Natural Gas Medium Speed Product

CATERPILLAR POWER PLANTS
Natural Gas Medium Speed Product
Contents
• Overview
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Our Product Line
Natural Gas Product
Performance & Maintenance
Natural Gas References
Caterpillar, Inc.
Making Progress Possible For More Than 85 Years
•
2012 Revenue = US$65.875B
34%
32%
30%
27%
25%
Company Headquarters
Peoria, Illinois USA
Established 1925
Construction Industies
Resource Industries
Power Systems
Financial Products
North America
33%
Latin America
EAME
15%
Asia/Pacific
• 110 Global Manufacturing facilities
• 125,341 full time employees world-wide (end of
•
2012)
Independent Dealer network: 200 countries,
1200 outlets
Caterpillar Motoren GmbH & Co KG
Caterpillar Motoren
Kiel, Germany
Caterpillar Motoren Rostock
Rostock, Germany
Guangzhou MaK Diesel
Engine, Ltd. Co.
Guangzhou, China
Overview
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Caterpillar is a leading supplier of medium speed reciprocating
engine power plants for both interconnected (parallel to grid) and
captive power (island mode) applications.
We offer both simple cycle and combined cycle operation and our
plants can be configured to provide combined heat & power (“CHP”).
Plant output capacities range from 2 to over 200 MWe.
We offer a full range of power generation equipment and complete
engineering, procurement & construction (“EPC”) capabilities.
Our plants offer tremendous fuel flexibility including the use of
traditional fossil fuels, renewables (e.g. straight vegetable oil and
bio-diesel), natural gas and dual fuel capabilities.
Capability Highlights
We are a Full-Service Power Generation Supplier
Fuel Flexibility
Performance Guarantees
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Traditional fossil fuels and renewables
(SVO, bio-diesel, etc.)
Natural gas
Dual Fuel / Fuel conversion
Asset Flexibility
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Excellent heat rates over wide
operating range
Low de-rate at higher elevations and
temperatures
Excellent load response (meets Utility’s
10 minute ramp rate requirement)
Closed loop cooling (does not consume
process water or require waste water
treatment / disposal.
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Technical Performance (output, heat
rate, emissions)
Commercial Performance (delivery of
the power plant on-time and on-budget
Operating Performance (O&M costs,
lube oil consumption, net plant heat
rate)
All guarantees backed-up by
Caterpillar, Inc. (minimizing counterparty risk)
Customer O&M Plans
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Design to meet client’s needs
Can leverage the CAT Dealer network.
Contents
• Overview
• Our Product Line
• Natural Gas Product
• Performance & Maintenance
• Natural Gas References
Electric Power Division Product Range
World Leading Engine Program (4kW to 14.4 MWe)
Medium
Speed
1,020 - 14,400 kW
High
Speed
15 – 7,200 kW
Dual Fuel
AFO
HFO
400 – 4,300 kW
Diesel
Gas
4 – 1,539 kW
5
50
100
kW
200
500
1
2
5
MW
10
15
20
Medium Speed Engine Families
Contents
• Overview
• Our Product Line
• Natural Gas Product
• Performance & Maintenance
• Natural Gas References
Caterpillar G16CM34
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Genset Rating (kWe):
7,800
Cylinder Configuration:
Vee 16
Bore x Stroke (mm):
340 x 420
Cylinder output (kW):
500
Speed (rpm):
750 (50 Hz)
720 (60 Hz)
Assumptions: Elevation 0ft ASL;
Temperature 77°F (ISO); Continuous
Duty; 97% Generator Efficiency
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Mean piston speed (m/s):
10.5
Fuel Type:
Natural Gas
Methane No.:
70
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Genset Heat Rate (Btu/kW.h.):
Type:
4-stroke
Aspiration:
Turbo-charged &
After-cooled
BMEP (bar)
21.9
Approx. weight – engine (kg):
81,000
Caterpillar G20CM34
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Genset Rating (kWe):
7,800
Cylinder Configuration:
Vee 20
Bore x Stroke (mm):
340 x 420
Cylinder output (kW):
500
Speed (rpm):
750 (50 Hz)
720 (60 Hz)
Assumptions: Elevation 0ft ASL;
Temperature 77°F (ISO); Continuous
Duty; 97% Generator Efficiency
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Mean piston speed (m/s):
10.5
Fuel Type:
Natural Gas
Methane No.:
70
Genset Heat Rate (Btu/kW.h.):
Type:
4-stroke
Aspiration:
Turbo-charged
BMEP (bar)
21.9
Approx. weight – engine (kg):
81,000
Timeline
2013
2014
2015
2016
2017
Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
G20CM34
Pilot Phase
Full Production
Common Applications
Peaking / Intermediate Baseload: Single or multi-engine plants can
be strategically located to feed into the distribution system (i.e. grid
support). Scalable, modular design allows for efficient future plant
expansion.
