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Caterpillar China Generator Set Case Study

There are a number of key facilities in China, including Tianjin, Suzhou and Wuxi.


Asia Power Systems (Tianjin) Ltd.

Asia Power Systems (Tianjin) Ltd. was established in 2000 at the Tianjin Port Trade Zone as a Caterpillar wholly-owned subsidiary. The facility provides assembly, testing and related services for Cat® branded and FG Wilson branded generator sets ranging from 5.5 to 900 kVA. Asia Power Systems (Tianjin) Ltd. The facility’s 400 employees maintain a reputation for world-class operations regarding safety, quality, reliability and values.

AsiaTrak (Tianjin) Ltd.

AsiaTrak (Tianjin) Ltd. is a joint venture incorporated in September 1997 by Caterpillar (China) Investment Co., Ltd. together with SCM Singapore Holdings Pte Ltd and SNT Corporation from Japan. AsiaTrak is located in the Tianjin Port Free Trade Zone, covers an area of 54,000 square meters and has approximately 400 employees. AsiaTrak manufactures high quality and low cost undercarriage components for hydraulic excavators and track-type tractors, including track rollers, carrier rollers, link assemblies and track groups, for Caterpillar Inc.’s facilities and relevant Original Equipment Manufacturers (OEMs).

Caterpillar Tianjin Ltd.

Caterpillar Tianjin Ltd. is a Caterpillar wholly-owned subsidiary. Established in Tianjin Airport Economic Area in November 2010, Caterpillar Tianjin is the largest investment of Caterpillar in the Asia-Pacific area.  The facility is the only producer of large engines and generator sets in China.

Covering a land area of 250,000 square meters, the facility manufactures 3500 series generator sets and FG Wilson 400 series generator sets. These products are used in various industries including electric power generation, petroleum, well drilling, railway, marine, industrial and mining applications. Once fully operational, Caterpillar Tianjin will become Caterpillar’s second largest global manufacturing base for 3500 series generator sets by production capacity.

Caterpillar Shared Services Center

Created to leverage the benefits of the best-in-class business practices and maximize regional effectiveness, Caterpillar established the Caterpillar Shared Services Center in China (also called Caterpillar (China) Investment Co., Ltd. Tianjin Branch).

With an office area of 4,200 square meters, the facility has 185 employees who provide support services to various Caterpillar facilities located in Beijing, Tianjin, Qingdao, Shanghai, Wuxi, Suzhou, Nantong, Wujiang, Xuzhou and Shandong.


Caterpillar (China) Financial Leasing Co., Ltd.

Caterpillar (China) Financial Leasing Co., Ltd. is the financial arm of Caterpillar Inc., serving customers in China since 2004. It is the first finance leasing company in China’s construction equipment industry.

Solar Turbines (Beijing) Trading & Services Co., Ltd.

Solar Turbines (Beijing) Trading & Services Co., Ltd. is a subsidiary of Caterpillar (China) Investment Co., Ltd.  It covers Solar Turbines Incorporated (where applicable, Solar Turbines Incorporated and its affiliates, individually or collectively referred to as “Solar”) products and aftermarket services business in Great China (Chinese mainland, Taiwan and Hong Kong).

Established in 1927, Solar Turbines Incorporated is headquartered in San Diego, California. It was acquired by Caterpillar in 1981. Solar products, including gas turbine and gas compressor first entered into the Chinese mainland in the 1980s.  As Solar’s fleet grew, Solar established a representative office in Beijing in 1992, set up China service area in 2007 and then established Solar Turbines (Beijing) Trading & Services Co., Ltd in 2011.

MWM (Beijing) Co., Ltd.

Founded in Mannheim, Germany in 1871, MWM is a Caterpillar-owned, global leading brand focusing on gas gensets. With power outputs between 400 and 4,300 KW, MWM is one of the international leading brands for decentralized energy supply.

In 1995, MWM gas gensets entered the Chinese market. In 2007, MWM (Beijing) Co., Ltd. was established, which has provided hundreds of gas gensets for more than 50 projects in China, with an installed capacity of more than 300MW nationwide in a wide range of applications, including natural gas distributed energy, landfill gas, coal mine gas, sewage gas, biogas and natural gas power generation.


Caterpillar (Langfang) Mining Equipment Co., Ltd.

