Flare-to-power intelligence across the monitored fleet
AI-derived score combining gas conditioning quality, generator availability, and power output vs. rated capacity across all monitored packages.
System Health
Across Flare Gas Conditioning Train™ (FGCT) stages, NovaStar generator modules, and switchgear. Submetric detail lives in the operational dashboard.
YTD Value & ROI
Four value streams tracked: flare gas monetized, diesel and grid power avoided, emissions and carbon credit value, and avoided unplanned downtime.
Financial values are estimates based on available operational data and customer-configured assumptions.
Flare Reduction & Value Recovered
Flaring wastes energy, increases emissions, and creates regulatory exposure — this system converts that liability into a controlled, usable energy source.
Flare-to-power efficiency is 6% below optimal capacity. The H2S removal bed on KPS-6 Unit B is approaching breakthrough, Generator Module 3 at Site 2 is showing rising exhaust temperature deviation, and the coalescing filter on the Site 1 conditioning skid has a climbing differential pressure consistent with early fouling.
Top Performance Issues
AI Recommendations
Replace coalescing filter element
Site 1 · Conditioning Skid
Replace H2S media
KPS-6 Unit B · Site 3
Inspect Generator 3 exhaust valves
Site 2 · KPS-4.5
Recalibrate Wobbe index monitoring
Site 3 · KPS-6 / KPS-3
Recommended FlareGuardian Upgrades
Real-Time Gas Composition Analyzer (GC)
Stream live Wobbe index, BTU content, and H2S/CO2 composition instead of periodic spot samples.
Why it matters: Combustion efficiency predictions currently rely on daily lab samples.
Benefit: Real-time fuel quality correlation with generator derating events.
Generator Vibration & Exhaust Monitoring
Per-cylinder exhaust temp + vibration sensors on each NovaStar generator module.
Why it matters: Today's diagnostics infer engine health from aggregate runtime and availability only.
Benefit: 2–3 weeks earlier warning on mechanical failures.
Methane & Emissions Telemetry
Add flare-stack and fugitive methane monitoring to the same asset model.
Why it matters: Emissions data currently lives outside FlareGuardian and isn't tied to conditioning-skid performance.
Benefit: Single compliance view + early leak detection tied to equipment degradation.
CMMS / Maintenance History Integration
Ingest work orders and parts consumption.
Why it matters: Failure-signature matching currently has no repair-outcome data attached.
Benefit: Higher-confidence predictions grounded in real repair costs.
FlareGuardian Add-On Bots
Flare-to-Power Revenue Bot
Tracks MCFD flared-gas converted to MWh generated, priced against live power/fuel offset rates, by day/week/month/YTD.
Emissions & Carbon Credit Bot
Quantifies avoided flaring volume as CO2e reduced and estimates carbon-credit/regulatory value.
Generator Fleet Benchmarking Bot
Compares identical NovaStar generator modules across all sites/packages to flag units drifting from peer performance, not just their own history.
Fuel Gas Quality Bot
Predicts conditioning-skid maintenance timing from H2S, moisture, particulate, and Wobbe index trends before they breach generator OEM fuel specs.
FGCT Fuel Quality Bot
Continuously trends Wobbe index and contaminant carryover against generator wear indicators — turning KenTech's oversized-conditioning claim into a measurable, provable generator-life extension metric versus minimal-filtration competitors.
Executive sales pilot · explore the process twin to see the live site schematic.