Caterpillar Introduces Multiple New Products at OTC 2012

Caterpillar to Introduce New Dynamic Gas Blending Kit and Fracturing Transmission at OTC 2012

Technologies displayed will improve productivity and safety, reduce downtime

Caterpillar, Inc., announced Monday it will introduce two new technologies as part of its overall display at the 2012 Offshore Technology Conference (OTC), held in Houston, Texas, April 30 – May 3. Among the products on display in the Caterpillar booth will be the company's new Dynamic Gas Blending retrofit kit and the Cat® CX48-2300 transmission. In addition, the company will showcase its C175-16 generator set, and C15 ATEX Pyroban power package, an explosion proof power solution.

The new Dynamic Gas Blending retrofit kit provides customers with a cost-effective dual fuel option. The Dynamic Gas Blending kit allows customers to reduce fuel costs and meet changing emissions regulations by utilizing a wide range of gaseous fuels in their existing diesel generator sets.

The first generation of the Dynamic Gas Blending kit is available for the following Cat generator set models and specifications:

  • 3516B 50 hz production rating, 1.6 eMW (1750 hp) – package and kit
  • 3512C 60 hz drilling rating, 1.0 eMW (1477 hp) – kit only
  • 3512B 60 hz drilling rating, 1.0 eMW (1477 hp) – package and kit
  • 3512B 60 hz production rating, 1.3 eMW – package and kit
  • 3512B 50 hz production rating, 1.0 eMW – package only
  • 3512B 50 hz drilling rating, 1.2 eMW (1757 hp) – package and kit

The Dynamic Gas Blending kit automatically adjusts to changes in incoming fuel quality and pressure allowing your engines to run on a wide variety of fuels, from associated gas to 2 gasified LNG with no loss of performance integrity. It maintains diesel performance levels with up to 70 percent replacement of diesel with gas, accepts up to 55 percent inerts, and can be applied to existing engines with EPA certification.

Also being introduced is the Cat CX48-P2300 transmission, designed specifically for hydraulic fracturing associated with well stimulation and completion. Weighing in at 3,530 pounds (1,601 kg), the CX48-P2300 is the lightest weight transmission available for frac applications. With an input power of 2,300 bhp (1,716 bkW) and peak input torque of 6,656 lb-ft (9,024 N·m), the CX48-P2300 also features improved durability to match engine life, and an industry-high horsepower-to-weight ratio. Its cutting-edge controls are tailored for the frac market, with a focus on safety and flexibility.

"We are constantly searching for ways to make our products more effective, relevant and reliable for our customers, especially when it comes to meeting the demands associated with harsh on- and offshore environments," said Antti Ekqvist, Caterpillar global offshore business development manager. "These two technologies address very specific needs related to safety, flexibility and durability, and we are pleased to be able to introduce them to the marketplace at this year's show."

The company will also display the Cat® C175-16 generator set at OTC 2012. The C175-16, which is the ideal power supply for jack-up drill rigs in the offshore market, is now globally available to customers seeking a high power density and lower emissions offshore drilling module. Rated 1,830 ekW at 1,200 rpm (60 Hz), five Cat C175-16 drilling modules provide 9,150 ekW of rated power. This platform was designed to address the increased power demand, emissions requirements and other current needs of the global drilling industry. The C175-16 meets U.S. EPA Tier 2 and IMO Tier II requirements.

Also on display will be the C15 ACERT™ hazardous location solutions, ideal for on- and offshore applications such as blending, cementing, and coiled tubing where personnel and rig safety are critical during daily operations. The C15 ACERT meets the most current offshore emissions requirements, including IMO Tier II, EPA Marine Tier 2, and is EPA Marine Tier 3 beginning in 2013.

The C15 ACERT is Caterpillar's first hazardous location solution for compliance up to customer hookup points. The hazardous location engine is rated at 536 bhp between 1,800- 2,000 rpm, with an ambient capability of 50° C on a mechanical system and 60° C on an electrical system. A variety of hazardous-location certified attachments are available, including an alternator, ATEX Messenger and ATEX throttle control, air compressor and inlet air flame trap. This engine also features Non-Sparking (nA) and Intrinsically Safe (ic) ECM wiring harnesses and sensors, as well as harness cable jackets that meet flame propagation requirements of IEC 60332-1-2.

All Cat products are backed by the worldwide Cat dealer network with trained technicians to ensure service support is never out of reach. To learn more about these Cat products, please visit the company's booth at the 2012 OTC event, booth 3341. For more information, visit catoilandgasinfo.com.

Caterpillar Releases Dynamic Gas Blending Generator Sets and Retrofit Kit for Diesel Generator Sets

Adding Dual Fuel Capacity to Existing Engines will Reduce Overall Fuel Costs

Caterpillar Inc. today announced that it has developed a Dynamic Gas Blending retrofit kit to provide customers with a cost-effective dual fuel option. The Dynamic Gas Blending kit allows customers to reduce fuel costs and meet changing emissions regulations by utilizing a wide range of gaseous fuels in their existing diesel generator sets.

