An industrial generator is a must-have for any factory, hospital, school, or corporate organization that intends to operate without interruption. The need for constant standby power in some industries cannot be ignored because it promotes a sense of safety and security, which can, in turn, boost work efficiency, cost efficiency, and productivity.
In the following sections, we provide a thorough breakdown of industrial generators, the various individual benefits of generator rentals and purchases, and finally, when to rent vs when to buy an industrial generator.
What Purpose Do Industrial Generators Serve?
Industrial generators are reliable and durable pieces of machinery. Unrivaled in its ability to supply constant energy, an industrial generator can provide power over long distances and is recommended for use in sectors that require constant or standby power supply.
Sectors such as health care, technology, information, communication, manufacturing, and agriculture (among many others), are all vulnerable in the area of power. A power outage in one of these types of facilities could result in substantial harm, including production losses, data and information loss, and even serious accidents.
In recognition of these dangers, and in accordance with legal norms and production parameters, 24/7 Compression partnered with Belair Power and Production Equipment. This collaboration helps to provide custom industrial power generator packages that come with a unique in-house design, structural fabrication, electrical & mechanical assembly, and a reliable control panel.
Factors to Consider When Selecting an Industrial Generator
You might be wondering, “how do I choose an industrial generator, and what factors should I consider when doing so?” Rest assured; we are here to answer all your questions.
Industrial Generator Size and Power
You need to first determine the ideal generator size and power output for your business requirements before you even begin looking for an industrial generator.
Industrial Generator Type
Next, you’ll want to determine which type of generator will suit your needs. Types include a closed set, with weather and soundproof canopy, and open sets, which come without the canopy.
Industrial Generator Function
The industrial generator's exact purpose should be carefully determined and agreed upon before rental or purchase is made. This is to ensure it efficiently serves that purpose.
Industrial Generator Brand
Most people prefer to avoid unknown industrial generator brands and go with the most reputable ones. Therefore, you should speak with a power generation expert to get informed recommendations on the top sellers in the industry.
Industrial Generator Pricing
We understand that the acquisition of an industrial generator or even a commercial generator can be quite costly. So, at this point, you could consider renting an industrial generator rather than buying one, especially if you don’t require it long-term.
Benefits of Industrial Generator Rental
From cost savings to not having to worry about maintenance, there is a long list of benefits when it comes to renting a generator. Here are the major advantages of industrial generator rentals:
- On short notice, you can quickly acquire an industrial generator that’s immediately prepped and ready for use
- With industrial generator rental, you minimize cost and maximize efficiency while saving money in the process (with reduced cost of maintenance, servicing, and installation)
- Renting an industrial generator is perfect for short-term events or projects that require the need for backup and standby power
- When renting an industrial generator from a reliable source, you can rest assured knowing your generators are properly tested, certified, and well maintained
- You aren’t required to pay for insurance or a warranty on a rented generator. The renter covers that.
Benefits of Purchasing an Industrial Generator
We’ve been asked the question, “How much does an industrial generator cost?” countless times. The answer? It varies; however, purchasing, running, and upkeeping an industrial generator can be a costly investment.
Unfortunately, most people avoid the option of purchasing an industrial generator simply because of the cost. However, buying an industrial generator could be one of the best decisions you make for your company and here’s why:
- It is your personally owned asset
- Buying an industrial generator assures you of a reliable source of continuous and stable power.
- It completely eliminates downtime and extends runtime
- It can come in handy during storms, power outages, and other emergencies
- Unlike industrial gas generators, a purchased diesel generator provides more power with a smaller engine. Also, it is the safer option, has quieter motors, and is highly efficient.
When to Rent vs When to Buy
When deciding to rent an industrial generator, many factors play a key role in the final decision. First, however, you also need to determine the following:
How Often Do You Need Backup Power?
If you’re a production business owner, it’s safe to say that you need an uninterrupted power supply to ensure smooth operations. Buying would be the better option in this scenario.
Can you Cover Maintenance and Repair Costs?
