Overview of Gas Compression Engine Upgrades

Note: Local and federal emissions regulations vary by location

and application. Compliance with these regulations is the
responsibility of the engine owner or operator. Customers who
purchase upgrades for Caterpillar gas engines should first
consider the applicable environmental regulations which may be
triggered by the upgrade, such as the reconstruction and
modification clauses within the EPA Spark Ignition New Source
Performance Standards (NSPS) rule. Owner/operators should be
sure to complete appropriate testing and/or notifications before
and after the upgrade, as applicable under state and federal
regulations.
Contents
G3500 EIS to A3 Upgrade
G3512 & G3516 A3+NOx Sensor Upgrades
– G3512 & G3516 EIS to A3+NOx sensor
– G3512 & G3516 A3 to A3+NOx sensor
G3508 A3+NOx Sensor Upgrades
– G3508 EIS to A3+NOx, including twin turbo to single turbo
– G3508 A3 to A3+NOx, including twin turbo to single turbo
G3516 Ultra Lean Burn Upgrade
G3600 ESS to A3 Upgrade
G3600 VTC to TPS Upgrade
Order Fulfillment Process
G3500 EIS to A3 Upgrade (Basic)
• Upgrade from EIS Electronic Ignition System to
A3 engine electronics
• Basic upgrade allows option of AFRC using O2
sensing
• Improved reliability
– Increased component life with
pre-lube
– Wiring harness improvements
• Remote monitoring capabilities
• Provides easier troubleshooting
• For further information see:
– IRM PELJ0856
– Data Sheet PEHJ0204
– Special Instructions REHS2849
– Gas Engine Ratings Pro (GERP)

DNN: G3512 ~27k, G3516 ~30k

 G3500 Upgrade – “’07 NSPS” Configuration
• Upgrade from EIS Electronic Ignition
System to A3 engine electronics with
Air-Fuel Ratio Control and NOx sensor
• Upgrade from A3 with O2 sensor to A3
with NOx sensor
• Improved control of NOx emissions
• Improved diagnostics
• Remote monitoring capabilities NSPS NSPS
• For further information see: 7/07 Reconstructed

– IRM PELJ1002, PELJ1001 EIS w/AFRC

– Data Sheet PEHJ0204 A3 w/AFRC (O2 Sensor)

– Special Instructions REHS3419, REHS3423
NSPS
– Gas Engine Ratings Pro (GERP)
1.5 2.0 3.0
“NSPS:” Relating to emissions limits dictated by the US EPA New Source Performance
Standards for Spark Ignited Engines, 40 CFR Parts 60, 63, 85, et al. NOx Emissions, g/bhp-hr

DNN: G3512 ~33k, G3516 ~38k

 G3508 Upgrade – “’07 NSPS” Configuration
• Upgrade to A3 engine electronics with
Air-Fuel Ratio Control and NOx sensor
• Improved altitude, turn-down, ambient,
NSPS NSPS
power 7/07 Reconstructed

• Improved control of NOx emissions EIS w/AFRC

• Improved diagnostics A3 w/AFRC (O2 Sensor)

NSPS
• Remote monitoring capabilities 1.5 2.0 3.0

• For further information see: NOx Emissions, g/bhp-hr

– IRMs PELJ1004, PELJ1003

– Special Instructions
REHS3415, REHS 4711
Performance Summary with the Conversion (100°F / 38C) Before After
– Data Sheet PEHJ0205
Power, bhp (bkW) @ 1400 rpm 630 (470) 670 (500)
– Gas Engine Ratings Pro (GERP) Engine Efficiency BTU/bhp-hr (MJ/kW-hr) ISO 3046/1 7550 (10.80) 7510 (10.64)
Maximum Operating Altitude without Derate, ft (m) <500 (<150) 2600 (780)
Maximum Operating Altitude with 25% Speed Turndown, ft (m) 0 (0) 12000 (3600)
Fuel Methane Number Range without Derate (CAT MN) 45-100 45-100
NOx Not-to-Exceed Emissions Level, g/bhp-hr (g/kW-hr) 4.2 (5.6) 2 (2.7)
DNN: EIS ~55k, A3 ~40k Nominal NOx Emissions Level, g/hp-hr (g/kW-hr) 2 (2.7) 1.5 (2.0)