Caterpillar (Langfang) Mining Equipment Co., Ltd. is a wholly-owned facility of Caterpillar. In 1998, Caterpillar Langfang was established and began production in Langfang Economic & Technical Development Zone, Hebei Province. In the beginning, the company specialized in manufacturing of AFC line pans in coal mining.  With the company’s continuous development, and the progress of Caterpillar’s underground mining strategy, Caterpillar Langfang is committed to becoming a manufacturer of premium AFC for customers worldwide.


Caterpillar (Qingzhou) Ltd.

Caterpillar (Qingzhou) Ltd, formerly known as Shandong SEM Machinery Co., Ltd., was founded in 1958 and reorganized as a share-holding company in 2003. In 2008, Caterpillar Qingzhou became a wholly-owned subsidiary of Caterpillar Inc. In November 2013, the company changed its legal entity name to the current name.

Today SEM is an important brand in the Cat portfolio, supporting a fast-growing China customer base. Caterpillar Qingzhou employs approximately 2,500 employees and is located in Qingzhou City, in eastern Shandong Province, which is easily accessible by major highways. At a wholly-owned subsidiary of Caterpillar Inc., Caterpillar Qingzhou manufactures both Cat® brand and SEM brand products. SEM brand products include wheel loaders, soil compactors, motor graders, track-type tractors, landfill compactors, pavement machinery components and work tools. The facility also launched the first Cat® 950 GC wheel loader in March 2014.


Caterpillar (Zhengzhou) Ltd.

Caterpillar (Zhengzhou) Ltd. is a wholly-owned Caterpillar company. Located in Xingyang, Henan Province, Caterpillar Zhengzhou manufactures roof supports for underground longwall coal mining.  As an important part of Caterpillar's underground mining strategy, Caterpillar Zhengzhou aims to be a manufacturer of lifecycle value roof supports and parts for customers worldwide.


Caterpillar Remanufacturing Services (Shanghai) Co., Ltd.

Caterpillar Remanufacturing Services (Shanghai) Co., Ltd. was established in December 2005. Located in the Lingang Industrial Park, Shanghai, Caterpillar Reman Shanghai is Caterpillar’s first remanufacturing company in China. Remanufactured products of Caterpillar Reman Shanghai include hydraulic components (hydraulic pumps and motors), engine components (oil pumps, water pumps, cylinder heads and cylinder packs) and fuel systems (fuel injectors). Moreover, Caterpillar Reman Shanghai also provides services to external companies and other Caterpillar businesses in China.

Caterpillar Logistics (Shanghai) Co., Ltd.

Set up in January 2005, Caterpillar Logistics (Shanghai) Co., Ltd. is located in Shanghai Lingang Industrial Park, next to the Shanghai Free Trade Zone. It covers an area of 84,000 square meters, including 45,000 square meters of bonded and non-bonded warehouse space.

A fully functional, well equipped and modern technologically-advanced parts service platform was put into operation in February 2006 at Caterpillar Logistics (Shanghai) Co., Ltd., covering the businesses from purchasing, testing, packing, storage and sales to import/export services of Caterpillar aftermarket parts. Acting as an important entry point of Caterpillar global parts distribution network, the facility provides parts supply and around-the-clock services to Caterpillar dealers in China, and also serves Caterpillar parts distribution centers in other regions.

Caterpillar Marine Trading (Shanghai) Co., Ltd.

Caterpillar Marine Trading (Shanghai) Co., Ltd. is well known in the marine and oil & gas industries as “MaK Asia.” MaK Asia is a wholly-owned Cat dealer that specializes in medium-speed engines and systems. Its brands include MaK Marine, CM Petroleum and EMD. The Shanghai headquarters has about 50 employees and serves as a direct sales and service dealer to support customers in the Greater China region. A similarly sized operation in Singapore handles the remainder of Asia.

Caterpillar Marine Trading (Shanghai) Co., Ltd offers the following products and services: engines for marine propulsion allied with gearboxes, drive shafts and propellers; engines for auxiliary generator sets and DE propulsion; main generator sets for offshore petroleum applications with complete auxiliaries; and a full range of services for MaKTM engines in all aspects of marine applications, from project start-up to product sale and commissioning, from local parts supply and parts logistics, maintenance, workshop and onboard repair services to engine upgrade and customer training.


Caterpillar (Xuzhou) Ltd.

Caterpillar (Xuzhou) Ltd. was the first manufacturing facility Caterpillar established in China, mainly producing hydraulic excavators. Opening its doors in 1994, it was originally located in Xuzhou Economic & Technological Development Zone, Jiangsu Province. The facility plays a significant role in implementing Caterpillar’s China strategy, including new product introduction, improving local market share and exporting products.

