Caterpillar Natural Gas Compression Engines Library Section

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
G3600 Family
Bore x Stroke: 300 x 300 mm (11.8 x 11.8 in)

G3606:
1775 - 1895 bhp
G3612:
3550 - 3785 bhp
G3608:
2370 - 2520 bhp
G3616:
4735 - 5045 bhp
G3600 Family Slides

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
TPS57 vs. VTC254 Turbo

Durability
TPS57 Turbo is now standard on all G3600 engines
New TPS design is radial exhaust flow, weight is centered and
its less likely to have build up on blades
Benefit - Improved turbo life for increased uptime
VTC vs
TPS
Turbos
G3600 Fuel System

Fuel/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
G3600 Hp Range
5500
5000
G3606 LE 32C
4500
G3606 LE 54C
Hp
4000
G3608 LE 32C
3500
G3608 LE 54C
G3612 LE 32C
3000
G3612 LE 54C
2500
G3616 LE 32C
2000
G3616 LE 54C
1500
1000
1000 rpm
900 rpm
800 rpm
750 rpm
Ariel & Cat 1000 RPM Matchup
JGC/2-1000 RPM
JGK/4-1000 RPM
JGZ/2-1000 RPM
JGB/2-1000 RPM
JGK/6-1000 RPM
G3606
JGC/4-1000 RPM
JGZ/4-1000 RPM
G3608
JGB/4-1000 RPM
JGC/6-1000 RPM
G3612
JGZ/6-1000 RPM
JGB/6-1000 RPM
G3616
0
1000
2000
50% to 85% Rated Engine HP

85% to 100% Rated Engine
3000
4000
5000
BHP
6000
7000
70% to 100% Rated Comp HP

50% to 70% Rated Comp HP
8000
9000
G3606 @ 1895 hp
High Altitude Capability (0 - 12,000) ft
Altitude Derate Factors
Derate Factor
110%
100%
90%
120 F
80%
90 F
70%
60 F
60%
50%
0
2000
4000
6000
8000
Altitude (ft)
10000
12000
G3606 @ 1895 hp
G3606 @ 1895 hp
25% Speed turndown @ constant torque
G3608 @ 2520 hp
Derate Factor
110%
100%
90%
120 F
80%
90 F
70%
60 F
60%
50%
0
2000
4000
6000
8000
Altitude (ft)
10000
12000
G3608 @ 2520 hp
G3608 @ 2520 hp
G3612 @ 3785 hp
Derate Factor
110%
100%
90%
120 F
80%
90 F
70%
60 F
60%
50%
0
2000
4000
6000
8000
Altitude (ft)
10000
12000
G3612 @ 3785 hp
G3612 @ 3785 hp
G3616 @ 5045 hp
Derate Factor
110%
100%
90%
120 F
80%
90 F
70%
60 F
60%
50%
0
2000
4000
6000
8000
Altitude (ft)
10000
12000
G3616 @ 5045 hp
G3616 @ 5045 hp
G3600 Family Slides

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

Easy to Maintain
Benefit
Lower O&O costs
All controlled by one system.
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
G3600 Family Slides

Benefit - low N0x emissions
G3600 Family Slides

Catalyst Option
Engine
Hp
G3606
NOx
NOx w/ CO
Catalyst
CO w/
Catalyst
NMHC NMHC w/
Catalyst
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
G3600 Fuel System Lean Combustion

Fuel-enriched pre-combustion
chamber
centrally located with 8 nozzle holes
Ultra-lean main combustion

chamber
Check Valve
Real-time main chamber

combustion monitoring
Pre-chamber
Spark timing- optimized vs. speed

and load
Best efficiency
Main Chamber
Spark Plug
Benefit - Lower emissions

Takes lower energy to ignite
rich mixture in pre-chamber
Longer spark plug life
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
G3600 Family Slides

Transportable
May move by ground by truck with special permits
ADEM A3 Controls for G3600s
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
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
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
G3600 ADEM A3 Control System
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
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
Sealed customer connectors

eliminate terminal blocks
Cat-standard service tool
connector is common to
other Cat electronics
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 ignition
timing retard)
What does it do?
Protects engine operations and extends life.
ADEM A3 Design Features
Ignition & detonation
wiring in foam-filled rail

Continuous yellow
braid wiring harness
(except for cylinder
head thermocouples)
G3600
G3600 Family Slides

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
Air/Fuel Ratio Control
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.
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.
G3600 Family Slides
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
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

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Caterpillar Natural Gas Compression Engines Library Section 5 060427.

Feature & Benefits

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Family Slides

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Bore x Stroke: 300 x 300 mm (11.8 x 11.8 in)

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Family Slides

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Family Slides

TPS57 vs. VTC254 Turbo

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Fuel System

admission valve in cylinder air inlet elbow

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Ariel & Cat 1000 RPM Matchup

50% to 85% Rated Engine HP

70% to 100% Rated Comp HP

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Altitude Derate Factors

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Altitude Derate Factors

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Altitude Derate Factors

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Altitude Derate Factors

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Family Slides

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Family Slides

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Oil & Coolant

Segmented camshaft Ease of service

Plug comes in through the side of the head

Benefit - Easier Serviceability = Lower

Pressurized cooling system

Helps prevent cavitation

Reduces risk of boiling

Excellent top end life

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Family Slides

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Family Slides

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Fuel System Lean Combustion

Ultra-lean main combustion

Real-time main chamber

Spark timing- optimized vs. speed

Benefit - Lower emissions

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Combustion Probe

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

G3600 Family Slides