Caterpillar has introduced two new high efficiency gas gensets for the 1 MW market, a 1.5 MWe unit based on its G3512H engine and an 800 kWe offering based on the TCG 3016 engine developed by its subsidiary MWM.

High efficiency G3512H

This is a natural gas unit said to deliver power up to 1500 kWe at an electrical efficiency of 44.9% (ISO, 1.0pf), Cat’s third model in its high-efficiency H Series. It was developed to fulfil customer demands for improved performance on combined heat and power systems in industrial and commercial facilities in 50Hz zones but is applicable to industrial, commercial, utility and greenhouse applications generally, says Caterpillar.

It has been designed as a robust power plant that is easy to install and commission, and was built on the legacy of the proven G3500 platform, which has over 8000 units and 10 000 MWe of power installed worldwide. Cat says that its performance has been achieved while still exhibiting the lowest total ownership and operating costs in its class, driven by low oil consumption, extended service intervals, and reduced downtime.

Other characteristics include high power density, ISO 8528-5 Class G1 transient performance with specified load steps, and genset reliability verified through torsional vibration, fuel consumption, oil consumption, transient performance, and endurance testing.

The generator, which has been designed to match the performance and output characteristics of Cat engines, uses EMCP 4 control panels. The genset add-ons include expansion modules and site specific programming tailored to customer requirements.

MWM TCG 3016 / Cat CG132B

Cat’s new CG132B series is based on an MWM TCG 3016 engine. CAT took over MWM in 2011. The new gensets are said to boast the highest efficiency in their output category, which is 400-800 kW. In natural gas operation electrical efficiency reaches 43.5 %, while in cogeneration applications an overall efficiency of up to 90 % can be achieved. The gensets are also equipped with a new digital power plant control designated TPEM. Cat is launching this genset as ‘a machine for the modern age’. It is, says its maker, a new generation of gas gensets whose ‘trend-setting components, state-of-the- art sensors, and digitised power plant control deliver maximum efficiency and availability.’

A greatly reduced oil consumption of less than 0.1 g/kWh and longer oil change intervals make the operation of the gas gensets more economical, and the interval between overhauls has been stretched from typically 64 000 to 80 000 operating hours for natural gas applications.

A number of measures have been implemented to make the new series more robust. For example, the generator is now flanged to the gas engine, and the vibration decoupling now takes place directly between the components and the base frame. Cat has also introduced its fully integrated digital power plant control system TPEM – Total Plant & Energy Management. The system, says Cat, which can be customised to specific needs and the individual application case, delivers improved efficiency and flexibility compared to the controls it replaces.

TPEM can handle automation and closed-loop control with maximum operating security and seamless communication. In this way, additional controls are no longer necessary, and optimum control of the energy generation by the gas power plant is ensured.