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200 to 18,000HP - Gas , Diesel, Heavy Fuel, Dual Fuel
Technology Update
By Wayne Longer
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2
February 13, 2013
�Next Generation - G3600 Petroleum Gas Engines
– Improved fuel flexibility – Methane Number; Inerts
– Increased power, ambient-based rating capability
– Improved altitude / ambient capability
Four Models: G3616, G3606, G3608, G3612
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3
February 13, 2013
New Turbocharger
• Improved power
• Improved altitude
2 Stage Aftercooler
• Improved power
• Improved fuel tolerance
• Improved altitude
• Improved ambient temps
Cold Compressor Bypass
• Electronically controlled
• Improve turbo management
• Improves ambient/altitude capabilities
NOx Emissions Control
• Closed loop feedback
• Engine mounted NOx Sensor
Next Generation - G3600 Petroleum Gas Engines
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4
February 13, 2013
Air Inlet on outside
New design
Exhaust on inside
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5
February 13, 2013
5
February 13, 2013
Three discrete ratings will be available
• 54 ° C - 0.5 gram/bhp-hr NOx - 5000 bhp
• 43 ° C – 0.5 gram/bhp-hr NOx – 5175 bhp
• 32 ° C – 0.5 gram/bhp-hr NOx – 5350 bhp
Ambient based ratings feature will be available
• ECM output signal available for load management
• Provides continuous operation:
� 54 ° C to 43 ° C ratings
� 54 ° C to 32 ° C ratings
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February 13, 2013
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February 13, 2013
Performance Parameters: unit
Current
Production
G3616
Rated power bhp 4735 5000 5175 5350
Rated speed rpm 1000 1000 1000 1000
Rated BMEP bar 12.5 13.2 13.6 14.1
Full Torque Turndown % 25 25 25 25
NOx emissions g/bhp-hr (NTE) 0.5 0.5 0.5 0.5
SCAC Temp °C 54 54 43 32
Nominal BSFC Btu/bhp-hr 6766 6766 6746 6726
Altitude capability @ 100°F feet 2000 4000 4500 5000
45MN rating factor x 0.76 0.93 0.95 0.97
32MN rating factor x no rating 0.73 0.78 0.83
Fuel LHV range - std iron & maps Btu/scf820 - 1050
SRR up to 1150
Max inert content @ 45MN % 10
Max inert content @ 32 MN % no rating
G3616
Fuel Tolerant
775 - 1400
15
25
105% power
2x Altitude w/o derate
More power @ MN45
More power @ MN32
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Substitute Natural Gas for Diesel
Well ServiceDrilling
Dynamic Gas Blending
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Why Dynamic Gas Blending?
� Low natural gas prices – Save money
� Abundance of natural gas
� Reduce emission
� Opportunity to reduce flaring
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Dynamic Gas Blending Technology
1. Customer connection point
2. Gas Shut Off Valve, Gas
heater, Pressure Regulator
3. Gas Fuel Control Valve
4. Line supplying metered
gas to the intake air stream
5. Integrated Sensor Module (ISM)
Monitors combustion and
communicates data to the
updated Engine Control
Module(*) and controls system to
adjust and protect the engine
6. EMCP 4.4 Control Panel
Engine, Generator, DGB control
Improved display performance including
16 languages, paralleling &
troubleshooting capability
12
34
56
6
Factory Bolt On Solution
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Caterpillar Dynamic Gas Blending
Substitute Nat Gas for Diesel
Capable of 70% substitution
Dynamically adjusts to fuel quality changes
Maintain emissions compliance
NOx, PM and CO within regulated limits
Certified over a range of Lower Heating Value
Maintain diesel performance
Power and Transient Response
Reliability, Durability and Warranty
Maintains Caterpillar product design guidelines
Cat global dealer network support
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Delivering Project Success
Sources:
http://www.apachecorp.com/News/Articles/View_Article.aspx?Article.ItemID=2957
http://www.marketwatch.com/story/halliburton-uses-clean-burning-us-
natural-gas-to-power-a-complete-hydraulic-fracturing-fleet-2013-01-
11?siteid=nbsh
Source:
http://www.cat.com/cda/files/4303040/7/DGB%20OOB%20FINAL.pdf
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Specific Project Details - Drilling
� (3) 3512C 1200rpm 1.1 eMW gensets
– Encana, Colorado 8,200ft altitude, drilling application
– 70 Methane Number field gas
– Previously running aftermarket kits – 20-25% average
substitution
– Improved average substitution to ~40%,
Estimated fuel savings
– $3.30/gal diesel, $3.75/MMBTU field gas + oper costs
– 280 days/year operation, 2 gensets (1 idle)
– $500,000/year estimated annual savings
– >45% net fuel cost savings
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DGB - Savings
Potential Fuel Savings - Caterpillar Dynamic Gas
Blending System
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
$1,400,000
$1,600,000
0 25 50 75 100
% Engine Load
Po
ss
ible
An
nu
al F
ue
l S
av
ing
s Aftermarket - 30%
Aftermarket - 50%
Cat DGB - 70%$170k per year
Advantage
* Estimation based on $4.00/MMBTU of gas, $4.00/gal of diesel,
engines running 16 hours/day.
70% substitution rate
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Information contained in this publication may be considered
confidential.Discretion is recommended when distributing.
Materials and specifications are subject to change without
notice.CAT, CATERPILLAR, their respective logos, ADEM, “Caterpillar
Yellow” and the “Power Edge” trade dress, as well as corporate
and product identity used herein, are trademarks of Caterpillar
and may not be used without permission.
LESW0023-00 (11/09) 2009 CaterpillarAll rights reserved.
catoilandgas.cat.com
