G3520C Series Gas Engine

Gas Engine Business Strategy & Markets What are the market drivers for the 1 2 MW gas engine series?Efficiency Emissions Installed Cost Performance / Availability Maintenance Cost

G3500C Design ModificationsFuel System Controls Air System

Head Exhaust System

G3520C GAS ENGINE / GENSET RATINGS

G3520C Gas Engine Ratings 50 Hz RatingsJW 50 Hz Rating CHP Gen Set * C 90 99 Open Gen Set 90 99 Emissions Efficiency** Heat Rate SCAC C 32, 54 32, 54 32, 54 70 2437 1950 1500 Continuous kVA 2500 Generator eKW 2000 Frequency rpm 1500

0.5 g/bhp hr & 1.0 g/bhp hr; TA Luft & TA Luft* 42.3% (ISO 3046/1 @80MN) 8.67 MJ/ekw-hr ( ISO 3046/1 80MN) CHP Genset 8532 BTU/ekw-hr ( ISO 3046/1 80MN) Open Package

* No JW/ SCAC pump

** Mechanical Efficiency (CHP w/o pumps)

G3520C GAS ENGINE SYSTEM

G3520C Gas Engine SystemGas Engine vs. Diesel Configuration Basic Engine Design Based on Proven Diesel Engine Kept the following strong diesel components gas engines BMEP levels are lower than diesel Crankshaft Cylinder Block Rods & Bearings Camshaft Unique Gas Components which are not common to Diesel New Cylinder Head Design New Larger Exhaust and Air Intake System Larger Turbo, significantly Larger After-cooler, and now Outboard Mounted Exhaust.

New Patent Pending Control System Senses Combustion Air Density for Power & Air Fuel Ratio Control.

G3520C Gas Engine SystemCurrent Fuel Requirements Designed for Pipeline Quality Natural Gas 80 MN is the base fuel for 50/60 Hz At 65 MN the fuel is burning faster and it is necessary to retard timing Derates from 5 14% (for 50Hz) The derates for both (50 / 60 Hz) depends on JW and SCAC temperatures and emission levels.

Power & Fuel Efficiency Estimates on 31 & 55MN (Japan 13A ) Fuel system sized for 31.5 - 47.2 MJ/Nm3 (800 - 1200 btu/ft3) range System design permits easy adaptation to low energy fuels.

G3520C Gas Engine SystemLow Pressure Fuel System Low pressure gas capability 35 345 mbar (0.50 - 5 psi for 50 Hz) and 45 345 mbar (0.65 - 5 psi for 60 Hz) Possible by the open chamber design Exclusive Caterpillar Fuel Control Valve Receives control signal from ECM (ADEM III based control) to deliver proper fuel flow. Electronic controls lead to accurate fuel flow and low emissions with more diagnostic capability BENEFIT: Simple effective design with state of the art electronics control.

G3520C Gas Engine SystemFuel SystemG3500 B G3500 C Combustion System Combustion System14 Bar BMEP 19.2 Bar BMEP* (50 Hz) 16.6 Bar BMEP* (60 Hz) *19.2 BMEP @ 32C SCAC 16.6 BMEP @ 54C SCAC High Swirl Combustion 11.7:1 Offset Bowl Piston ABB RR151 Turbo Low/No Swirl Combustion 11.3:1 Center Bowl Piston One ABB TPS57 Turbo (50Hz) Two ABB TPC49 Turbo (60Hz)Top view of 60Hz Product Fuel System

G3520C Gas Engine SystemFuel SystemBenefits of G3520C Fuel System: Charge density closed loop air to fuel ratio control Maintains the level of NOx emissions Closed Loop Control without Oxygen Sensor

Fuel system designed for high BMEP operation Optimizes cylinder to cylinder flow distribution Higher power density, thus better fuel efficiency

G3520C Gas Engine SystemFuel System Engine installed electronic fuel metering valve. Throttle plate, electronically controlled 24 V DC Actuator: GECM Controlled. Gas shutoff valve ( 24V DC) energized-to-run, ETR. Fuel Filter required. ANSI/din flange connections.

