3500B History - Oct 04

History and Objectives of the 3500BAdvantages of the 3500BNew 3500B Products3500B RatingsCertifications

3500B DevelopmentFirst Electronic Engine - 1992B Production Started -1995Low Speed B Petroleum Model - 1997 OTCLow Speed 3516B High Displacement - 2000 OTCCurrent Population Over 8,000 Bs Over 5,000 EUIs Over 36,000 MUIs

Development of the 3500BChanges from mechanical to electronic engine Combustion process Separate Circuit Aftercooler Air Delivery Electronics Fuel injection Controls

3500B ObjectivesImproved exhaust emissionsImproved fuel economyImproved horsepower outputsImproved monitoring capabilities All without reducing reliability and durability

The 3500B AdvantageCombustion processCamshaft, valve train, fuel system, pistons, gear trainMore powerLower emissionsBetter fuel economyDurabilityOptimized performance

The 3500B AdvantageSCACAssists ability to produce low NOxAir DeliveryReduced system restrictionsIncreased air flowNew turbos

The 3500B Engine Control AdvantageOptimum performance across complete operating range ADEM (Advanced Diesel Engine Management) 4 Dimensional timing- Looks at engine speed, engine load, aftercooler inlet temperature, and adjusts timing- Optimized BSFC or emissions based on all parameters Smokeless engine- 7% opacity (not visible to the eye)

The 3500B Engine Control Advantage

Sheet1

ParameterAlarmDerateShutdown

ECM Voltage

Engine Oil Pressure

J/Water Temp High

J/Water Temp Low

Overspeed

Air Inlet Restriction

Altitude Derate

Exhaust Temp

Oil Filter Diff.

Fuel Filter Diff.

Crankcase Pressure

Aftercooler Temp High

Sheet2

Sheet3

The 3500B Engine Control Advantage

Sheet1

ParameterAlarmDerateShutdown

ECM Voltage

Engine Oil Pressure

J/Water Temp High

J/Water Temp Low

Overspeed

Air Inlet Restriction

Altitude Derate

Exhaust Temp

Oil Filter Diff.

Fuel Filter Diff.

Crankcase Pressure

Aftercooler Temp High

Sheet2

Sheet3

The 3500B Advantage - Engine MonitoringDiagnose Problems / Reduce DowntimeOver 100 codes, each code has 2 elementsOccurrences recorded, active and loggedLogged diagnostics locate difficult intermittent problemsEngine monitoring

The 3500B Electronic AdvantageEngine Control

Engine Monitoring Engine Servicing Information Management- Electronic Control Module- Sensors- Injectors

The 3500B Engine Servicing Advantage Caterpillar Electronic Technician (ET)

Real time accessCreate histogramsSelf diagnosing

1200 rpm Product AdvantagesIncreased Ratings +3% to 9%Reduced Fuel ConsumptionLand Rigs 2-3%Offshore 9%Certified To Meet Jan 1, 2000 EPA Off-road and IMO Emission Regulations

3500B High Displacement25 mm Increase in Stroke (190 to 215)Increased Compression Ratio, 14:1 to 15.5:1Extensive Field Development Program3 Years25,000 Operation Hrs.Initial Production 1999/2000

High DisplacementFeature Benefit+13% Displacement Higher Output

Improved Breathing Better Fuel ConsumptionImproved Combustion Lower Emissions

3512B OILWELL SERVICE ENGINE Rated bhp - 2000 & 2250 rpm - 1900Pilot Engines August 99EPA Certification December 99Production February 00

Oilwell Service Engine

3508B Land MechanicalRated bhp - 900 & 760 rpm - 1200EPA CertificationJuly 00ProductionJuly 00

HP121514761855 2150BSFC0.3900.3240.324 0.345(lb/bhphr) RPM120012001200 1200Displ. (in cu.)392731584210 4761D399 3512B3516B3516B H.D.

3500 Petroleum Ratings (BHP)

* 3500B EPA &/or IMO Certified Engine 3508 3512 3516 3516 B H.D.

Fracturing 1135 2250* -- --@ 1900 rpm 2000*Drilling @1200 rpm Electric 915* 1476* 1855* 2150* Drives 860 1435 1804 760 950 1408

Mechanical 900* 1250 1649 -- Drives 760* 1025 1400

EPA REGULATED EMISSIONSHydrocarbons

Carbon Monoxide

Oxides of Nitrogen (NOX)

Particulate Matter

Smoke / Opacity

Current Regulatory ApproachCertification of new engines

Certification testing program

Selective Enforcement Audits / New engines

Emphasis on Compliance of new engines

Compliance for useful life

International Maritime Organization(IMO)

Installed in a ship constructed on or after Jan 1, 2000Undergoing a major conversion on or after Jan 1, 2000Annex VI of MARPOL 73/78 Regulations for the Prevention of Air Pollution from Ships defines emissions regulations for NOx

Impacts commercial and pleasure crafts with engines over 174 bhp (130 bkW)

Response to IMO

Tremendous amount of research to optimize performance, fuel efficiency, and low emissions Changed engine configuration, software, and components

International Maritime Organization (1500 rpm) - 2000US EPA 2000 Tier 1Particulate ReductionNOx Reduction3500B3500 EUI3500AUS EPA 2006 Tier II

In ReviewHistory and Objectives of the 3500BAdvantages of the 3500BNew 3500B Products3500B RatingsCertifications

Questions ?

Current population is for total number of 3500 not just petroleum

The changes in the combustion process associated with the transition from the A Series (MUI) to the B Series engine were: 1. New higher compression ratio articulated piston with a new bowl design (14:1 C/R vs 13.5:1 for PH2 MUI and 13:1 for PH1 MUI) 2. Higher injection pressures achieved using... a. Beefed up rear gear train b. New cam with more aggressive injector lobe profiles and a bigger base circle c. Beefed up injector train (lifter, rocker arm, rocker shaft, etc.) d. B Series injector

Air delivery enhancements, include a higher mounted aftercooler and a more streamlined exhaust manifold.For EPA and IMO engines we do not adjust the timingAll engine faults are stored until cleared by a servicing tool. Every fault code sent to the ECM consists of two parts 1) component identifier (CID) which identifies which component is abnormal and 2) failure mode identifier (FMI) which describes the abnormal occurrenceThe primary function of the ECM is to control engine governing, fuel injection duration, and timing control.

There are 14 sensors on a 3500B ADEM II genset control system with EMCP II. They include things such as JW and exhaust temperatures; filtered fuel, unfiltered fuel, filtered oil, unfiltered oil, turbo inlet and outlet, and atmospheric pressures. There are also fuel/timing sensorsFuel consumption was reduced more on the offshore rigs mainly due to offshores requirements are less stringent on emissions (IMO vs. EPA).In order to meet EPA emissions, land rigs retard timing which increases fuel consumption Also, overall land rigs are less efficient. Offshore rigs have a gas tight exhaust so they dont waste as much internal energy, which increases their efficiency.EPA tests only when we come out with a new family of engines or a new engine that has a higher fuel consumption. We test the highest rating plus a big overload in able for us to get the certification and be able to cover the rest of the ratings in each family of engines. We send EPA our raw emissions data and they will tell us whether our engines are certified. EPA also holds the power of selective enforcement audits. They come to the plant and pick out of the list of certified engines and test whichever one they want. If 1 out of 5 fail we have to test 2 more if 2 of the 7 fail we test 9 more and so on. Once a month we run our own emission self test We have been very successful and have not had to fail an engine yet. Useful life is defined as 8,000 hours or 10 yrs. At this point we are no longer responsible for the engine to be emissions certified.