Used & New Caterpillar and MTU Marine Diesel Engines - October 2012
Caterpillar Natural Gas Compression Engines Library Section .ppt
Transcript of Caterpillar Natural Gas Compression Engines Library Section .ppt
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Feature & Benefits G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3600 Family Slides Reliability Durability Flexibility of Application Easy to Package Easy to Maintain Emissions Capability Transportable
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3600 Family G3606:
1775 - 1895 bhp
G3608: 2370 - 2520 bhp
Bore x Stroke: 300 x 300 mm (11.8 x 11.8 in) G3612:
3550 - 3785 bhp
G3616: 4735 - 5045 bhp
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Reliability
Caterpillar ADEM A3 control system with detonation-sensitive timing control for individual cylinders
Robust diesel strength design provides prolonged life and lower owning and operating costs.
G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
TPS57 vs. VTC254 Turbo
TPS57 Turbo is now standard on all G3600 engines New TPS design is radial exhaust flow, weight is centered
and it’s less likely to have build up on blades Benefit - Improved turbo life for increased uptime
Durability
G3600 Family Slides
VTC vs TPS
Turbos
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Flexibility of Application
G3600 Fuel SystemFuel/Air Mixing
Main chamber fuel supplied through gas admission valve in cylinder air inlet elbow
Electronic fuel metering – Throttle plate on the fuel line - control of
fuel supply pressure relative to inlet air pressure
Benefit Speed/load control = stable + responsive
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3600 Hp Range
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
1000 rpm 900 rpm 800 rpm 750 rpm
Hp
G3606 LE 32C G3606 LE 54CG3608 LE 32CG3608 LE 54CG3612 LE 32CG3612 LE 54CG3616 LE 32CG3616 LE 54C
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.pptAriel & Cat 1000 RPM Matchup
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
G3616
JGB/6-1000 RPM
JGZ/6-1000 RPM
G3612
JGC/6-1000 RPM
JGB/4-1000 RPM
G3608
JGZ/4-1000 RPM
JGC/4-1000 RPM
G3606
JGK/6-1000 RPM
JGB/2-1000 RPM
JGZ/2-1000 RPM
JGK/4-1000 RPM
JGC/2-1000 RPM
BHP85% to 100% Rated Engine
50% to 85% Rated Engine HP
50% to 70% Rated Comp HP
70% to 100% Rated Comp HP
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Altitude Derate Factors
50%
60%
70%
80%
90%
100%
110%
0 2000 4000 6000 8000 10000 12000
Altitude (ft)
Dera
te F
acto
r
120 F90 F60 F
G3606 @ 1895 hpHigh Altitude Capability (0 - 12,000) ft
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3606 @ 1895 hp
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3606 @ 1895 hp25% Speed turndown @ constant torque
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Altitude Derate Factors
50%
60%
70%
80%
90%
100%
110%
0 2000 4000 6000 8000 10000 12000
Altitude (ft)
Dera
te F
acto
r
120 F90 F60 F
G3608 @ 2520 hpHigh Altitude Capability (0 - 12,000) ft
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3608 @ 2520 hp
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3608 @ 2520 hp25% Speed turndown @ constant torque
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Altitude Derate Factors
50%
60%
70%
80%
90%
100%
110%
0 2000 4000 6000 8000 10000 12000
Altitude (ft)
Dera
te F
acto
r
120 F90 F60 F
G3612 @ 3785 hpHigh Altitude Capability (0 - 12,000) ft
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3612 @ 3785 hpFlexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3612 @ 3785 hp25% Speed turndown @ constant torque
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Altitude Derate Factors
50%
60%
70%
80%
90%
100%
110%
0 2000 4000 6000 8000 10000 12000
Altitude (ft)
Dera
te F
acto
r
120 F90 F60 F
G3616 @ 5045 hpHigh Altitude Capability (0 - 12,000) ft
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3616 @ 5045 hpFlexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3616 @ 5045 hp25% Speed turndown @ constant torque
Flexibility of Application
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Easy to Package
Integrated control of ignition, air, and fuel (has four separate control boxes tied into one)Benefit – All controlled by one system.
G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Easy to Maintain
Integrated control of ignition, air, and fuel (has four separate control boxes tied into one)Benefit – – Lower O&O costs– All controlled by one system.