Wind Load-following: Extremely flexible dispatch control and
fast load response. Use of renewable fuels provides a “green”
complement to installed wind capacity.
Industrial CHP: Total plant efficiencies can exceed 90%. Easily integrated into
existing infrastructure. Tremendous reliability has made CPGS a popular choice
amongst mining, textile, cement and many other industrial segments.
Combined Cycle: Traditional heat recovery steam generator (HRSG) and steam
turbines or organic rankine cycle (ORG) can be used to improve plant efficiency.
Ancillary Services
Regulation: Our power plants can:
– respond rapidly to requests for up and down movements
– Track minute to minute fluctuations in system load and correct for
unintended changes in generator output
– Ramp load up from 0% to 100% and back down in less than 5
minutes
– Restart in less than 30 minutes
Spinning Reserve: Once synchronized to the grid, plants can
increase output almost immediately in response to major
generation or transmission outages
Non-Spinning Reserve: With CPGS’ standard starting air system, our plants can
go from 0% to 100% in less than 8 minutes.
Replacement Reserve: Generator sets can run for as little as a few minutes to as
many hours as needed to restore spinning and non-spinning reserves to their precontingency status.
Ancillary Services
Voltage/Frequency Support: CPGS’ power plants can be used to
maintain transmission system voltage and frequency within
required ranges.
Black Start : Can be started without support from the grid
Island Mode: Sufficient real and reactive capability/control to energize
parts of the transmission system allowing for the start of other
generation units.
Contents
• Overview
• Our Product Line
• Natural Gas Product
• Performance & Maintenance
• Natural Gas References
Lower & Higher Heat Rates
G16CM34
G20CM34
Unit Heat Rate LHV
BTU/kW‐hr
7,291
7,275
with 5% tolerance
Unit Heat Rate HHV
BTU/kW‐hr
8,020
8,003
with 5% tolerance
Net Plant Heat Rate LHV
BTU/kW‐hr
7,516
7,500
with 5% tolerance
Net Plant Heat Rate HHV
BTU/kW‐hr
8,268
8,250
with 5% tolerance
Unit Heat Rate LHV
BTU/kW‐hr
7,675
7,658
with no tolerance
Unit Heat Rate HHV
BTU/kW‐hr
8,442
8,424
with no tolerance
Net Plant Heat Rate LHV
BTU/kW‐hr
7,912
7,895
with no tolerance
Net Plant Heat Rate HHV
BTU/kW‐hr
8,703
8,685
with no tolerance
Unit Heat Rate LHV
kJ/kWh
7,692
7,676
with 5% tolerance
Unit Heat Rate HHV
kJ/kWh
8,462
8,443
with 5% tolerance
Net Plant Heat Rate LHV
kJ/kWh
7,930
7,913
with 5% tolerance
Net Plant Heat Rate HHV
kJ/kWh
8,723
8,705
with 5% tolerance
Unit Heat Rate LHV
kJ/kWh
8,097
8,080
with no tolerance
Unit Heat Rate HHV
kJ/kWh
8,907
8,888
with no tolerance
Net Plant Heat Rate LHV
kJ/kWh
8,348
8,330
with no tolerance
Net Plant Heat Rate HHV
kJ/kWh
9,182
9,163
with no tolerance
Environmental Compliance
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Caterpillar Power Plants:
– Are designed with state of the art emissions
controls devices (SCR, Oxidation Catalyst,
Air Filters, Silencers)
– Require minimized footprints to comply with
environment standards
– Meet environmental regulations and
guidelines from governmental and financial
agencies
Emissions
Emission controls
G16CM34
G20CM34
(Americas)
Uncontrolled Emission
NOx
g/kW‐hr
1.21
1.21
CO g/kW‐hr
2.5
2.5
Total VOCs (as NMNEHC)
g/kW‐hr
0.44
0.44
Formaldehyde
g/kW‐hr
0.194
0.194
CO2
g/kW‐hr
325
325
SCRs + Catalysts Oxidizers
SCRs + Catalysts Oxidizers
Controlled Emission
NOx
g/kW‐hr
0.1
0.1
CO g/kW‐hr
0.25
0.25
Total VOCs g/kW‐hr
