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 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

Detonation Sensors

Exhaust Thermocouples ISM ADEM 4

EMCP4.4
EKW Signal

Reg Fuel Htr Gas Supply

Fuel Valve Shutoff
in
 Dynamic Gas Blending Technology
Integrated Sensor Module (ISM)
Monitors combustion and communicates
data to the updated Engine Control
Module(*) and controls system to adjust and
protect the engine

3 *Not shown – ADEM A4 ECM

4 (new with DGB)

1 2

1. Customer connection point

2. Gas heater, Gas Shut Off
Valve & Pressure Regulator
3. Gas Fuel Control Valve EMCP 4.4 Control Panel

4. Line supplying metered gas Analog gauges for quick daily walk-around
to the intake air stream Improved display performance, 16 languages,
paralleling & troubleshooting capability
 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
 Panel Side by Side Comparison

Old New

 Generic gauges with some inactive
 Very small display interface
 Toggle switch navigation
 No programmability
 No generator monitoring or control
 Gauges with walk around parameters
 5.5” Graphical Interface
 Improved troubleshooting/diagnostics
 16 language capability
 Integrated generator monitoring & control
 Dynamic Gas Blending Controls
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

GAS BLENDING CONTROL

Caterpillar: Confidential Yellow
Concept Only
DGB Parameters
GAS BLENDING  Gas Blending on/off (Switch Input)
STATUS ENABLED
MAX %
ACTUAL %
70%
40%
 Max % Substitution (Operator Input)
 Act % Substitution (Feedback)
ON OFF RAISE LOWER
 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
 Dynamic Gas Blending
Substitution Curves*

Above 60% for majority of load range

Drill rig majority load range

 Drilling : Theoretical Fuel Savings
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 Diesel consumption / site Gas consumption / site 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

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.
 Production: Theoretical Fuel Savings
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 Diesel consumption / site Gas consumption / site 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

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*
9

8
 Dynamic Gas Blending kit will NOx (g/hp-hr)
CO (g/hp-hr) 7

retain the original emissions PM (g/hp-hr) 6

5
certifications of the engine 4

 Retrofit kits will include Cat DOC 1

0
Tier 1 Tier 2 3512C with G3516B
3512B 3512C DGB

 Full emissions documentation will

be available through TMI

*Slide applicable for U.S. kits only

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 Increased fuel savings
operating load factors opportunity
– Ensures emissions compliance on certified range of gases over all Emissions peace of
operating load factors* mind
– Protects engine and expands load factor range over which substitution Reliable, durable
can be safely achieved & optimized product
 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 additional operating
costs, maintenance
– No need to retune or swap controls as sites, gas quality change activities
– 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
 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

Drilling Installation - Oklahoma

Drilling Installation - Canada

Production Installation - Argentina Frac Installation - Oklahoma

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: 95951542
Tel: (976) 70187588
Fax: (976) 70187587
Email: otgontugs@wagnerasia.com
Web: www.wagnerasia.com