cat dynamic gas blending technology
Post on 16-Apr-2017
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Dynamic Gas Blending What is it?
A way to use two fuels simultaneously in a power application
Why is it important to our customers?
Savings ↑
Regulated Emissions
What is Caterpillar’s competitive advantage?
Superior substitution and more tolerant of low quality gas
Emissions Certification*
Factory warranty with more coverage
*Applicable to U.S. kits
Why Dynamic Gas Blending?
Historical high discrepancy between natural gas and diesel fuel prices
Abundance of field gas in various shale plays worldwide
Expanding infrastructure for gas delivery
Regulatory pressure to reduce flaring
Maintain regulated emissions compliance
Product Overview Core diesel engine with gas introduced into the intake air stream
Still a compression ignition engine
Use gas when it’s available, seamlessly revert to diesel-only mode if no gas available
Continuously optimizes gas substitution up to 70%-gas, 30%-diesel while maintaining diesel power and transient performance
Closed loop feedback monitors combustion characteristics to continuously protect engine from detonation
Can handle poor fuel quality, up to 2300 Btu/scf (Non Regulated)
Automatically adjusts to operate under a wide range of methane number gas quality
Simple installation and no load bank required
Integrated control panel for engine, generator, and gas system control and monitoring
Generator Set Schematic
Fuel Valve Reg Shutoff Fuel Htr
EKW Signal EMCP4.4
ISM ADEM 4 Exhaust Thermocouples
Detonation Sensors
Gas Supply in
Integrated Sensor Module (ISM)
Monitors combustion and communicates
data to the updated Engine Control
Module(*) and controls system to adjust and
protect the engine
*Not shown – ADEM A4 ECM
(new with DGB)
EMCP 4.4 Control Panel
Analog gauges for quick daily walk-around
Improved display performance, 16 languages,
paralleling & troubleshooting capability
Dynamic Gas Blending Technology
1 2
3
4
1. Customer connection point
2. Gas heater, Gas Shut Off
Valve & Pressure Regulator
3. Gas Fuel Control Valve
4. Line supplying metered gas
to the intake air stream
Estimated Fitting Times
Engine Hardware : 16-32 labor hrs Control System : 16-32 labor hrs
No manual tuning or additional
genset commissioning required
for DGB system operation
+
Gauges with walk around parameters
5.5” Graphical Interface
Improved troubleshooting/diagnostics
16 language capability
Integrated generator monitoring & control
Panel Side by Side Comparison
Generic gauges with some inactive
Very small display interface
Toggle switch navigation
No programmability
No generator monitoring or control
Old New
Dynamic Gas Blending Controls
Caterpillar: Confidential Yellow
Concept OnlyGAS BLENDING CONTROL
STATUS ENABLEDMAX % 70%ACTUAL % 40%
LOWER
GAS BLENDING
ON OFF RAISE
Panel Value
Direct Rack Input Connection (mAmps to PWM
Converter)
Plug and Play Connection to Engine and CAT
Generator
6 Gauge Direct Readout
Supports future Caterpillar Remote Monitoring
DGB Parameters
Gas Blending on/off (Switch Input)
Max % Substitution (Operator Input)
Act % Substitution (Feedback)
Reason Code for % Diff
Gas Pressure
Gas Valve Position Status (Open/Closed)
Generator Power KW (PWM Input to Engine)
Safety
Unique safety features
Design of genset as a whole fully
reviewed by Caterpillar
Diesel control ECM intertwined with gas
controls and combustion sensors
Flame arresters at each cylinder to
protect engine and operators
Knocking and exhaust monitoring at
each individual cylinder
Caterpillar-quality components used :
no plastic piping for gas
Drill rig majority load range
Dynamic Gas Blending
Substitution Curves*
Above 60% for majority of load range
Drilling : Theoretical Fuel Savings
Additional savings will be realized by reducing the number of truck deliveries of
diesel. If using only flared gas, gas price can be considered to be near zero.
Working hypothesis :
Quantity 3 units
Gensets Engine power 1,450 bhp / unit
Electric power 1,000 kWe / unit
Associated gas : typical 50% substitution Average load 35%
Pipeline gas : typical 70% substitution Hours per year 4,000 hrs (8,766/yr)
Subject to gas analysis and load profile.
