Reliability is keyZF transmission systems for the oil and gas industry

Shaping the future responsibly

Petroleum and natural gas are still two of the most important energy sources of modern society. The deposits are usually deep in the ground and tapping these resources is technically challenging and associ-ated with high costs. However, not only powerful drilling and pump technology is required: The utilization of state-of-the-art conveying lines and the most advanced facilities are needed in order to ensure that the environ-mental impact is kept to a minimum and that operation only poses the lowest possible risk to humans and the environment while safeguarding sustainable production is guaranteed.

Reliable transmission technology for drilling, completion and productionPump systems in petroleum and gas production must work in a particularly uniform manner. Constant torques as well as a stable pressure and flow rate are therefore key requirements that must be met. At the same time, safety, cost-effectiveness, and the reduction of fuel consumption and emissions also play a significant role in the application of modern hoisting and conveying technology.

ZF provides comprehensive system solutions all from a single source. The transmission components are perfectly harmonized with one another. The result: every transmis-sion system is a brand name product known for its reliability around the world.

Make visions come true

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The functional diversity places the highest of demands upon the driveline, especially the transmission. It must be designed for powerful engines with a high input torque, gear changes must take place under full load without a tractive force interruption and „bucking“. Furthermore, the transmission must be space-saving, light, and easy to assemble. ZF wishes to establish inter-active partnerships with customers that include design, manufacturing and customer services.

Wide range of applications

Thanks to the extensive experience stretching back over 100 years in the field of driveline technology, ZF Friedrichshafen AG offers intelligent, tailor-made, and utilization optimized drive solutions for the specific demands of the market and manufacturers. The wide product range offers transmission solutions specifically designed for the harsh requirements in oil and gas pro-duction, such as in pumping systems, workover and coil tubing rigs, cementing and acidizing units. ZF has the right automatic transmission for every imaginable engine configuration. This ensures that everything runs smooth-ly and is individually tailored for each customer.

Excellently networked worldwide

As a leading worldwide automotive supplier for driveline and chassis technology, ZF can look back over 100 years of experience in developing and building transmissions. ZF does not simply supply the transmis-sion, but supports its customers with the installation and transmission adjustment. Both users and the mainte-nance team are trained on site. Should additional sup-port be required at some stage, one of the approximately 650 ZF Service Centers is surely nearby.

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The ZF 8 TX automatic transmission for well servicing: lightweight, powerful, and durable – designed for the application in high pressure pumping applications.

Functional powerhouse

Weight savings

- 33 %compared to the lightest competitor product of the same class

Making the difference – powershifting and power densityZF exactly customized the 8 TX to the specific require-ments for well servicing. It offers eight gears and par-ticularly harmonious gear transitions as well as a high spread of gear ratios. Together with the very robust basic design, this minimizes both component stress and wear and results in a reliable, durable transmission with very low life cycle costs. More than anything else, it ensures a precise control of the pumping station. The latter can be highly powerful with the new ZF automatic transmission because the 8 TX has been prepared for a power of 2,600 hp/1,912 kW and an input of up to 7,744 ft-lb/10,500 Nm. This makes it the transmission with the best power-to-weight ratio in the market.

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lb and hp ratio hp/lb

2,600

0.926

2,806

9,000

8,000

7,000

6,000

5,000

4,000

3,000

2,000

1,000

0

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0ZF 8 TX

Power density [hp/lb] Weight, dry [lb] Gross input power [hp] Best value

Competitor 1 Competitor 2 Competitor 3 Competitor 4 Competitor 5

Smart Operation Management

• Activation management for coming online and pressure testing

• Targeted control of pressure and volumetric flow rate• Statistics memory for recording operating data• Data logging for detailed analysis of special events• Oil health monitoring and oil level sensing system• GPS position of the unit for easy location and optimized

route planning• Self-learning shifting behavior• Tracking and analysis of fuel economy of the engine

(if supported by the engine)

“ Due to the extreme conditions in oil and gas fields, we rely on robust and reliable equipment, which includes the 8 TX. ” says Volker Hein from GOES GmbH.

Fulfilling our ambition

What makes it literally unique, however, is its special de-sign: Thanks to state-of-the-art BUS communication and modular programming possibilities, the ZF transmission operates without a torque converter. Trouble-free continuous operation is ensured by a flex-ible coupling with the latest damping technology which prevents the transfer of engine vibrations. Furthermore, the 8 TX dissipates less heat thanks to its sophisticated design. ZF integrated the complete electronic controls into the transmission. Additional optimizations such as an all aluminum housing make the ZF transmission the light-est transmission currently available in its class: It weighs only 2,806 lbs/1,273 kg including the coupling and with-out oil. Regardless of that, the 8 TX offers a high level of flexibility: Two power take-offs are also available. Also installation and removal of the ZF transmission is simpli-fied thanks to its three lifting points, it can be safely and easily moved into its needed position.

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ZF transmissions are designed for specific application conditions. The drive components ensure maximum per-formance, cost-effectiveness and comfort. Reliability and user-friendly operation guarantee maximum efficiency.