Caterpillar Paving Products (Xuzhou) Ltd.

Founded in March 2000, Caterpillar Paving Products Xuzhou Ltd. is the only paving products manufacturing facility of Caterpillar’s Global Paving sector in the Asia Pacific region.

The Caterpillar Paving Products Xuzhou Ltd facility covers an area of 22,306 square meters and employs 270 people. Its main products are soil compactors, asphalt compactors and pneumatic compactors and cold planers. It manufactures products mainly for overseas markets in Asia Pacific, Africa, Latin America and the Middle East.

Caterpillar Undercarriage (Xuzhou) Ltd.

Established in June 2011, the Caterpillar Undercarriage (Xuzhou) Co., Ltd. facility has an area of 67,000 square meters and produces undercarriage products and components for Caterpillar (Xuzhou) Ltd. and OEM customers.


Caterpillar (China) Machinery Components Co., Ltd.

Established in 2005, Caterpillar (China) Machinery Components Co. Ltd. is the first Caterpillar wholly owned company of supporting components. Located in the Wuxi New District, Jiangsu Province, Caterpillar (China) Machinery Components Co., Ltd. covers a land area of 19 hectares and a manufacturing space of 101,000 square meters.  The company has 1,500 employees in total. The three independent plants design and manufacture hydraulic components, operator stations and powertrain components, respectively. 

Caterpillar R&D Center (China) Co., Ltd.

Established in 2005, Caterpillar R&D Center (China) Co., Ltd. is headquartered in Wuxi, Jiangsu Province and has branches in Wuxi, Qingdao, Tianjin and Nantong. The headquarters has a land area of 31,290 square meters and a construction area of 25,000 square meters.

The Caterpillar China R&D Center aims to provide cost-competitive, world-class research and development and intellectual property management services to support the implementation and execution of Caterpillar’s strategies in China and other growth markets. It supports Caterpillar’s manufacturing facilities and supplier bases in the region, allowing Caterpillar to get closer to customers and take advantage of regional engineering talent to develop market-leading products beyond customers' expectations.

Perkins Shibaura Engines (Wuxi) Co., Ltd

Established in December 2007, Perkins Shibaura Engines (Wuxi) Co. Ltd. is a joint venture between Caterpillar and long-term, small-engine partner IHI Shibaura Machinery Co. Ltd. Perkins Shibaura is the first project in Caterpillar’s Wuxi Engine Campus, located in Wuxi High-Tech Industrial Development Zone, Jiangsu Province. The facility has a land area of 29,083 square meters and a building area of 10,242 square meters. Perkins Shibaura began operations on November 27, 2008.

Perkins Shibaura produces Perkins 400 series engines ranging from 11Hp to 68Hp, which are sold primarily to original equipment manufacturers (OEMs) for the use of small construction machinery, agricultural machinery, earthmoving machinery, material delivery machinery and generator sets.

Perkins Power Systems Technology (Wuxi) Co., Ltd.

Established in March 2009, Perkins Power Systems Technology (Wuxi) Co. Ltd. is a Caterpillar wholly owned company and the second project in Caterpillar’s Wuxi Engine Campus. The facility has a land area of 135,000 square meters. Perkins Power shipped its first batch of engines in July 2010. 

Perkins Power mainly produces Perkins 1100 series engines ranging from 75Hp to 350Hp, which are sold to original equipment manufacturers (OEMs) in agriculture and other industrial sectors as well as being used in Cat core construction equipment and generator sets.


Caterpillar (Suzhou) Co., Ltd.

Caterpillar (Suzhou) Co. Ltd. was established in Suzhou Industrial Park, Jiangsu Province in 2006. The facility has a construction area of 74,561 square meters and about 800 employees. Fully owned and operated by Caterpillar, it is a major production base in Asia Pacific for medium wheel loaders and motor graders, with products sold in Asia, Russia, the Commonwealth of Independence States, Africa, Middle East and South America.

Caterpillar (Suzhou) Logistics Co., Ltd.

Caterpillar (Suzhou) Logistics Co., Ltd. a Caterpillar wholly owned subsidiary under the Product Support & Logistics Division (PSLD) of the Caterpillar Enterprise System Group. The facility was registered in Suzhou Industrial Park in October 2009 and officially opened in August 2010. It covers 12,000 square meters of bonded and non-bonded warehouses. The facility has more than 120 employees.


Caterpillar (Tongzhou) Co. Ltd.

