Power Up: Modernizing Gas Compression Operations with Cat® G3600 A4 Gen 2 Engine Upgrade 

Gas Compression Engines
Gas Compression Engines

As gas compression operators face evolving requirements and operational needs, valuable engineering updates are available for existing Cat® engines. The Cat G3600 A4 Gen 2 upgrade kit helps modernize Cat A4 Gen 1 engines1  by not only lowering methane and other types of emissions but also offering the flexibility to increase power compared to the previous model. Crucially, the optional power increase enables higher throughput which helps maximize revenue without impacting service intervals or engine life.

Power-Packed Benefits

Gas compression operators can unlock even more value with the Gen 2 upgrade kit when installed during a G3600 A4 Gen 1 engine’s overhaul cycle. Gen 2 upgrade kits use the same engine footprint as the A4 Gen 1, and operators performing the upgrade during an overhaul can effectively optimize costs. 

The A4 Gen 2 upgrade kit is available in three options to meet specific needs and operating conditions:

  • The first option lowers greenhouse gas (GHG) emissions without changing power output or modifying the existing gas compression package2.
  • A second option reduces GHG emissions while providing up to a 10% increase in power and up to a 1% reduction in fuel consumption. This enables operators to compress more gas while reducing fuel costs, which can positively impact revenue. The 10% power increase is available for all engine models G3606 and higher. While total fuel use increases with a more powerful engine, operators experience an overall efficiency improvement on a per-horsepower basis. Depending on site conditions, this option can increase heat rejection, so capacity must be evaluated to determine any updates for the cooler or compression package3. 
  • A third option is available specifically for high-altitude applications to lower GHG emissions while providing up to a 10% power increase. This may also require updates to the cooler or compression package depending on site conditions4. 

The Gen 2 kit maintains the inherent advantages of G3600 lean burn technology – longer life, lower fuel consumption, wider fuel tolerance and higher altitude capability – while affording the ability to be rebuilt to extend service life.

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Support for Operators' Sustainability Objectives

Evolving regulations have made emissions reduction a top-of-mind sustainability objective for operators. The G3600 A4 Gen 2 upgrade can achieve the following emissions reductions, compared to the previous model:

  • Up to 33% methane reduction.
  • Up to 32% volatile organic compounds (VOCs) reduction.
  • Up to 24% formaldehyde reduction.
  • Up to 13% carbon monoxide reduction.
  • Up to 5% GHG reduction.

For operators seeking to enhance those benefits, Cat Reman offers the ability to support sustainability objectives holistically – while also lowering total cost of ownership. The Gen 2 Kit includes Cat Reman heads and prechamber components, and additional remanufactured parts are available to complete an overhaul maintenance cycle. The remanufacturing process not only reduces waste, conserves resources and supports a circular economy, but also enables operators to experience like-new performance at a fraction of the cost of new components. 

With Cat Reman, only genuine Cat parts are used and every component is disassembled, cleaned, inspected, updated with critical engineering improvements and then remanufactured with advanced techniques. Compared to the manufacture of new parts, the remanufacturing process significantly reduces environmental impact by using 65–87% less GHG emissions and energy5  and offers solutions at 45-85% of the price of a new part when operators return used cores6.

Field-Proven to Weather Any Conditions

The G3600 A4 Gen 2 Kit not only provides operators flexible power and a range of emissions-reduction capabilities, but also field-proven dependability as it has accumulated hundreds of thousands of operational hours of testing across major oil and gas basins. The Gen 2 kit represents Caterpillar Oil & Gas’ dedication to continuous improvement to support gas compression operators’ evolving needs. This powerful upgrade not only helps operators keep pace with the industry’s shifting requirements but also helps decrease operating costs to positively impact revenue. 

Applying an A4 Gen 2 upgrade during a scheduled overhaul is a convenient, cost‑effective way to access the latest gas compression technology. Working with the Cat dealer network to add Cat Reman components to an overhaul further amplifies cost savings and positively impacts performance and uptime with drop-in convenience. 

1 Cat G3600s manufactured from 2015-2023.

2 Cat.com. The Next Gen Cat® G3600 engines. We’ve really outdone ourselves this time. https://www.cat.com/en_US/by-industry/oil-and-gas/gas-compression/g3600-engines.html.

3 Cat.com. The Next Gen Cat® G3600 engines. We’ve really outdone ourselves this time. https://www.cat.com/en_US/by-industry/oil-and-gas/gas-compression/g3600-engines.html.

4 Cat.com. The Next Gen Cat® G3600 engines. We’ve really outdone ourselves this time. https://www.cat.com/en_US/by-industry/oil-and-gas/gas-compression/g3600-engines.html.

5 Represents U.S. environmental impacts of gate-to-gate remanufacturing and remanufacturing processes for Cat engines and components, as defined in the 2018 United Nations Environment Programme report “Redefining Value – The Manufacturing Revolution.” Does not include impacts elsewhere in our value chain.

6 Cat.com. 2024 Caterpillar Sustainability Report. https://caterpillar.sharepoint.com/:b:/r/teams/MarcomTeam-MarineOilGasGroup/Shared%20Documents/General/Oil%20%26%20Gas/06.%20Aftermarket/Campaigns/COG%20Aftermarket%20Campaigns/AFT_Cat_Reman/04%20Additional%20Resources/Reman%20Ref/2024%20Caterpillar%20Sustainability%20Report.pdf?csf=1&web=1&e=wjCWk6. 

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