Even after paying a steep purchase price, you will need to periodically conduct maintenance and repairs. Depending on fund availability, the rental option may be better for your business.
Where is your Business Located?
Physical location is also important. Transporting a generator to remote areas can be problematic due to terrain and distance. However, a generator may be your only option if you’re off the grid. If the location is extremely remote, buying a backup industrial generator and installing it on-site is a more viable option than renting.
Get Expert Advice
With 24/7 Compression and Belair Power as your trusted industrial generator supplier, you can look forward to uninterrupted power, whether you rent or buy. Our synchronized custom packages, along with our in-depth equipment knowledge, expertise, and know-how, ensure you find the perfect fit for your business or project needs.
Contact us today, and let us build a power generation package specifically designed for you.
Is the compressor station on your site functioning less than optimally? If so, you can rest assured, knowing you likely won’t require a whole new system. Many common troubles with natural gas compressors can be solved with a quick fix, clean or part replacement.
Compression systems consist of extremely expensive equipment and technology. By keeping your site’s gas compressors in good condition, you’ll improve operation efficiency and reduce downtime so you can get the most out of your investment.
Below, we outline the basics of natural gas compression as well as how to perform compression repairs so you can ensure your operations run as smoothly and efficiently as possible.
How Gas Compressors Work
A natural gas compressor station is a vital component of a gas processing facility. Typically located every 60-100 km along a pipeline, compression stations ensure methane (natural gas) can move efficiently through pipelines to end-users. In addition, compressing cooled methane is the safest way to transport it.
The first step of natural gas compression is the scrubbing process. Scrubbing removes solid, liquid and gaseous impurities from the methane before it becomes pressurized.
The purified gas then travels through yard piping to the compression stations, where computers monitor and regulate the gas flow and increase its pressure by reducing its volume. Once full operational pressure is achieved, the natural gas is released into the pipeline.
Common Issues With Compression Systems
Like all processing systems with multiple moving parts, compression stations require regular maintenance and upkeep to run smoothly. However, sometimes basic servicing isn’t enough, and parts can fail. Below, we discuss common issues with methane compression systems to help you troubleshoot any problems you may be experiencing with your system.
Valve Failures
If your system has shut down unexpectedly, this may be due to a valve failure. Compressor stations have various safety systems in place to protect both workers and the public. These systems include emergency shutdown devices that prevent gas from leaking along with other dangerous situations.
Often, a shutdown is caused by a defective valve. Valve springs can become worn, preventing the valve from operating properly and leading to malfunctions in the compression system.
Fluid Leaks
Methane is a highly flammable gas but is virtually undetectable due to being colourless and odourless. Therefore, methane leaks are extremely hazardous and may trigger a shutdown.
Excessive Noise
Even under normal operating conditions, gas compressors are a significant source of industrial noise. However, if your system becomes more noisy than usual or exhibits unusual sounds, this may be a sign that something is critically wrong within the system.
The cause of excessive noise could be as simple as particle build-up on plates, which is easy to fix, or it may be due to a cracked damper plate.
Damper plates are designed to dampen the noise from vibrations in the system. Since these plates are under constant mechanical stress, they are prone to breaking and require frequent replacement.
Not Building Pressure
Properly pressurizing natural gas is crucial for efficient fluid flow. If you aren’t reaching the desired gas pressure, or if it is taking an excessive amount of time to achieve your operational pressure, you should check your valves and seals. Leaks within your system can lead to significant operational inefficiencies, leading to more money lost in the long run.
How to Repair a Natural Gas Compressor
So, can a faulty gas compressor be repaired? In most cases, repairs are simple and to be expected; otherwise, you may need to replace various parts and components. If problems with your gas compressor persist beyond simple repairs, then it may be time to call in an expert technician to assess your system and determine whether your devices are beyond repair or not.
This section outlines some common and simple repairs you can perform to ensure your compressor runs as smoothly as possible.