0.22
0.22
Formaldehyde
g/kW‐hr
0.194
0.194
CO2
g/kW‐hr
325
325
Emissions (EAME & AP)
G16CM34
G20CM34
TA Luft
TA Luft
NOx
mg/Nm3
500
500
CO mg/Nm3
1000
1000
PM10
mg/Nm3
19
19
THC
mg/Nm3
2500
2500
1/2 TA Luft
1/2 TA Luft
NOx
mg/Nm3
250
250
CO mg/Nm3
1400
1400
PM10
mg/Nm3
19
19
THC
mg/Nm3
2800
2800
GCM 34 Maintenance Schedule+
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1,500 hrs
– Spark plugs replacement
3,000 hrs
– Replace non‐return check valve
4,500
– Replace combustion sensor
15,000 hrs
– Cylinder head inspection/overhaul
– Replace SOGAV valve
24,000 hrs
– Turbocharger overhaul
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+ Complete maintenance schedule available upon request
30,000 hrs
– Cylinder head overhaul
– Replace crankshaft bearings – Replace ignition coils
45,000 hrs
– Recondition cylinder pack – Lube oil pump overhaul
48,000 hrs
– Replace turbocharger cartridge
60,000 hrs
– Replace air cooler
– Replace cam shaft bearings
90,000 hrs
– Replace piston crowns
Customized Long-term Service Agreements
On‐site Tech. Support
On‐the‐job Training
Annual costs –
Normal parts
Regular fluid analysis
Maintenance Staff
Annual cost –
Unscheduled parts
Tools & Diagnostic Equipment
Lube oil, chemicals & fluids
Operations & Admin.
staff
Operations & Maintenance Agreements
Maintenance & Repair Agreements
Maintenance
Service Agreements
Technical Service Agreements
Contents
•
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•
Overview
Our Product Line
Natural Gas Product
Performance & Maintenance
• Natural Gas References
Basin Creek Power Plant - Butte, Montana
Basin Creek – Butte, Montana, USA
Dispatch Energy Contract with Utility
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51.8 MWe Peaking Power Plant
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9 x G16CM34 @ 5.75 MWe each
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Natural Gas
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Caterpillar Components:
– Project Engineering
– Project Management
– Commissioning
– Construction
– Operations & Maintenance
CityGeneva
of Geneva
- Geneva, Illinois,
Illinois USA
City of
– Geneva,
Municipal Utility
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29MWe plant
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Reduced the city’s energy costs
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5 x G16CM34 @ 5.9 MWe each
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Caterpillar provided:
– Caterpillar manufactured switchgear
& controls
– Engineering
– Commissioning and Start-Up
support
– Maintenance & Repair Contrac
Bramming Fjernvaerme - Denmark
District Heating Station
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Municipal utility for Bramming, Denmark
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Producing power & district heating
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1 x G16CM34 @ 5.9 MWe
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Natural Gas
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Caterpillar engineering services provide
a comprehensive heat recovery system Overall CHP efficiency exceeding 92%
Estonia - Wihuri
Customer: Estonia
Application: Combined Heat & Power
Fuel: Natural Gas
Engine: 1 x G16CM34
Additional Power References
Purchaser
Station
Saeby
Silmet Group
Sillamae
Seafresh
Type
Mode of Operation
Fuel
Year of Delivery
G 16
CM 34
Cogen
Gas
2001
1
G 16
CM 34
Cogen
Gas
2003
1
G 16
CM 34
Cogen
Gas
2003
2
G 16
CM 34
Emergency
Gas
2004
Country
No.
