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.
Print Media