Replace Consumable Parts
Gaskets, belts, valve plates, and similar parts are prone to cracking, warping and breaking apart since they are subjected to continuous movement and vibrations. Ensure these components are replaced regularly and assess your system frequently to avoid extended downtime if they fail before expected.
Check for Corrosion
If you’re noticing corrosion or warping on any parts within your machine, this should be dealt with as swiftly as possible. In general, corrosion should be minimal; therefore, it may mean the wrong materials are being used in certain areas of the system. Consult with a specialist if you suspect there are unsuitable materials being used in your system.
Clean Pistons
Dirty pistons and valve plates can contribute to excessive noise in the system. Removing and cleaning these parts is generally a simple enough task to keep your machine running smoother for longer.
Check Valve Plates and Seals
Valve plates are notorious for causing problems in gas compressors. Warped or damaged valve plates can lead to leaks in the system as well as failures to reach the desired operational pressure. Ensure valve plates and seals are functioning optimally by inspecting them thoroughly whenever a leak or malfunction is suspected.
Contact a Professional
If a gas compressor repair appears too great for your team to handle, it’s best to contact a compressor maintenance professional to assess your system and potentially make extensive repairs. On the other hand, if your site’s equipment is old and inefficient, it may be best to purchase new parts and components for the best operational outcomes.
At 24/7 compression, we have the equipment, experience and know-how to get your gas compression systems running as smoothly as possible. Contact us today to learn more about what we can offer.
There is a growing production and use of natural gas across North America. While this comes with many advantages, it also poses other threats. The environmental impact is at the top of the list of concerns, which calls for gas compression emission management.
Sources of Gas Compression Emissions in the Industrial Sector
Managing your gas compression starts with understanding your compression system. Notably, centrifugal compressors use wet gas seals or dry gas heals. The seals help prevent methane gas or process gas leakage at the points where the shafts and compressor casings meet.
The configuration of gas compressor systems utilizes packing technology to prevent leakage. The packing includes nose cup seals, gaskets, and a stuffing box. However, this is never wholly preventable. Thus, it calls for the need for specific changes in the design of compressors and their blowdown units.
Among the sources of methane and other greenhouse gas compression emissions include:
- The Counter Surface of the Stuffing Box: Over time, the counter surface of the stuffing box will degrade. The degradation is often due to unwanted deposits, corrosion, and minor indentations from previous gaskets. These irregularities will prevent the creation of a tight interface that can prevent leakage.
- Nose Gasket Overuse: Gaskets should plastically deform when put under clamping pressure. This characteristic ensures that gaskets can fill any irregularities between mating services. Overuse reduces the ability of gaskets to deform plastically. The result is that the gasket will fail to fill all the irregularities, leading to gas leakage.
- Misapplication of Gasket: Ideally, copper, aluminum, iron, and stainless steel are among the materials often used for manufacturing gaskets. Each material has unique clamping load, pressure, and process gas specifications. The material used should always be compatible with the application since misapplication could cause leakage.
- Cup-to-Cup Leakage: Finally, defects can cause gas compression emissions between two flat surfaces. Usually, this could be due to clamping force and size disparities.
How to Effectively Manage Compression Gas Emissions
Regardless of the source of leakage of liquid gases in the industrial sector, they are pretty manageable. Among the ways through which you can manage gas compression leakage include;
Reinjection into Turbine Inlets
Controlling carbon emissions from compression units can be expensive and demanding. But a more cost-effective method of burning fugitive gas emissions is to reroute the vents emanating from the dry gas seals into the inlet of your turbine.
Your worry could be about the flammability of the resulting air (oxygen) and methane mixture. Interestingly, this mixture falls below the flammability limits, which could often cause concern.
This emission management method does not require extensive maintenance. However, you may have to improve certain design aspects. The aim is to improve the mixing of intake air with the vented air to maintain low flammability. Of course, this is necessary both when the compressor is in operation and when it is not working.