Denmark
2
Estonia
Russia
Cyl.
Heavy Eng. Manuf.Comp.
Khodro Factory
Shah Cement Power LTD
Shah Cement
Bangladesh
2
G 16
CM 34
Base Load
Gas
2004
CGT SPA
Bardonecchia
Italy
1
G 16
CM 34
Cogen
Gas
2004
CGT SPA
Bardonecchia extension
Italy
1
G 16
CM 34
Cogen
Gas
2005
Juglas Jauda
Riga
Latvia
2
G 16
CM 34
Base Load
Gas
2005
Lucky Cement Limited
Karachi
Pakistan
5
G 16
CM 34
Base Load
Gas
2005
India
2
G 16
CM 34
Base load
Gas
2006
Gujarat Flurochemicals Ltd.
CGT SPA
Legnano
Italy
1
G 16
CM 34
Cogen
Gas
2006
R.A.K. Ceramics
Station: Ras Al Khaimah gas phase I
United Arab Emirates
2
G 16
CM 34
Cogen
Gas
2006
CGT SPA
Prato Nevoso
Italy
1
G 16
CM 34
Cogen
Gas
2007
Hellenic Gas Transmission System Operator S.A.
Revithoussa
Greek
2
G 16
CM 34
Base Load
Gas
2008
CGT SPA
Surgital
Italy
1
G 16
CM 34
Base Load
Gas
2009
CGT SPA
Seregno
Italy
1
G 16
CM 34
Base Load
Gas
2009
Gas Compression References
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Our CM34 Gensets are also used
in the many gas compressions
stations worldwide to enable the
transportation of natural gas
through pipelines
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The next slides will show a list of
some of these facilities
Gas Compression References
Owner/Project Lead
End‐User
Compressor Station
Name
Country
Qty
Engine
Model
Delivery Year
COD
2011
Boardwalk Pipeline
Gulf South Pipeline
Hall Summit Station
USA
1
G16CM34
2011
Inergy Midstream
CNYOG
CNYOG M1‐S
USA
1
G12CM34
2011
Inergy Midstream
CNYOG
CNYOG M1‐S
USA
1
G16CM34
2011
Energy Transfer
ETC Tiger Pipeline, LLC
Bienville Station
USA
5
G16CM34
2010
2011
Energy Transfer
ETC Tiger Pipeline, LLC
Chatham Station
USA
4
G16CM34
2010
2010
Williams
Williams‐Mobile Bay
Williams Station 85
USA
1
G16CM34
2010
2011
Enterprise Products
Acadian Gas LLC
Enterprise Mansfield Station
USA
6
G16CM34
2010
2011
Enterprise Products
Acadian Gas LLC
Enterprise Cheneyville Station
USA
3
G16CM34
2010
2011
PAA Nat. Gas Storage
Pine Prairie Energy Center LLC
Pine Prairie Energy Center Exp
USA
2
G16CM34
2009
2010
PAA Nat. Gas Storage
SG Resources Mississippi LLC
Southern Pines Energy Center
USA
2
G16CM34
2009
2010
Kinder Morgan
Kinder Morgan Energy Partners
Herscher 201
USA
1
G16CM34
2009
2010
Kinder Morgan
Midcontinent Express Pipeline LLC
MEP 4
USA
4
G12CM34
2009
2010
Energy Transfer
Fayetteville Express Pipeline LLC
Russell Station
