With over 100 years of operative experience in the oil and gas industry, KOLLER Maschinen- und Anlagenbau GmbH, a European well service product manufacturer, is known globally for its supply machines and wireline, pumping and coil tubing units.
To enhance offshore application offerings, KOLLER needed customized hydraulic power packs for its lightweight wireline units. More specifically, the units had to meet two mandatory criteria: the power pack must be certified for ATEX Zone II (safety codes for potentially explosive atmospheres), and the weight limit must not exceed 1,500 kg.
The engine usually weighs the most in any setup, so the simple answer would be to utilize a lightweight engine. However, use of lightweight materials for the skid does not comply with the offshore regulations from DNV GL, an international certification body and classification society for risk management, so KOLLER needed another solution.
KOLLER partnered with Cat® dealer Zeppelin Power Systems for a lightweight power pack solution, including reliable engines and excellent service.
"Looking back, the decision to work with Zeppelin Power Systems as a dealer and as an engineering partner for the Cat engines has been absolutely right,” said Holger Ahrens, division manager of well servicing products at KOLLER. “Under the same circumstances, we would choose this setup again.”
To reduce the power pack weight, Zeppelin Power Systems used customized, self-sufficient HazPak engines with variable speed and a 60 kW power rating. Pyroban, a Caterpillar subsidiary, was called upon to manage the additional equipment required for the ATEX regulation compliance.
Engineers from KOLLER, Pyroban and Zeppelin Power Systems modified the entire electrical system in the engine with mechanical components. Now the design provides hazard-free operation in areas where risk of explosion exists as well as a substantial weight reduction of 150 kg. After completing a successful testing phase in November 2012, KOLLER sent the hydraulic power pack for series production.
Zeppelin Power Systems supplies the engines as a customized solution and offers service, parts and warranty support – all from one source. KOLLER also has access to the global Cat dealer network, which helps support international business projects while reducing costs.
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About Zeppelin Power Systems
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.
About Caterpillar Oil & Gas
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 2014 sales and revenues of $55.2 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.