G3520C Gas Engine SystemLube & Cooling System Cooling Circuits JW, Oil Cooler and 1st Stage AC are all combined on one circuit for easy heat recovery Standard outlet temperature of 90 C Optional 99 C for CHP applications DIN/ANSI flanged customer connections.

Lube System Spin on oil filters for easy oil changes Long oil life (estimate 1500 hrs of typical operation) A very low 0.3 g/bkw-hr (1500rpm) & 0.35 g/bkw-hr (1800rpm) of oil consumption.

G3520C Gas Engine SystemLube & Cooling System Remote Radiator Options 43 C ambient capability for 54 C SCAC (90 C JW)

Remote radiator at 60 Hz field test site

G3520C Gas Engine SystemCooling System

Added cooling ring around cylinder head valve seat inserts BENEFIT: Cooler Valves for Longer Life

G3520C Gas Engine SystemAir System Front Mounted Turbocharger Benefit: Front mount reduces concentration of heat from generator and engine as opposed to the rear mounted turbochargers. Single TPS57 turbocharger for 50 Hz Dual TPC49 for 60 Hz

V-design Air Inlet, Outboard Mounted Exhaust Benefit: Larger piping size minimizes flow losses and virtually eliminates inlet charge reheating.

G3520C Gas Engine SystemAir SystemCompletely NEW Redesign of Cylinder Head Staggered Valves: Moved Guide Bosses Out of Intake and Exhaust Port Paths.

BENEFIT: Less Flow Restriction and Better Efficiency.

G3520C Gas Engine SystemAir System Exhaust Manifold Bellows and Clamps Band clamps push bellows and castings together Sloped shoulder mates with clamps and applies compression to joint. Joints are gas tight and easy to remove and install without leakage.Sloped Shoulder Design Mates With Band Clamp

G3520C Gas Engine SystemsAir System Air Cleaner with enclosure is a ship loose standard item Horizontal mount is the standard

G3520C Gas Engine SystemAir System Exhaust Shielding Molded foil lined insulation halves spring clamp around the exhaust manifold. Outer metal covering over insulation. All piping to turbo and most of turbo is covered in molded insulation and a soft wrap.

Molded Insulation Halves

G3520C Gas Engine SystemOptional Positive Crankcase Ventilation Ingestive Crankcase Fumes System -- Strongly Recommend this System if a PCV system is needed! Removes 99.9 % plus of Oil Mist from Crankcase Fumes. Returns Oil Free Crankcase Fumes to Air Intake for Combustion No More Oil Mist Condensing at Crankcase Breather Tube. Alternative to Systems which Place Oil Fumes in the Exhaust Stack which can cause Plugging and Extra Maintenance. Essentially No Buildup of Oil in Air Intake or AC Core which can lead todecreased Engine Performance.

G3520C Gas Engine SystemShock Mounted back plate

Control SystemSecondary Primary GECM GECM

Service Tool Connector

Right Ignition Harness

Cover Seal Internal Harness GECM Enclosure

BENEFIT: Rear mounted for easy serviceability.

G3520C Gas Engine SystemControl System Newer Gas Engine Control Module based on ADEM III This is a single source for full engine control of following: Air to Fuel Ratio Nitrogen Oxide Control Governing (4 20 ma speed input) Iso Sync or Droop Ignition Detonation protection per cylinder Start / Stop logic Diagnostic reports Alarms and Shutdowns Remote data access and communications

G3520C Gas Engine SystemControl System Gas Engine Control Module based on ADEM III Programmable Engine Protection System There are protection systems for the following: Detonation Sensitive Timing Failure to start (Over crank) High Jacket Water Temperature High Oil Temperature Low Oil Pressure High Exhaust Port Temperature Temperatures are monitored from the Integrated Temperature Sensing Module (ITSM)

G3520C Gas Engine SystemControl System Gas Engine Control Module Communications Digital, User Friendly, ET Programmable, CCM offers PLC Monitoring.

