplex Air Compressor • Integrated Air Dryer with over 25 deg C dew point suppression • Air available to customer: Continuous 11 scfm @100 psi • Auxiliary AC Power: 1000 W / 240 VAC at a flow rate of 11 scfm @100 PSI NOTE: If less air is used, the system will have more power available.
2.2. CAP3-M Skid Package CAP3-M package will consist of the following: • Skid: 42" x 86" c/w checker plate floor & (2) rail extension for installation of the Qnergy unit and separator. • Enclosure Type: Fiberglass with stainless steel hardware (147" H x 70.7" L x 65.25" W) • Insulation: 2" R14 PU Foam • Doors: 2 only double access doors in front for service. • Ventilation: Gravity louver with rain hood, bug screen • Heater: 1000-watt c/w thermostat • Exhaust fan: 524 cfm with thermostat • Dryer Type: Desiccant • 80 Gallon Air Tank • 2nd VFD (dedicated to second compressor head) • Line Reactors to protect system (2nd VFD) • Package flow meter c/w summary display for volume of air produced in operation • Transfer switch inside of HMI control panel • Flow monitoring and summary directly to the HMI display • Modbus communication to the HMI
2.3. ELECTRICAL SUPPLY AND INSTALL (Doghouse) • Connection of Duplex IA Package Power • Connection of 5.6 kW Generator 120V/240V • Connection of 120VAC Exhaust Fan • Transfer switch for an external backup generator • NEMA 4 Compressor Distribution panel c/w 5.7" HMI Heater • Oil-less low maintenance Duplex Air Compressor • Filter/Dryers • Dual 10 HP 230 VAC VFD c/w 3% Line Reactor • All RA Conduit and Wire • All Electrical Lamacoids • SmartView Remote Monitoring Package • Distribution Panel (heated) has space available (bottom) for: up to four x 120 AH AGM batteries and 24VDC rectifier/charger - Included
2.4. PNEUMATICS • Cabinet package compressed air lines all in braided hydraulic hose for temperature and weathering protection • Fuel Gas Scrubber: Qnergy Gas Conditioning Unit (GCU) protects against liquids in gas inlet
• 120 VAC Heat Trace Power Kit
• 120 VAC Heat Trace End Kit
• All 5W/Ft 120VAC heat trace
3. POWERGEN - PG5650 Max. Output Power 5.6 kW Max. Fuel Consumption (Natural Gas) 112 cubic m/day (3,964 cu.ft/day) Max. Fuel Consumption (Propane) 166 l/day (44 Gal./day) Generator Design Life 10 - 15 Years Fuel Type Gaseous Fuels: Natural Gas, LPG,Propane, Wellhead Gas Area Classification General Purpose - (Non-Hazardous) Fuel Pressure Range 3 - 50 PSI (Natural Gas) 2-10 PSI (Propane) Ambient Temperature Operation -40 deg C to 50 deg C (-40 deg F to 122 deg F) Cabinet Electrical Rating IP54 Electrical Configurations 120 / 240 VAC Split Phase Output A:120 VAC 60Hz Output B:120 VAC 60Hz 3 Wire: L1, L2 & Common/Neutral Electrical Configuration "B" 120 / 240 VAC 2 Phase Output A:120 VAC 60Hz Output B:240 VAC 60Hz 3 Wire: L1, L2 & Common/Neutral Certification cETLus (UL2200) (CSA C22.2#100/C22.2#14)e3w Dry Weight 392 kg (866 lbs)
3.1. POWERGEN -COOLING SYSTEM The PowerGen cooling system is designed to reject remaining unused cycle heat from the PowerGen in a reliable and controlled manner. With two highly reliable sequentially operated fans, it has built-in redundancy as well as a robust industrial grade radiator. The cooling hardware couples with the PowerGen heat management system to not only stabilize the generator at its optimal operating temperature but also make heat available to an onsite heat application, such as the Qnergy Glycol Heat Trace module. OilPro also offers a mini line heater option should that be of interest.
3.2. POWERGEN - COMMUNICATIONS The PowerGen configuration integrates on-board ModBus serial interface as well as set of discrete signals in dry-contacts form. Both serial and discrete interfaces can be wired to onsite SCADA or with communication devices connected to control/monitoring systems through local internet, cellular or satellite transmitters.
*The following signals have been provided as set of discrete signals: CONTROL SIGNALS: • START / STOP - the signal depend on state starts or stops the generator. - To comply to fail safe requirement the open contacts (circuitry) acts as "stop" • LOAD DISCONNECT - the signal controls the actual physical connection of the Power output. - The open contacts of the signal circuitry lead to output power contactor to disconnect the generator output as well as the generator system battery from customer loads.
