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Gaining Ground in the Energy Transition with Smart Tech for Onshore Drilling
Smart technology transitions onshore drilling rigs to EPA Tier 4 final engines
By Caterpillar | Posted: June 24, 2025
For more than a decade, original equipment manufacturers (OEMs) have continually improved technology solutions to support a transition to fully integrated, rig systems that meet U.S. EPA Non-Road Mobile Tier 4 emissions standards. Today, smart technologies are central to this effort. Such innovations enable more efficient performance and reliability in the field, helping drilling companies reduce diesel consumption, decrease operational costs and reduce greenhouse gas (GHG) emissions in some of the strictest regions in North America.
Amplifying this trend, a suite of digital solutions featuring the Cat® Smart Engine Management System (Smart EMS) is driving greater efficiency and cost savings for new rigs equipped with the Cat® 3512E Tier 4 Final Land Electric-Drive Drilling Engine.
As some drilling companies transition onshore drilling rigs to EPA Tier 4 Final engines, it’s useful to compare the Cat 3512E to the previous Tier 2 model – the 3512C. In terms of overall performance, the 3512E meets or exceeds 3512C standards in nearly every category, delivering the same power over the same operating range.
Emissions-Reduction Technologies
Drillers must meet demands for safer, faster performance in a cost-effective operational environment while targeting climate-related objectives. However, enabling EPA emissions compliance for the various constituents typically produced by a diesel engine poses unique challenges. Measures taken to reduce nitrogen oxides (NOx) often increase particulate matter (PM), hydrocarbon (HC) and carbon monoxide (CO) emissions. Alternatively, reducing PM, HC and CO emissions typically lead to increased NOx levels.
To meet both application requirements and driller’s needs, the Cat 3512E Tier 4 Final engine for land drilling uses an optimal combination of GHG emissions-reduction technologies. It’s field-proven to meet or exceed the reliability standards set by the 3512C without the burden of complex aftertreatment systems or secondary fluid requirements.
A closer look at four key benefits of the Cat 3512E Tier 4 Final engine reveals the advantages of upgrading an onshore drilling fleet to the latest technology systems engineered to maximize performance and uptime while lowering GHG emissions.
Exhaust Gas Recirculation to Reduce NOx
NOx typically forms at high combustion temperatures inside engine cylinders. Exhaust gas recirculation (EGR) reduces the oxygen level and peak combustion temperature inside the cylinder, which reduces NOx formation. The Cat 3512E engine’s NOx Reduction System (NRS) cools and meters recirculated exhaust gas.
High-Pressure Fuel Injection System Reduces PM
PM generally forms due to an uneven air-fuel mixture and combustion inefficiencies within the cylinder. Two common technologies for PM reduction include high-pressure fuel injection and diesel particulate filters (DPF), which filter PM from the exhaust stream.
The 3512E uses a high-pressure fuel injection system to finely atomize the fuel mixture in the cylinder and minimize the formation of PM, eliminating the need for DPF.
Cat® 3512E EGR
HC and CO Reduction Through Diesel Oxidation Catalyst Use
The 3512E relies upon a diesel oxidation catalyst (DOC) that reduces HC and CO to simply CO2 and water vapor. The compact, maintenance-free device also provides additional exhaust sound attenuation, reducing noise pollution for a quieter jobsite.
Eliminating the Challenges of Selective Catalytic Reduction
Selective Catalytic Reduction (SCR), an aftertreatment technology, injects diesel exhaust fluid (DEF) into the exhaust to separate NOx into nitrogen and water vapor with the aid of a catalyst element. This approach can create significant challenges for drillers:
- The size and arrangement of the aftertreatment, DEF storage tanks, DEF pumping units and associated piping are prohibitive on a land drilling rig.
- The additional logistics and handling required for on-site storage and distribution of large quantities of DEF is difficult for remote drill sites.
- DEF freezes at 12 °F and shelf life decreases dramatically at temperatures above 90 °F, which can create additional challenges for year-round use in certain geographies.
Rather than rely upon SCR to reduce various emissions, the Smart EMS augments the emission reduction benefits of the Cat 3512E Tier 4 Final engine through automating performance monitoring and engine load management. The Smart EMS helps reduce engine runtime through automatically turning engines off and on based on real-time power demand. This allows drillers to lower fuel consumption – as well as range of constituents produced.
System Installation Changes
The 3512E offers the same physical footprint as the 3512C, with factory-installed NRS and common rail fuel system components. The most significant changes to a 3512E installation are evident in the exhaust and cooling system.
Exhaust System Leaves Master Skid Unchanged
The exhaust system features a single DOC between the turbocharger outlet and muffler. The DOC can be mounted in a variety of locations and orientations to fit the design of the exhaust and roof structure without affecting the overall size of the master skid.
Cat 3512E exhaust system
Cooling System Increases Heat Rejection
The NRS cools re-circulated exhaust air before returning it to the intake air stream, resulting in higher overall engine heat rejection. However, the 3512E’s two-stage aftercooler offsets nearly all of the impact on the radiator or cooler’s size. Minor fan design and speed changes further minimize the effect on the cooling system’s size.
Cat 3512E Cooling System
Smart Controls Reduce Fuel Consumption and Engine Run Time
While EGR technology is believed to increase fuel consumption, the 3512E offers improved fuel consumption compared to the 3512C. Comparing identical drilling load profiles, the 3512E consumes 2% less diesel. Additionally, the absence of an SCR system mitigates costs related to DEF or urea use.
Importantly, the Cat 3512E engine controls employ the same direct rack throttle controls as the 3512C, offering the ability to utilize the Smart EMS to ensure individual engines operate at optimal loads to improve fuel efficiency. The EMCP 4.4 control panel is the foundational component that enables drilling rig engine power management possible. These digitalized advancements are field-proven to produce increase fuel efficiency up to 10% and reduce engine run time up to 25%.
Remote Monitoring Expands Visibility into Operations and Maintenance
The 3512E adheres to the same service intervals and procedures as the 3512C. It also includes Product Link™ remote monitoring to track productivity and engine health by engine, rig or fleet globally.
| 3512C (Tier 2) | 3512E (Tier 4 Final) | |
|---|---|---|
| Fuel spec (sulfur ppm) | 500 ppm | 15 ppm |
| Required oil spec | ECF-2 (CI-4) | ECF-3 (CJ-4) (CK-4) (ACEA #9 or JAS DH-2 that meet CJ-4) |
| Fuel consumption | Base | Reduced1 |
| Control system | ADEM A3 | ADEM A5 |
| Control panel | Engine Instrument Panel | EMCP 4.4 with Product Link |
| Closed crankcase ventilation | None available | Optional |
| Service intervals (air, oil, fuel)2 | 250, 500, 1000 hours | 250, 500, 1000 hours |
| Valve lash | 4000 hours | 4000 hours |
| Alternator | Tensioning required | Auto tensioning |
| Published overhaul life3 | 11,000/22,000/33,000 hours | 16,500/33,000 hours |
1 Application specific. 2 Targets based on maintenance practices and location. 3 Depends on operation and maintenance practices.
Digitalization Supports Climate-Related Objectives
The land-based drilling evolution continues as OEMs introduce new technologies leveraging digitalization and automated tools for the North American onshore drilling sector. Such efforts help usher in new realms of performance and efficiency gains.
1. Cat® Smart Engine Management System (EMS). Learn more