Caterpillar (Tongzhou) Co., Ltd. is located in Xitong Technology Park, Tongzhou, Jiangsu Province, China and occupies 53 acres on a shared campus with the Asia Pacific Proving Ground.  The Asia Pacific Proving Ground is an expansion of the Caterpillar China Research and Development Center in Wuxi and provides engineering validation and product development services for Cat products designed or produced in the Asia Pacific region.


Caterpillar (Wujiang) Ltd.

Established in July 2011, Caterpillar (Wujiang) Ltd. is based in the Wujiang District, Suzhou in East China’s Jiangsu Province. The facility has a construction area of 110,466 square meters and specializes in the production of 300 series mini-hydraulic excavators for China and global markets.

The facility opened producing two types of mini-hydraulic excavators, 306 and 307D. In response to increasing demand of Chinese customers for higher performance and lower operating costs, the facility began production of E-series mini-hydraulic excavators in 2013. Today, six types of E-series mini-hydraulic excavators are produced at the facility: 303.5E CR, 305.5E2, 306E2, 307E2, 308E2 and 307E2 Tier 4F.


Caterpillar Motoren (Guangdong) Co., Ltd.

Caterpillar Motoren Guangdong Co., Ltd is a wholly-owned company of Caterpillar in Shunde, Foshan, Guangdong Province, China. The facility occupies an area of 18,642 square meters and a building area of 6,154 square meters.

Founded in 1994 as a joint venture between German diesel engine manufacturer Krupp Mak and China Guangzhou Diesel Engine Factory, the company was first called Guangzhou MaK Diesel Engine Co., Ltd. The company assembled, produced and tested Mak-brand marine engines and gensets. In 2005, it became a Caterpillar wholly-owned company and was renamed Caterpillar Motoren Guangdong Co., Ltd.  Caterpillar Motoren Guangdong designs, manufactures, assembles, tests and conducts after sales service of marine engines and supporting systems. 

Considerations for transfer switch selection

by Brett Greene
Sales Representative, Peterson Power Systems
(510) 618-5536 | (925) 457-5135 cell |

The best way to select a transfer switch is to understand the types of loads connected to the standby system. Consider the characteristics of the connected load, and loads that may be connected in the future.

Here are common switch types, along with their advantages and disadvantages:

This family of transfer switches provides fast load transfer with “break-before-make” action. In their standard form, they assure that the utility and the gen set are never connected simultaneously.

However, double-throw transfer switches should not be used with larger (20-hp and up) motors, compressors and transformers. Voltage in motor devices decays at much longer rates than other loads because the motor continues to rotate and the magnetic flux causes the motor to act like a generator. They will likely be out of phase if power is reconnected too quickly. Out-of-phase start-ups will trip circuit breakers or needlessly stress load and/or generator windings.

Circuits serving motors or transformers should be transferred to standby power with time-delay neutral (TDN) transfer switches, which allow flux voltages to decay before these devices are brought back on line.

TDN switch design is simple and reliable. When specifying TDN switches, select units with an adjustable time delay so it can be best set for the application.

Since most facilities with emergency power have HVAC compressors or motors, a TDN transfer switch can meet the needs of lighting and motor circuits.

In-phase monitoring (IPM) transfer switches (usually an open transition switch) monitor the phase difference between the load and oncoming source. It is a more expensive transfer switch, since it anticipates the best time to trigger the transfer, or prevent it from happening if the desired power source remains out of phase with the load.

A speed (frequency) difference larger than 0.4 Hz may occur with gen sets equipped with a droop-type governor which may prolong the out of phase condition and prevent a quick transfer to the desired source. In this case, an isochronous engine governor with synchronization should be specified with the IPM to secure a quick transfer.

Another higher-cost option to consider is a “make-before-break” closed transition switch. It momentarily parallels the two power sources before transfer. Complex safeguards must be added to guarantee that “in-parallel” time be no longer than 100 milliseconds. These systems increase engineering costs because utilities require extensive documentation to assure grid safety. It also increases customer liability.

The owner usually has one consideration — low cost. However, the overriding goal should be a reliable system with reasonable installation and operating costs over the system life.

Before specifying a double-throw switch, be sure that motors and compressors will not be added to the gen set circuit load in the future. Upgrading to a three-position switch can cost considerably more than installing a three-position switch at initial installation.

We suggest you specify time delay neutral transfer switches with variable and immediate transfer capability. TDN switches are reliable and keep system design simple and flexible.