G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3600 Serviceability Crankcase inspection covers
Service ports– Oil & Coolant
Segmented camshaft – Ease of service
Easy spark plug access – Plug comes in through the side of the head– Benefit - Easier Serviceability = Lower
Maintenance Costs
Pressurized cooling system– Helps prevent cavitation– Reduces risk of boiling
Excellent top end life
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Emissions Capability
Integrated control of ignition, air, and fuel (has four separate control boxes tied into one)Benefit - low N0x emissions
G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Engine Hp NOx NOx w/ Catalyst
CO CO w/ Catalyst
NMHC NMHC w/ Catalyst
G3606 1895 .7 .07 2.5 .025 1.53 .153
G3608 2520 .7 .07 2.5 .025 1.48 .148
G3612 3785 .7 .07 2.5 .025 5.6 .056
G3616 5045 .7 .07 2.5 .025 1.48 .148
Catalyst OptionEmissions Capability
G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3600 Fuel System — Lean Combustion
Pre-chamber
Check Valve
Main Chamber
Fuel-enriched pre-combustion chamber
– centrally located with 8 nozzle holes
Ultra-lean main combustion chamber
Real-time main chamber combustion monitoring
Spark timing- optimized vs. speed
and load
– Best efficiency
Benefit - Lower emissions
– Takes lower energy to ignite rich mixture in pre-chamber – Longer spark plug life
Spark Plug
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3600 Combustion Probe Used to measure flame speed
Adjustments to air/fuel ratio made
based on probe readings
Benefit - More efficient fuel use,
helps maintain NOx
Probe
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Transportable
May move by ground by truck with special permits
G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
ADEM A3 Controls for G3600’s
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Control System Standardization – Why? Different control systems used on different engine platforms
– G3600 Caterpillar Ignition System + Engine Supervisory System (ESS)– G3500 Caterpillar Electronic Ignition System (EIS) + Status Control– G3300/G3400 magneto ignition + manual
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Control System Standardization – Why A3? G3600 Engine Supervisory System (ESS) was very complex
– Many components– Hard to troubleshoot– Limited expandability
ADEM A3 control adapted from existing diesel engine system– Fully redeveloped for gas engine specific needs– More modern electronics exploited to simplify system architecture
while expanding system functionality
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Control System Standardization – Why A3? G3600 platform received a performance increase
– Fully integrated system incorporating ignition, governing, and protection in a centralized system
– ADEM A3 migration from diesel product to G3600 well received
G3500 platforms needed more capable controls to drive more advanced ignition and fuel systems
– ADEM A3 system adapted from G3600 platform to give the comprehensive control needed for G3500
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
G3600 ADEM A3 Control System
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Gas Engine Control Module Engine Control Module (ECM) provides
total engine control from one source– Ignition– Governing– Air/fuel ratio control– Start/stop logic & engine protection– Communications (via PL1000 module)– “Flash” programmable software
Compatible With Electronic Technician
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Gas Engine Control Module Mounted in NEMA 4
watertight enclosure Includes door-mounted
E-stop push button Continuous lead ignition
primaries run from module to coil without a break
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Gas Engine Control Module Sealed customer connectors
eliminate terminal blocks Cat-standard service tool
connector is common to other Cat electronics
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Integrated Combustion Sensing Module G3600 & G3520B only One per bank to read thermocouples
& combustion probes Feeds cylinder data directly to ECM Individual cylinder protection from
detonation (independent ignitiontiming retard)
What does it do?– Protects engine operations and extends life.
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
ADEM A3 Design Features Ignition & detonation
wiring in foam-filled rail Continuous yellow
braid wiring harness(except for cylinderhead thermocouples)
G3600
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Air/Fuel Ratio Control– Allow improved control over the Air-Fuel Mixture to regulate the performance limits of
engine such as the detonation limits– To lower overall NOx levels– Automatically maintain NOx emissions– Rich Burn To provide combustion and emission control to allow use of a three-way
catalyst setting– Lean Burn Lower and Constant emissions across speed and load for NOx setting
Active control monitors engine operating parameters to maintain desired air/fuel ratio as conditions change
Effective for a limited range of LHV's
Engine Models Include: G3606, G3608, G3612, G3616
G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Air/Fuel Ratio Control
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Electronic Air/Fuel Ratio Control (AFRC) Caterpillar designed
Low pressure, carburetor fuel mixing
Oxygen sensor feedback
CSA certification (Class I, Division II, Group D)
Closed-loop control designed to regulate emissions that adjusts Air/Fuel Ratio to prevailing conditions to regulate exhaust emissions.
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Electronic Air/Fuel Ratio Control (AFRC) Caterpillar designed
Low pressure, IMPCO carburetor fuel mixing
Oxygen sensor feedback
CSA certification (Class I, Group D, Division II
Closed-loop control designed to regulate emissions that adjusts Air/Fuel Ratio to prevailing conditions to regulate exhaust emissions.
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Lean Burn Design Option Higher BMEP Low Pressure Fuel System High/low CR- leads to better fuel flexibility AFRC allows engine to operate and maintain emissions
control in ambient conditions Detonation Protection
G3600 Family Slides
Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt
Lean Burn Engines Lean Burn
– Reduced Maintenance Costs• Lower combustion temperature results in longer cylinder
head life and exhaust system component life• More detonation tolerance results in longer ring and piston
life • Less oil degradation (less heat, lower NOx and CO, less
contaminants in oil)– Reduced Operating Costs
• Lower fuel consumption (higher efficiency)
Engine Models Include: G3606, G3608, G3612, G3616
G3600 Family Slides