Turbochargers for Gas Compression

Grant Heinold

Lead Engineer for Aftermarket Parts, Gas Engine Product Group

+1 765.448.2159
Heinold_Grant@cat.com

Zach Zeller

Turbocharger Engineer, Gas Engine Product Group

+1 765.448.5402
Zeller_Zachary_A@cat.com

What are your roles with Caterpillar?

Grant Heinold: My job is to make sure we have the right service offerings, whether that means new, Reman or kit solutions. I also help to identify gaps in any of those solutions in parts availability, so we know where we need to invest to fulfill customer needs.

Zach Zeller: I am a turbocharger application engineer who interfaces between our suppliers, performance groups and engine platform teams to ensure we have the best fit turbo for new product design and service offerings for Cat® 3500 and 3600 gas engines.

What are the advantages of using Cat® gas compression turbochargers?

GH: From a full system perspective, our newest generation of Cat G3600 engines really shine in altitude capability and fuel flexibility. Obviously, the turbocharger is an integral part of that performance. This allows the customer to run the engine in a wider variety of locations and still get the maximum power out of the system. So the generator set can have more variance in the type of fuel that goes into the engine and still operate at full power and efficiency.

ZZ: Cat turbos are selected for each engine application to optimize performance, reliability and the overall efficiency of the air systems. This results in better fuel efficiency and a longer product life.

How do turbos work with the rest of the engine to improve performance and reliability?

GH: Having a properly designed and matched turbocharger allows the rest of the engine systems to run at their best and have the best durability and reliability.

For example, a turbocharger that is not performing optimally may result in much higher exhaust temperatures coming out of the engine than usual. With high exhaust temperatures, you’re going to wear out components like exhaust valves more quickly. An optimally designed and maintained turbo will allow for increased life expectancy for other engine components within the air system.

ZZ: In terms of performance, pressurizing the engine with a turbocharger lets you to insert more air and fuel into the cylinder, allowing for more combustion and power.

Why are these features and benefits important to gas compression customers?

GH: The oil and gas market in general is all about uptime, and that is taken to the extreme in gas compression. In this market, you’re either moving gas and booking that revenue, or you’re not. The lost revenue from downtime is never really recovered. So, having a complete system, including the turbocharger, that is reliable enough to have uptime in the high 90s percent-wise is critical to running a gas compression operation efficiently and profitably.

ZZ: Most gas compression engines are in remote areas and unmanned. A reliable turbo gives the customer confidence that when they start their engines, the next downtime will be for scheduled maintenance.

What is the impact of using non-genuine Cat parts on a Cat gas compression engine?

GH: Putting inferior quality parts on the engine will cause the turbocharger to not perform well over its life. That leaves open the possibility of damaging other parts of the engine and shortening the life of the overall system.

ZZ: I heard an example from a dealer that a customer used a reverse engineered internal part in their turbo and it had ill effects, causing the turbo to fail sooner. According to the dealer, they used to lose business to that type of situation, but now customers are coming back due to the failures caused by not using genuine Cat parts.

What options are available for customers who need turbos rebuilt or repaired?

ZZ: The primary options for turbo repairs range from dealer rebuilds and exchange turbos to Cat Reman or new turbo cartridges and turbos. A customer can reduce rebuild costs by purchasing the right option for their situation.

Are remanufactured turbos rebuilt to the same quality as new?

ZZ: Yes, all remanufactured turbos are built to the same specifications as a new turbo. When a customer brings in a turbo, it is disassembled, cleaned and inspected for parts reuse. The turbo is then remanufactured with the latest technology and made available through the Cat Reman channel.

Why is important for a customer to have multiple options for their turbos?

GH: Not every customer’s engine is in the same situation. An engine that has gone through its overhaul life and is being rebuilt on a proactive basis, that turbocharger might be in significantly better condition than one that has damage from a catastrophic failure. Multiple options help customers get service in a timely fashion and reduce costs by only paying for what they need based on the condition of their components.