Reciprocating Compressor Units
An electric reciprocating compressor that recompresses gas emissions is arguably the most widely used emission management method. This method reliably recovers and recaptures greenhouse gases leaked across seals and injects them back into the stream of process gas. Of course, this process happens at the discharge header or station suction.
Apart from injecting this fugitive gas into the process gas stream, it is also possible to directly inject it into the fuel inlet, the electrical generator, or the gas turbine. The fugitive gas is also usable as heating fuel. The size of the reciprocating compressor used in this method is dependent on the flow rate and volume of the emitted gases.
Recompression comes with two benefits. Firstly, it allows for the successful recapturing of emissions caused by station depressurization during planned shutdowns and maintenance activities. Again, recompression is pretty scalable, and a single unit is useable across multiple centrifugal compressors.
Frameless Thermal Oxidizer
Frameless thermal oxidizers will premix methane with auxiliary fuel and ambient air and pass it through a preheated ceramic media bed. The system effectively transfers heat to the gaseous mixture from the media bed.
The high temperature oxidizes the methane in the mixture into carbon dioxide and water. This method requires gas burners or electric heaters to preheat the ceramic media.
Thermal oxidizer units are vital in handling emissions resulting from compressor settle-outs and blowdowns. Besides, media beds used in this method are quite stable and resistant to fluctuations in temperatures. This feature enhances more reliable temperature controls.
Enclosed Vapour Combustion Units
Another interesting method of managing greenhouse emissions from compressor units is through enclosed vapour combustion units. Notably, vapour combustion units use enclosed stacks to collect and burn compression gases. The combustion in these systems happens at the bottom and is completely invisible.
These systems are pretty easy to set up and work flawlessly. They do not require any mechanical devices to help move fugitive gases into the stack inlet. Instead, they naturally draw in the heat generated from the combustive process.
Combustion stacks are can accommodate high temperatures to allow more fugitive gases to burn as they rise in the stacks. Enclosed vapour pressure combustion units work differently. Their burners are not ideal for high-pressure applications. Moreover, their enclosed designs could lead to too much flame on exposure to too much gas. Of course, very intense flames could damage the stuck insulation.
Supersonic Ejector Systems
Ejector systems are devices used for sucking in fugitive gas emissions from primary dry seals. This emission management mechanism does not feature any moving parts. Thus, it requires little or no maintenance.
In this method, the energy created by the motive fluids pressure will convert to velocity energy. The result is the creation of a low-pressure region which will easily capture emitted greenhouse gases. The captured air will mix with ambient air and move through the diffuser. At the diffuser, the air pressure increases while the velocity decreases to recompress the gas effectively.
You can then re-inject the recompressed methane-air mixture for various applications. It is useable in compressor inlets, heater inlets, and fuel system inlets. Unfortunately, you cannot use ejector systems to capture fugitive gas emissions from settle-out or blowdown emissions.
Double Opposed Gas Seals
Double opposed gas seals can also help you manage gas compression emissions. But unlike all the other methods discussed above, this method does not rely on recapturing fugitive gas emissions for combustion or reinjection into the system. Instead, it is a preventive method that ensures that there is no leakage altogether.
The method uses primary and secondary seals in a back-to-back arrangement. The mechanism then supplies inert gas such as nitrogen between the two seals. Any leakage will comprise nitrogen only, which is inert and harmless.
The reliability of this method depends on the consistent availability of sealed nitrogen gas. Again, it is impossible to rely on this method to address methane gas leakage from compressor blowdown.
Putting it All Together
Gas companies across the supply chain are under intense pressure to reduce the emission of greenhouse gas into the environment. Of course, the pressure and concerns are pretty much in order. Natural gas compressor stations are responsible for a sizeable amount of the emissions. Focus now shifts from reducing emissions from combustion processes to cutting down gas compression emissions. The above technologies are very helpful.
There hasn't been a better time to upgrade, especially if you're looking to reduce your carbon footprint! 24/7 Compression is your solution. Contact us today, and we'll help you reduce your greenhouse emissions in no time!