When Herrenknecht Vertical GmbH, a leading manufacturer of complex, specialized drilling rigs worldwide, needed not only power but intelligent power they turned to Cat® dealer Zeppelin Power Systems to deliver a customized configuration unmatched by any other in the world. “Our deep drilling rigs set new standards when it comes to technology, safety, efficiency, service and environmental protection. In addition, our end customers have special and individual requirements. Therefore, we need reliable partners, who are able to implement our ideas, and to provide us with suitable technical solutions. Not every company is able to fulfill this – this is why we decided for Zeppelin Power Systems” said Jürgen Binder, Technical Director at Herrenknecht Vertical.
Herrenknecht Vertical needed a generator set solution with an individual configuration to fit into a given system environment for the end customer. The end customer required a container solution with low maintenance and easy handling for the intelligent power supply of the entire drilling rig including mud pump unit, hosting system and top drive. A special requirement was the maximum container height of 3.15 m for the highway transport (standard height is 3.40 m). Therefore, in addition to the supply of the power generator sets, a special frame for the container was required. Set-ups as well as installations had to be constructed on top of the container for easy installation and dismantling.
Another challenge was the integration of the alarm and safety system into the container, the configuration and implementation of the pipework for the fuel system, the exhaust and silencer system, as well as special connecting systems for the power cables and the connection to the existing steering system for the drilling rig. In addition, the customer wanted to conduct all test runs on-site at their Asian drilling location.
Zeppelin Power Systems configured the complete system solution including an intelligent power-management to the customers need in an incredibly short delivery time. Three Cat 3512B diesel generator sets, preinstalled in a container were delivered. Each generator set has a power rating of 1,500 kVA @ 690 V/50 Hz. The total power output is 4.5 MW. Each generator set is completely packaged and pre-configured in a 40-foot container. Included in each container were the generator, cooling unit, frame, as well as the complete alarm- and safety system for the monitoring and synchronizing of the generator sets. The complex specialty involved beyond the containers was the intelligent power-management: all three generator sets were capable of switched on or off to supply power as needed by the drilling rig processes during operation (either manually or automatically). During automatic operation, the three generator sets synchronize themselves via internal switchboard and reliable supply exactly the amount of power required by the rig. This allows efficient and cost effective operation of the drilling rig.
Zeppelin Power Systems conducted the configuration and the entire test run at their modern engine out-fitting plant in Achim, Germany. At the end customer’s location in Asia, the Zeppelin Power Systems service team performed the initial installation, commissioning and test of the entire drilling rig. In addition, the customer received an individually customized training on-site at the drilling rig and at the container generator sets. All test runs were performed together with the customer and directly on location.
The generator package with intelligent power-management allows a high performance, powerful and efficient operation of the drilling rig. The container solution offers flexible operation at various locations, easy transport and quick access for maintenance and handling. Due to the plug-and-play solution, the system can be operated by one person and can easily be connected directly at the drilling rig.
For the end customer, Zeppelin Power Systems realized an individually customized solution on with very short delivery time. The customer received an intelligent turn-key solution and ready to plug-in system package, and all from one source: Zeppelin Power Systems. From configuration, to the design of incredibly complex specifications, and installation, commissioning and training for the end customer, all was successfully completed by the highly trained staff at Zeppelin Power Systems. All customer’s requirements were successfully implemented and the power packaged installed completely without changes to the existing systems.
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Zeppelin Power Systems is the official partner of Caterpillar for Cat and MaK engines and a leading provider of drive, propulsion, traction and energy systems. It is a legal entity of Zeppelin group with over 7.500 employees and a turnover of 2.55 bil. Euro and has been partnering with Caterpillar for 60 years.
With about 800 employees Zeppelin Power Systems offers their customers individual, highly efficient system solutions with comprehensive services for industrial and marine applications, the oil and gas industry, rail vehicles and power generation. www.zeppelin-powersystems.com.
Caterpillar Oil & Gas, with headquarters in Houston, Texas, consolidates all the sales and service activities for Cat oil & gas power solutions that include reciprocating engines, generator sets, transmissions and well stimulation pumps. Since the 1930s, Caterpillar has manufactured engines for the oilfield and today provides power solutions with outputs from 31 to 16,000 kW. The sales and service network includes more than 2,100 dealer locations world-wide dedicated to support customers in the drilling, production, well service and gas compression segments. More information is available at: http://www.catoilandgasinfo.com
For nearly 90 years, Caterpillar Inc. has been making sustainable progress possible and driving positive change on every continent. Customers turn to Caterpillar to help them develop infrastructure, energy and natural resource assets. With 2013 sales and revenues of $55.656 billion, Caterpillar is the world’s leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. The company principally operates through its three product segments - Resource Industries, Construction Industries and Power Systems - and also provides financing and related services through its Financial Products segment. For more information, visit caterpillar.com. To connect with us on social media, visit caterpillar.com/social-media.
Jenna Janik Marcoux