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Dynamic Gas Blending
Overview
Dynamic Gas Blending
What is it?
 A way to use two fuels
simultaneously in a power
application
Why is it important to
our...
Why Dynamic Gas Blending?
 Historical high discrepancy between natural gas
and diesel fuel prices
 Abundance of field ga...
Product Overview
 Core diesel engine with gas introduced into the intake air stream
 Still a compression ignition engine...
Generator Set Schematic
Fuel Valve Reg Shutoff Fuel Htr
EKW Signal
EMCP4.4
ISM ADEM 4Exhaust Thermocouples
Detonation Sens...
Integrated Sensor Module (ISM)
Monitors combustion and communicates
data to the updated Engine Control
Module(*) and contr...
Estimated Fitting Times
Engine Hardware : 16-32 labor hrs Control System : 16-32 labor hrs
No manual tuning or additional
...
 Gauges with walk around parameters
 5.5” Graphical Interface
 Improved troubleshooting/diagnostics
 16 language capab...
Dynamic Gas Blending Controls
Caterpillar: Confidential Yellow
Concept Only
GAS BLENDING CONTROL
STATUS ENABLED
MAX % 70%
...
Safety
Unique safety features
 Design of genset as a whole fully
reviewed by Caterpillar
 Diesel control ECM intertwined...
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
dies...
Working hypothesis :
Quantity 5 units
Gensets Engine power 1,450 bhp / unit
Electric power 1,000 kWe / unit
Associated gas...
Emissions*
 Dynamic Gas Blending kit will
retain the original emissions
certifications of the engine
 Retrofit kits will...
Supply Gas Quality Requirements
 DGB system can accept gasified LNG, CNG,
pipeline, or associated field gas
 Recommended...
Dynamic Gas Blending - Value
 Unique diesel injection timing map for Gas Blending Mode
– Allows for 10-20% improved subst...
Timeline
 Currently conducting 3512C Land Drilling & 3516B Production field
follows in the US, Canada, Russia and Argenti...
Dynamic Gas Blending
Delivering Project Success
Frac Installation - OklahomaProduction Installation - Argentina
Drilling I...
Caterpillar Oil & Gas product
THANK YOU FOR YOUR ATTENTION
For more CAT OIL & GAS
Please contact
Mr. Otgontugs U.
Sales Engineer
PSD of WAE
Mob: 9595154...
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CAT Dynamic Gas Blending technology

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CAT Dynamic Gas Blending technology

  1. 1. Dynamic Gas Blending Overview
  2. 2. 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
  3. 3. 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
  4. 4. 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
  5. 5. Generator Set Schematic Fuel Valve Reg Shutoff Fuel Htr EKW Signal EMCP4.4 ISM ADEM 4Exhaust Thermocouples Detonation Sensors Gas Supply in
  6. 6. 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
  7. 7. 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 +
  8. 8.  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
  9. 9. Dynamic Gas Blending Controls Caterpillar: Confidential Yellow Concept Only GAS BLENDING CONTROL STATUS ENABLED MAX % 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)
  10. 10. 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
  11. 11. Drill rig majority load range Dynamic Gas Blending Substitution Curves* Above 60% for majority of load range
  12. 12. 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
  13. 13. 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.
  14. 14. 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)
  15. 15. 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
  16. 16. 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
  17. 17. 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
  18. 18. Dynamic Gas Blending Delivering Project Success Frac Installation - OklahomaProduction Installation - Argentina Drilling Installation - Oklahoma Drilling Installation - Canada
  19. 19. Caterpillar Oil & Gas product
  20. 20. 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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