“NSPS:” Relating to emissions limits dictated by the US EPA New Source Performance Standards for Spark Ignited Engines, 40 CFR Parts 60, 63, 85, et a
G3516B Upgrade - Ultra Lean Burn
• G3516 LE Proven Reliability and Durability
• New Standard for G3500 Performance
– Better fuel efficiency, altitude, turndown, and ambient
capability
• Meets & Beats U.S. EPA SI Stationary NSPS
Emissions (2010) DFW
NSPS
7/10
NSPS
7/07
NSPS
Reconstructed
– Lowest lean burn emissions while maintaining EIS w/AFRC
expected startability, stable load acceptance and A3 w/AFRC (O2 Sensor)
heat rejection
A3/NOx
– 0.5 g/bhp-hr NOx or 1.0g/bhp-hr with same hardware
ULB
• Higher Fuel Efficiency ULB

– Lower carbon footprint 0.5 1.0 1.5 2.0 3.0

– Lower operating cost NOx Emissions, g/bhp-hr

• Higher Power Density = Ideal for Fleet

Management
G3516B Upgrade - Ultra Lean Burn
• Upgrade existing lean-burn engines
to Ultra-Lean-Burn configuration
• Lower heat rejection for improved
compatibility with existing skids
• Lower capital cost than buying new
• Extends the useful life of existing
assets in a world of changing regulations
• Major upgrade - includes heads, pistons, air system, more, so
schedule with a planned overhaul for best economy
G3600 ADEM-III Upgrade
• Introduced in 2002 – hundreds sold!
• Eliminates problems due to the earlier
ESS Engine Supervisory System
• Significantly Improved Uptime
• Improved troubleshooting
• Expandable/retrofittable
• Remote monitoring capabilities
• Available for all G3600 models
• For further information see:
– Data Sheet PEHJ0184
– IRM PELJ0659
– Special Instructions REHS1708, REHS1709

DNN (10 Mar 2009)

G3606: $36,120
G3608: $40,330
G3612: $42,250
G3616: $45,680
G3600 VTC Turbo to TPS Turbo Upgrade
• Upgrade introduced in 2005
• Estimated 80%-90% converted to date
• Reduced fouling risk
• Longer life
• Improved uptime
• Upgrade Turbo, Aftercooler, and ECM
with latest software to get 0.5g NOx

DNN (1 Apr 2008)

G3606: $54,000
G3608: $54,000
G3612: $103,000
G3616: $110,000
Order Fulfillment Process
How soon do you
need the kit?

ASAP 45 Days 90 Days +

Place as Emergency Order Place as Stock Order Place as CPRO Order

Dealer should call Parts Expeditor directly. Default Estimated Ship Date is 45 days; actual Highest priority order category - parts will be fulfilled
Default Estimated Ship Date will be 45 days, ship date will vary. Typical order-to-delivery 90 days from the date of entry. Serial number and
but expeditor will work to improve. times are closer to 30 days. customer contract (order) are required.

Are Are
any components any components
backordered? backordered?
Yes
Yes No

Backordered materials are sent to a All orders containing backordered All orders containing backordered
dedicated expeditor material are sent to a dedicated material are sent to a dedicated
expeditor expeditor

Expeditor will work on any parts that Expeditor will work on any parts that
may compromise 45 day ship date may compromise 90 day delivery date
When all parts are available, the order
is released to kitting

Parts are picked and sent to kitting

area; shipping boxes are built

Components are put in shipping

container

Order is shipped
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corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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