The first generation of the Dynamic Gas Blending kit is available for the following Cat generator set models and specifications:

  • 3516B 50 hz production rating, 1.6 eMW (1750 hp) – package and kit
  • 3512C 60 hz drilling rating, 1.0 eMW (1477 hp) – kit only
  • 3512B 60 hz drilling rating, 1.0 eMW (1477 hp) – package and kit
  • 3512B 60 hz production rating, 1.3 eMW – package and kit
  • 3512B 50 hz production rating, 1.0 eMW – package only
  • 3512B 50 hz drilling rating, 1.2 eMW (1757 hp) – package and kit

The Dynamic Gas Blending kit automatically adjusts to changes in incoming fuel quality and pressure allowing engines to run on a wide variety of fuels, from associated gas to vaporized LNG with no loss of performance integrity. It maintains diesel performance levels with up to 70 percent replacement of diesel with gas, accepts up to 55 percent inerts and can be applied to existing engines with EPA certification. No customer input or gas analysis is needed during operation, and no recalibration is required when the equipment is moved or the gas supply changes. No testing is required at rig construction or rig up.

"This is a completely integrated solution that continually adjusts to varying fuel quality and requires no adjustments or re-testing, allowing the engine to run at maximum substitution while maintaining a high level of reliability and durability," said Sam Ternes, Caterpillar Global Petroleum engineering specialist.

Designed for compatibility with existing land drilling rig controls and production multi-generator set control systems, the gas blending kit provides robust transient response and an integrated gas induction control which maintains stable generator output. It is easily integrated with drilling and production generators in the oil and gas industry.

The Dynamic Gas Blending kits include Caterpillar's newest control system – EMCP4.4, which easily integrates the engine, generator and the gas blending system. Features of the EMCP4.4 include:

  • Plain text display of fault codes
  • Compatibility with customer inputs through MODBUS protocol and load sharing modules
  • Easy-to-view gas system parameters, simple daily walk-around inspections
  • Engine protection shutdown/startup ability with custom programmable alarms
  • Compatible with legacy direct rack control systems

"The fuel savings achieved with this system depends on a number of variables, including the application, the quality of the gas, the pressure and available volume," said Russell Goss, Caterpillar Global Petroleum engineering specialist. "But by retrofitting existing generator sets with this technology, a typical drill rig operator can operate on up to 30 percent diesel and 70 percent gas, and save as much as $400,000 in one year.*"

To ensure safety, the control panel and electric gas components are Canadian Standards Association (CSA) compliant. The gas blending kit includes an emergency stop purge cycle, generator temperature monitoring and air shut-off valves. If fault codes are detected in the gas system, it will be shut down and the system will seamlessly revert to full diesel operations.

To learn more about these Caterpillar solutions, please visit booth 3341 at the 2012 OTC event and the Dynamic Gas Blending product website.

* Calculation assumes 3 x 1476HP 3512C gensets with 70% substitution of diesel with gas; $4.35/MMBTU gas price and diesel fuel at $4.20 per gallon in North American market.

Caterpillar Introduces New Transmission for Well Fracturing

Cat® CX48-P2300 is lightest frac transmission available

Caterpillar, Inc., introduced Monday its new Cat® CX48-P2300 transmission, designed specifically for hydraulic fracturing associated with well stimulation and completion. Weighing in at 3,530 pounds (1,601 kg), the CX48-P2300 is the lightest weight transmission available for frac applications.

With an input power of 2,300 bhp (1,716 bkW) and peak input torque of 6,656 lb-ft (9,024 N·m), the CX48-P2300 also features improved durability to match engine life, and an industry-high horsepower-to-weight ratio. Its cutting-edge controls are tailored for the frac market, with a focus on safety and flexibility. The starter interlock feature ensures the engine cannot be started while the transmission is in gear, and the quick-to-neutral switch allows the operator to put the transmission in neutral immediately.

"We designed this petroleum transmission for the specific needs and demands of heavy well fracturing applications," said Carl Thiele, Caterpillar Global Petroleum technical sales manager. "This transmission offers increased reliability and durability, and yet is simple to install and maintain, resulting in lower owning and operating costs, and reduced downtime – all things that are of utmost importance to our customers."

Features enabling the simplified installation and maintenance include an integral PTO; integral filters with bypass indicator; reduced external hoses; rigid-mounted ECU with wire harness and remote mount capability; low oil level indicator and oil pressure monitoring.

The performance of the CX48-P2300 was built around the success of the TH55's advanced controls. Its eight usable gears allow it to come online quickly and eliminate damaging engine harmonics at low speeds.

Cat engines, generator sets and transmissions are backed by the worldwide Cat dealer network with trained technicians to ensure service support is never out of reach. To learn more about these Caterpillar products, please visit booth 3341 at the 2012 OTC event. For more information on Caterpillar, please visit catoilandgasinfo.com.

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