Email this page Email Print this page Print Feed Feed

Caterpillar Releases New Gas Engine

G2520B designed for gas compression applications

Posted on October 18, 2012

Caterpillar Inc. has introduced its redesigned Cat G3520B engine for gas compression applications, specifically for wellhead, gathering, processing and gas injection. The redesign enables the engine to provide greater altitude, temperature and speed turndown capabilities, providing broad application flexibility for customers, the company said. The engine’s light weight (24,622 lb. [11,168.4 kg]) coupled with high power density, make the Cat G3520B suitable for lean fleet management, the company said.

“The G3520B engine offers customers increased power and flexibility in a wide range of difficult applications,” said Greg Carpenter, Caterpillar’s Global Petroleum gas compression marketing manager. “Our goal is to provide customers with solutions that maximize their bottom line, and the redesigned G3520 delivers great value by bring more horsepower to unique sites with varying conditions, diverse operational needs and challenging fuels.”

The G3520B, which can burn a variety of gaseous fuels, is a V-20, four-stroke engine capable of providing 1490 bhp (1104 bkW) at 1200 rpm and 1725 bhp (1286 bkW) at 1400 rpm. The engine, which has a bore and stroke of 6.7 in. x 7.5 in. (170 mm x 190 mm) and a displacement of 5288 (86.7 L), offers full torque with speed turndown to 900 rpm and a full rating to 8000 ft. (2428 m) at 1200 rpm and 6500 ft. (1980 m) at 1400 rpm with the 1.0 g/bhph (1.3 g/kWh) NOx setting, Caterpillar said.

In addition to fuel flexibility and lower fuel consumption, the G3520B incorporates a low engine-out emissions technology without aftertreatment, Caterpillar said. A 0.5 g/bhph (0.67 g/kWh) NOx emission setting is also available.

Under the 0.5 g NOx setting, the engine is rated 2.22 g/bhph (2.98 g/kWh) for CO; 469 g/bhph (629 g/kWh) for CO2; and 0.45 g/bhph (0.6 g/kWh) for volatile organic compounds (VOC). Under the 1.0 g NOx setting, the engine is rated 2.6 g/bhph (3.49 g/kWh) for CO; 454 g/bhph (609 g/kWh) for CO2; and 0.37 g/bhph (0.5 g/kWh) for VOC. The engine also meets U.S. EPA Spark Ignited Stationary NSPS emissions for 2010 and some non-attainment areas.

The engine features an advanced digital engine management (ADEM) A3 system, which is designed to integrate controls for speed, air/fuel ratio, and ignition and detonation. The electronic ADEM A3 also includes a user interface, display system, shutdown controls and system diagnostics.

The engine’s intake system has an air inlet flow rate at 100% load of 3853 cfm (109.1 m3/min) under the 0.5 g NOx setting and 3618 cfm (102.45 m3/min) under the 1.0 g NOx setting. The exhaust system has a flow rate at 100% load of 11,215 cfm (317.57 m3/min) under the 0.5 g NOx setting and 10,600 cfm (300.2 m3/min) under the 1.0 g NOx setting. The exhaust stack temperatures are 989˚F (532˚C) and 997˚F (536˚C), respectively. The engine’s gas pressure is 7 to 50 psi (48 to 345 kPa) under both NOx settings.

The engine also is equipped with a gas engine rating pro (GERP), a PC-based program designed to provide site performance capabilities for Caterpillar natural gas engines. GERP provides engine data for a site’s altitude, ambient temperature, fuel, engine coolant heat rejection, performance data, installation drawings, specification sheets and pump curves, Caterpillar said.

The G3520B shares many of the same features and components with the G3516B, reducing parts inventory and requiring less technician training, the company said. A few of the shared components include much of the air/fuel ratio control system, cylinder heads, spark plugs, control panels and turbo frame. The shared components enable customers to drive down operational costs, particularly in parts and service.

The G3520B measures 13.7 ft. (4.2 m) long by 5.8 ft. (1.8 m) wide, and 7.8 ft. (2.4 m) tall.