ECM transfers engine information over Data link: All engine safety alerts Diagnostics and Prognostics Engine Operating Parameters Histogram Information Internal Engine Temperatures Cylinder & Turbocharger(s) Stack Temperatures BENEFIT: Accessible engine performance information 24 hrs / day.

G3520C Gas Engine SystemControl SystemCharge Density (Patent Pending) - Closed Loop Air-toFuel Ratio Control Tightly maintains the level of NOx emissions: Improved emissions control over previous Oxygen based system. Simple Design: No Oxygen Sensor - only the Inlet Pressure, Temperature Sensor,and ECM Maps are needed.

Built-In maps in the ECM to determine fuel flow for desired load and % of Rated Load. Flexible Design: Flash programming of ECM allows easy field updates.

G3520C Gas Engine System G3520C Engine Control Excellent Transient Response at TA Luft (1.0 g/bhp-hr) & island mode operation: Meets ISO 8528-5 Class 1 With up to 25 % first load step (See map next slide) Transient Richening software provides load pickup Turbo Bypass piping and ECM software allows block unload without turbo surge, improves engine stability Test were conducted at 21 kPa (3 psi) gas pressure to the engine

G3520C Gas Engine System Transient Capabilitieswith Transient Richening and Turbo By-Pass By-

G3520C Gas Engine System Transient Capabilities

Transient Richening software supports load pickup by momentarily richening the air-to-fuel mixture to improve load pickup. Turbo Bypass and the Gas Electronic Control Module software allows block unload without turbo surges, and improves the engine stability.

Turbo Bypass Valve Turbo Bypass Line

G3520C Gas Engine SystemIgnition System

Coil Pocket in top of valve cover Coil is isolated from all conditions, external and internal.(Slotted Top Cover shown in red on previous slide allows for Plug Connection & Heat to Escape)

Removal of coil is very easy by removing top cover. Jacking Screws to assist in removing coil if needed.

G3520C Gas Engine SystemIgnition System New feature on G3520C Spark plug is threaded into a water cooled insert in the cylinder head.

A slice through the bottom of cylinder head exposing the water passages to the valve inserts and spark plug sleeve

BENEFIT: Cooler spark plug for longer plug life

G3520C Gas Engine SystemIgnition System Based on proven G3600 Ignition Coil and Jumper Tube. Pre-chamber type sparkplug IGNITION ASSEMBLY

Ignition Coil

Jumper Tube Pre-Chamber Type Spark Plug

G3520C Gas Engine SystemIgnition System Ignition System Pre-Chamber Type Spark Plug Extends Lean Limit Fewer Misfires Proven on G3516B and G3520B

New Feature on G3520C Spark Plug is threaded into a water cooled Plug Sleeve in the Cylinder Head

BENEFIT: Cooler spark plug for longer plug life

G3520C Gas Engine SystemIgnition SystemImproved controls assist engine performance: Detonation Sensors There is one detonation sensor per two cylinders. In addition, the listening window for detonation has been decreased. This reduces the chance for extraneous noises and the chance of false detonations. One detonation sensor per two cylinders allows individual cylinder monitoring and timing control.

DST Sensor

BENEFIT: Optimized the detonation sensor to more accurately pick up only detonation related noises.

