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Caterpillar G3500 Lean-Burn Upgrade Guide

This document summarizes Caterpillar's Ultra-Lean-Burn engine upgrade for existing lean-burn engines. The upgrade lowers NOx emissions to 0.5 g/bhp-hr without aftertreatment, improves fuel efficiency and altitude/temperature performance, and extends the life of existing engine assets. It involves major component upgrades like new heads, pistons, air systems and has been in field validation since 2008 with over 8,100 hours of successful operation. The upgrade provides a new standard for Caterpillar G3500 engine performance while meeting EPA emissions regulations.

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Esau Jose Pablo
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335 views11 pages

Caterpillar G3500 Lean-Burn Upgrade Guide

This document summarizes Caterpillar's Ultra-Lean-Burn engine upgrade for existing lean-burn engines. The upgrade lowers NOx emissions to 0.5 g/bhp-hr without aftertreatment, improves fuel efficiency and altitude/temperature performance, and extends the life of existing engine assets. It involves major component upgrades like new heads, pistons, air systems and has been in field validation since 2008 with over 8,100 hours of successful operation. The upgrade provides a new standard for Caterpillar G3500 engine performance while meeting EPA emissions regulations.

Uploaded by

Esau Jose Pablo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Caterpillar Confidential: Green

Upgrade existing lean-burn engines


to Ultra-Lean-Burn configuration
Lower heat rejection for improved
compatibility with existing skids
Extends the useful life of existing
assets in a world of changing regulations
Major upgrade - includes heads, pistons, air system, and more
(schedule with a planned overhaul for best economy)

Caterpillar Confidential: Green


!"
# $ % &'( (
G3516B w/ ULB
Current Technology

NOx Emissions (g/bhp-hr NTE) 2 1 0.5


Performance w/o hp
de-rate @ 100 F Altitude 1,800' 6,000' 4,000'

Turndown 25% 25% 25%


Performance w/ hp de-
rate @ 100 F, 8,000’ De-rate 24% 15% 25%

Turndown 25% 25% 25%


Caterpillar Confidential: Green
g g
Settin Settin
gN Ox BSFC gN Ox BSFC
0.5 ieved p -hr 1
hi eved hp-hr
h bh Ac b
Ac BTU/ B TU/
0 0
740 715
Lean
Misfire
Limit
Current G3500

G3500B w/ ULB Technology 8%

Caterpillar Confidential: Green


# "
Compressor Bypass
Actuator and Lines Gp Fuel Mass Actuator
Lower Restriction Air Cleaners
Integrated Speed Control

Dry Exhaust Manifolds

Water Manifolds with Dry


Exhaust
2 Stage Stainless Steel Aftercooler
NOx Larger Turbo Inlet SCAC
Sensor Turbos Air Lines Aftercooler Lines
Caterpillar Confidential: Green
')* ( "
NOx Emissions Level Variation
O2 Sensor 2 g NOx/bhp-hr
(Not to Exceed)

-93% +111%
(0.1 g) (3.2 g)

NOx Sensor
-20% +20%
(1.2 g) (1.8 g)

1.5 g NOx
In production since July 2007
(Nominal)
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1400 rpm – 0.5 g NTE NOx 1400 rpm – 1.0 g NTE NOx*
Rating 1380 bhp 1380 bhp

Fuel 7400 Btu/bhp-hr 7150 Btu/bhp-hr


Consumption
Power Density 13.4 lb/hp 13.4 lb/hp

Emissions 0.5 g/bhp-hr 1.0 g/bhp-hr


(NTE NOx)

* Performance data for the 1.0 g NOx NTE rating is preliminary.

Caterpillar Confidential: Green


+ "+ "
$ "" ", "- ')* .

Meets 0.5 g NOx Requirements


through Engine Solution

Meets or beats NOx requirements


w/o NOx Exhaust Aftertreatment

Lowers Heat Rejection

Reduces Owning and Maintenance


Costs over Life of Engine
Caterpillar Confidential: Green
(

Builds upon G3516 LE Proven Reliability and Durability


New Standard for G3500 Performance
– Better fuel efficiency, altitude, turndown, and ambient capability
Meets & Beats U.S. EPA SI Stationary NSPS Emissions (2010)
– Lowest lean burn emissions while maintaining expected startability,
stable load acceptance and heat rejection
– 0.5 g/bhp-hr NOx
Higher Fuel Efficiency
– Lower carbon footprint
– Lower operating cost
Caterpillar Confidential: Green
/ 0

0.5 g NOx / bhp-hr field-validation began in 3Q 2008


Five running in Barnett Shale with 8100 hrs to date

Caterpillar Confidential: Green


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, “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.

(2/09) 2009 Caterpillar


All rights reserved.

Caterpillar Confidential: Green

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