USA
7
G16CM34
2009
2010
Energy Transfer
ETC Tiger Pipeline, LLC
Cannisnia Station
USA
3
G16CM34
2009
2011
Kinder Morgan
Midcontinent Express Pipeline LLC
MEP 2
USA
4
G16CM34
2009
2010
Kinder Morgan
Rockies Express Pipeline LLC
REX CS914 Chandlersville
USA
1
G16CM34
2008
2010
Vankorneft
CJSC Vankorneft
Rosneft Station 1
Russia
6
G16CM34
2008
Kinder Morgan
Midcontinent Express Pipeline LLC
MEP 1
USA
2
G12CM34
2008
2009
Kinder Morgan
Midcontinent Express Pipeline LLC
MEP 1
USA
4
G16CM34
2008
2009
Gas Compression References
Owner/Project Lead
End‐User
Compressor Station Name
Country
Qty
Engine
Model
Delivery Year
COD
Kinder Morgan
Rockies Express Pipeline LLC
REX CS907 Bertrand
USA
3
G16CM34
2008
2009
Kinder Morgan
Rockies Express Pipeline LLC
REX CS907 Bertrand
USA
2
G12CM34
2008
2009
Kinder Morgan
Rockies Express Pipeline LLC
REX CS911 Blue Mound
USA
3
G16CM34
2008
2009
Kinder Morgan
Rockies Express Pipeline LLC
REX CS911 Blue Mound
USA
2
G12CM34
2008
2009
Kinder Morgan
Midcontinent Express Pipeline LLC
MEP 3
USA
4
G16CM34
2008
2009
Energy Transfer
Energy Transfer Partners LP
ET1 ‐ Cleburne
USA
2
G16CM34
2007
2007
PAA Nat. Gas Storage
SG Resources Mississippi LLC
Southern Pines Energy Center
USA
4
G16CM34
2007
2008
Energy Transfer
Energy Transfer Partners LP
ET1 ‐ Reed
USA
2
G16CM34
2007
2008
Kinder Morgan
Rockies Express Pipeline LLC
REX CS914 Chandlersville
USA
2
G12CM34
2007
2010
Energy Transfer
Energy Transfer Partners LP
ET1 ‐ Stryker
USA
2
G16CM34
2007
2007
Energy Transfer
Energy Transfer Partners LP
Grimes Station
USA
3
G12CM34
2007
2009
Vankorneft
CJSC Vankorneft
Rosneft Station 2
Russia
6
G16CM34
2007
Kinder Morgan
Kinder Morgan Texas Pipeline LLC
Markham 581
USA
1
G16CM34
2007
2009
Kinder Morgan
Rockies Express Pipeline LLC
REX CS904 Arlington
USA
3
G16CM34
2007
2009
PAA Nat. Gas Storage
Pine Prairie Energy Center LLC
Pine Prairie Energy Center
USA
4
G16CM34
2006
2008
AGL Resources Inc.
Jeffersson Island Storage & Hub
Jefferson Island
USA
1
G16CM34
2004
2005
Kinder Morgan
Rockies Express Pipeline LLC
REX CS907 Bertrand
USA
3
G16CM34
2008
2009
Kinder Morgan
Rockies Express Pipeline LLC
REX CS907 Bertrand
USA
2
G12CM34
2008
2009
Kinder Morgan
Rockies Express Pipeline LLC
REX CS911 Blue Mound
USA
3
G16CM34
2008
2009
Kinder Morgan
Rockies Express Pipeline LLC
REX CS911 Blue Mound
USA
2
G12CM34
2008
2009
End