MONITORING SIGNALS: • ON - the signal reflects if the generator is up and running • FAULT - the signal reflects if the generator is faulty • OUT OF FUEL - the signal reflects that the generator is available, but no fuel is present at inlet of the generator fuel port • POWER AVAILABLE - the generator is up and running developing required power regardless if customer load is connected • LOAD DISCONNECTED - the signal reflects if the power contactor is open regardless of state of the generator • FAIL TO IGNITE - the signal reflects if the start attempt was successful or if combustion/ignition components are healthy • FLAME OUT - the signal reflects if there was unexpected loss of combustion. All signals described above as well as many more are available through Serial Interface (MOD bus) as well (the complete list and address table are available separately).
3.3. POWERGEN - MAINTENANCE REQUIREMENTS OilPro-supplied PowerGen Stirling Generator systems are designed to operate continuously without interruption for 12-month periods over the life span of the generator. Continued safe and efficient operation of the PowerGen is ensured with an annual inspection made by a trained service technician who will verify that air filter and cooling system are functioning as designed. The annual recommended inspection will take approximately one (1) hour at site per year.
3.4. POWERGEN - CONSTRUCTION AND PROTECTION The PowerGen enclosure is designed for outdoor, unsheltered operation. The standard enclosure is manufactured of Carbon Steel and it is powder coated.
3.5. STOCK DRAWINGS, CERTIFICATION AND DOCUMENTATION included with OilPro's standard Document Control package (as described in our Terms and Conditions below), we provide: • General Arrangement Drawing • P&ID Drawing • O&M Manuals • Electric Block Diagram • Vessel U1a form • SPE-1000 inspection and approval • CSA certification Loading, offloading on site and external piping and electrical interconnections from skid provided by others.
Insulation blanket for 6"OD x 30" OAL Fuel Gas Scrubber Teflon cloth 16.5 Oz. Fiberglass insulation Stainless steel pins, washers, and "D" rings Kevlar thread. Comes with cut outs forlet, outlet, drain and nameplate[…]
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 approximate 500W without insulation. C.W.: Cutouts for gauge glass, fill connection, outlet. Includes indicators for fill, high and low glycol levels. Designed to provide additional heat retention for the PowerGen GHT module. Construction: - 1/2" Insulation - Silicone impregnated fiberglass as outer cover and inner layer - Silicone straps with hook and loop fastening system - Sewn construction Overall blanket temperature rating: -58%u00B0 F to 200%u00B0 F - Blanket is designed for ambient temperature of -40%u00B0 C
Glycol Heat Trace Module for PowerGen.
Over 50,000 BTU/hr of heat available
No external power supply required
User selectable return temperature
Ultra-reliable rotary vane circulating pumpdent glycol reservoir
full monitoring and control
ideal for remote locations with fuel gas delivery challenges.[…]
Glycol Heat Trace Module for PowerGen. 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 ideal for remote locations with fuel gas delivery challenges.
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 vste 500W without insulation. C.W.: Cutouts for gauge glass, fill connection, outlet. Includes indicators for fill, high and low glycol levels. Designed to provide additional heat retention for the PowerGen GHT module. Construction: - 1/2" Insulation - Silicone impregnated fiberglass as outer cover and inner layer - Silicone straps with hook and loop fastening system - Sewn construction - Nomex Velcro on long seam sewn into blanket edge, 2nd part to be glued to frame/body with high temp glue. Overall blanket temperature rating: -58%u00B0 F to 200%u00B0 F - Blanket is designed for ambient temperature of -40%u00B0 C
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 approximate 500W without insulation. C.W.: Cutouts for gauge glass, fill connection, outlet. Includes indicators for fill, high and low glycol levels. Designed to provide additional heat retention for the PowerGen GHT module. Construction: - 1/2" Insulation - Silicone impregnated fiberglass as outer cover and inner layer - Silicone straps with hook and loop fastening system - Sewn construction Overall blanket temperature rating: -58%u00B0 F to 200%u00B0 F - Blanket is designed for ambient temperature of -40%u00B0 C
Glycol Heat Trace Module for PowerGen.
Supplied with Factory Blanket
Over 50,000 BTU/hr of heat available
No external power supply required
User selectable return temperatureable rotary vane circulating pump
Independent glycol reservoir
full monitoring and control
ideal for remote locations with fuel gas delivery challenges.[…]
Glycol Heat Trace Module for PowerGen. 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 ideal for remote locations with fuel gas delivery challenges.