Sales Information Maintenance Costs The cost for maintenance is < 6 /eMW hr * (Gen Set Only) The cost for fuel and travel time are not include in the above price. Varies by labor rates. Standard Overhaul IntervalsB10 Top End 15,000 Hrs Minor Overhaul 45,000 Hrs Major Overhaul 90,000 Hrs B50 B10** B50** 20,000 Hrs 12,000 Hrs 16,000 Hrs 60,000 Hrs 36,000 Hrs 48,000 Hrs 120,000 Hrs 72,000 Hrs 96,000 Hrs

* Based on average U.S. labor rates, 10 year, Continuous OperationIncludes: Lube oil, Coolants, Minor and Major Overhauls, Unscheduled Maintenance

Sales ProcessGenerator SR4B Generator Standard Features: Permanent Magnet Excited Form wound Class H insulation, Class F temperature rise @ 40 C/ 104 F 6 Lead SR4B with Digital Voltage Regulator 3-phase sensing Reactive droop RTD for Stator Winding Temperatures

Sales ProcessGenerator SR4B Generators - Optional Features Low / Medium Voltage: Oversize and & Premium Generators. Digital Voltage Regulator w/ kVAR/PF control. Form Wound. RTDs : Bearing Temperature Detectors. European Bus Bar Connection. Extension Box (Option on Low Voltage and Standard on Medium Voltage)

High Voltage: Wall mount EMCP II + panel is standard on Open PKG Gensets instead of generator mounted control. Extension Box and RTDs for bearing temperature detection are standard. K65-12B Voltage regulator is standard.

Sales ProcessStarting / Charging System Standard 24V DC starters Air starter Consult Application Support Center

Alternator, 45 Amps 24 V Standard on PKG Consult Application Support Center for CHP60 Hz G3520C Series Gas Engine

G3520C Gas Engine SystemEMCP II+ Control Panel

EMCP II+ control panel including: 24 volt DC control NEMA12, IP44 dust proof enclosure Lockable hinged door Generator terminal Box (Mounted Rear Facing) Single location customer connection UL 508A Listed Panel illuminating lights Auto start/stop control switch Voltage adjustment potentiometer True RMS AC metering, 3 phase Purge Cycle and Staged shutdown logic

G3500C Control System

G3500C Control System Oxygen Sensing Required NOx analyzer are commissioning Desired NOx level had associated O2 level Oxygen sensing did not account for atmospheric changes NOx levels could fluctuate +/- 130%

G3500C Control System Customer required inputs via Cat ET Fuel quality The lower heating value of the fuel

Gas specific gravity Fuels specific gravity in relation to the specific gravity of air

Fuel specific heat ratio Ratio of the fuels specific heat at a constant pressure and the fuels specific heat at a constant volume

G3500C Control System Required load inputs Engine full load rating Rating stamped on the engines information plate in kW

Engine driven load equipment Load of auxiliary equipment driven by the engine (such as a radiator)

Generator output power sensor scale factor Linear scale between the wattmeters output voltage and the generator output in kW

Generator output power sensor offset Offset used to make the wattmeters output accurate

G3500C Control System Calculation of the percentage of the engines load [ ( A + G ) / R ] * 100 = % Load A is the load of the auxiliary equipment in kW G is the generators output in kW R is the engines rated load

G3500C Control System Open loop mode Runs in open loop at loads < 25% ECM calculates air flow and fuel flow ECM utilizes volumetric efficiency (map in ECM) along with pressure and temperature to calculate air flow ECM sends signal to fuel metering valve to regulate fuel flow to the engine This process is continuous up to 25% load

G3500C Control System Charge density (patent pending) ECM uses patent pending algorithms incorporating charge density Maps pre-programmed in ECM compare engine speed and load to desired charge density ECM adjusts charge density as required Charge is too dense the volume of fuel is increased Charge is inadequate the volume of fuel is reduced

G3500C Control System Charge density (patent pending) FCF (fuel correction factor) calculated using map in ECM and fuel quality, allows programmed LHV to affect air/fuel ratio Charge density varies so will the FCF NOx emission gain adjustment Additional required customer input for charge density Allows small gain to richen or lean the mixture if needed Small change of gain results in a large change of NOx Example: 1% change in gain result in NOx change of 20-40 ppm