Figures for guidance only. Gas 4.35 $/MMBtu
Efficiency loss from using gas 7% of substitution
Diesel 4.20 $/USGal
42.80 MJ/kg 32.75 $/MMBtu
128250.30 Btu/USGal
Substitution Total fuel cost Fuel saved
rate (USGal/yr) $ / year (MMBtu/yr) $ / year $ / year / site $ / year / site
0% 297,440 1,249,249 0 0 1,249,249 0
10% 267,696 1,124,324 3,842 16,711 1,141,035 -108,214
30% 208,208 874,474 11,690 50,849 925,324 -323,925
50% 153,094 642,996 19,184 83,450 726,446 -522,803
70% 94,481 396,820 27,371 119,063 515,883 -733,366
Diesel consumption / site Gas consumption / site
Working hypothesis :
Quantity 5 units
Gensets Engine power 1,450 bhp / unit
Electric power 1,000 kWe / unit
Associated gas : typical 50% substitution Average load 70%
Pipeline gas : typical 70% substitution Hours per year 8,000 hrs (8,766/yr)
Subject to gas analysis and load profile.
Figures for guidance only. Gas 4.35 $/MMBtu
Efficiency loss from using gas 7% of substitution
Diesel 4.20 $/USGal
42.80 MJ/kg 32.75 $/MMBtu
128250.30 Btu/USGal
Substitution Total fuel cost Fuel saved
rate (USGal/yr) $ / year (MMBtu/yr) $ / year $ / year / site $ / year / site
0% 1,982,935 8,328,326 0 0 8,328,326 0
10% 1,784,641 7,495,494 25,610 111,406 7,606,899 -721,427
30% 1,388,054 5,829,828 77,930 338,996 6,168,825 -2,159,502
50% 1,020,628 4,286,639 127,892 556,332 4,842,970 -3,485,356
70% 629,873 2,645,468 182,472 793,752 3,439,220 -4,889,106
Diesel consumption / site Gas consumption / site
Production: Theoretical Fuel Savings
Additional savings will be made by reducing the number of truck deliveries
of diesel. If using only flared gas, gas price can be considered to be zero.
Emissions*
Dynamic Gas Blending kit will
retain the original emissions
certifications of the engine
Retrofit kits will include Cat DOC
Full emissions documentation will
be available through TMI
*Slide applicable for U.S. kits only
0
1
2
3
4
5
6
7
8
9
Tier 1
3512B
Tier 2
3512C
3512C with
DGB
G3516B
NOx (g/hp-hr)
CO (g/hp-hr)
PM (g/hp-hr)
3512C Diesel Oxidation Catalyst with insulation (insulation not included)
Supply Gas Quality Requirements
DGB system can accept gasified LNG, CNG, pipeline, or associated field gas
Recommended Lower Heating Value is between 900 and 1250* Btu/scf (can calculate using GERP)
– Clean, dry gas (Gaseous Fuels A&I guide LEBW4977)
– Up to 10ppm H2S (emissions certified kits)
– Up to 50ppm H2S (non-emissions certified kits with stainless steel aftercooler added)
Supply gas pressure to DGB: 12 to 35 psi
Supply gas temperature to DGB: 10 to 60 deg C
Supply gas flowrate: for 3512C, up to 6600 SCF/hr under max substitution conditions
* Applicable to U.S.A. Emissions Certified Kit
Dynamic Gas Blending - Value
Unique diesel injection timing map for Gas Blending Mode
– Allows for 10-20% improved substitution over diesel-only map at key
operating load factors
– Ensures emissions compliance on certified range of gases over all
operating load factors*
– Protects engine and expands load factor range over which substitution
can be safely achieved & optimized
Continuously maximized substitution as loads & gas
changes
– Comprehensive controls keep engine safely within peak cylinder
pressure, exhaust gas limits
– Keep engine out of detonation
– Closed loop feedback maintains genset power and transient
performance
No manual setup, extra commissioning, or tuning
– No need to retune or swap controls as sites, gas quality change
– Simple operator interface to set substitution, see live data on system
performance
– If no gas available, system automatically reverts to diesel-only mode
*Applies to U.S. kits only
Increased fuel savings opportunity
Emissions peace of mind
Reliable, durable product
No additional operating costs, maintenance activities
Timeline
Currently conducting 3512C Land Drilling & 3516B Production field
follows in the US, Canada, Russia and Argentina
Field follow progress indicates availability as shown below
*All availability dates are tentative and subject to change
Dynamic Gas Blending
Delivering Project Success
Frac Installation - Oklahoma Production Installation - Argentina
Drilling Installation - Oklahoma Drilling Installation - Canada
THANK YOU FOR YOUR ATTENTION For more CAT OIL & GAS
Please contact
Mr. Otgontugs U. Sales Engineer
PSD of WAE Mob: 95951542
Tel: (976) 70187588 Fax: (976) 70187587
Email: otgontugs@wagnerasia.com Web: www.wagnerasia.com
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