Tailormade transmission systems

EcoLife Offroad Gear Reducer IMA 330

EcoLife Offroad

With the new ZF EcoLife Offroad, ZF has designed a transmission system specifically for the harsh require-ments in oil and gas production, such as in pumping systems, workover and coil tubing rigs, cementing and acidizing units. It enables particularly economic opera-tions and handles more than 1,917 ft-lb/2,600 Nm of engine torque. The transmission system is precisely tailored to the respective facility and takes care of clutch actuation and shifting work for the user. An electronic monitoring system prevents any operating error.

Gear Reducer IMA 330

ZF has designed the reduction gearbox IMA 330 for the particular demands of sludge- und concrete pumps. The one-staged, helically-geared spur gear is compact and has a weight of only 410 kg. The gearbox can be mount-ed in various positions and can be operated in both rotation directions. Additionally, the IMA 330 is equipped with a dry sump lubrication and helically-geared spur wheels with high load carrying capacity. This enables a high efficiency of the gearbox. Thanks to a cast housing with integrated oil supply no external piping is necessary which minimizes the risk of an oil leakage. An integrated speed sensor ensures a smooth operation of the gearbox.

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ZF offers customized transmissions for a wide range of pump systems – from drilling to cementing and fracturing.

TraXon with modules (Perform, PowerDivide and Torque)

The TraXon automatic transmission is made for applica-tions up to 2,212 ft-lb/3,000 Nm (840 hp). Its space- saving design in combination with newly designed gearsets turns TraXon into a benchmark in terms of the power-to-weight ratio. At the same time reliable and robust, TraXon offers a wide ratio range and enough horsepower for the hard day-to-day work from drilling to cementing to fracturing. Easy to install and operate with options like remote control, TraXon is at home in vehicles or stationary platforms. One essential advantage of TraXon is its modular transmission design. This enables the basic transmission to be combined with three starting or shift modules, respectively, which make the transmission more eco-nomical in practice and giving manufacturers and opera-

tors the best possible flexibility for every application. The dry single-disc or – for particularly high-torque applications – double-disc clutch TraXon Perform is robust and has proven worthwhile millions of times over. It is also possible to combine the basic transmission with a torque converter clutch. Also at high input torques, TraXon Torque can be operated with zero wear and high power. Another module is the engine-dependent PTO PowerDivide. It is installed between the transmission and vehicle engine following the sandwich principle and is especially attractive for applications where the auxilia-ries require very high torques.

TraXon, TraXon Torque, PowerDivide

High pressure pumping units

Cementing and pumping units (mud pumps, nit-rogen units, etc.)

Rigs and coiled tubing units (drilling rigs, workover rigs, etc.)

8 TX

EcoLife Offroad

TraXon

TraXon Torque

TraXon PowerDivide

Gear Reducer

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Automatic transmission Powershift transmission Gear reducer

TraXon 8 TX EcoLife Offroad

IMA 330

Number of gears 12 16 12 8 7 –

Max. horse power [hp]* 730 840 840 2,600 730 600

Max. input torque [Nm] 2,600 3,000** 3,000** 10,500 2,600 8,200

Max. input torque [ft-lb] 1,843 2,212** 2,212** 7,744 1,917 6,048

Approx. weight [kg] 253 290 265 1,273 444 410

Approx. weight [lb] 557 639 584 2,806 979 904

Ratio range 12.92-0.77 14.68-0.82 12.92-0.77 3.67-0.81 5.60-0.61 4.61

Engine-dependent PTO PowerDivide

NMV 2000 L1 NMV 2003 L1 NMV 1600 L1

Max. horse power [hp] 421 421 336

Output torque [ft-lb] 1,476 1,476 1,180

Output torque [Nm] 2,000 2,000 1,600

PTO position 12 o’clock 3 o’clock 12 o’clock

Length [in / mm] 8.27 / 210

Approx. weight [lb / kg] 363 / 165

Speed increasing factor f = 1.21 f = 1.21 f = 1.54

Transmissions by ZF are ideal for the application in pump systems: Better profitability, less risk, customized service.

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* Indicative value only (engine auxiliaries are not covered)

** Up to 3,400 Nm / 2,508 ft-lb possible, depending on application

Technical data

EcoLife Offroad

Gear reducer IMA 330

We ensure the mobility of our customers worldwide and throughout the vehicle’s entire service life with comprehensive repair services, reliable quality products, and technical systems expertise.

Fully committed to perfect service

Globally present, locally anchored

As technology leader for driveline and chassis techno-logy, ZF considers itself not only a manufacturer, but also a reliable partner who supports you throughout the life cycle of your vehicles. And that worldwide. Wherever you may need us, ZF Aftermarket supports you with its own comprehensive service network and the entire range of aftersales services.

From prompt genuine parts supplies via technical service, up to consultancy and training. Quickly, directly, reliably. In a nutshell: ZF Aftermarket links powerful top-quality products with excellent services to provide a unique, premium offer. Around the world, around the clock: ZF’s service specialists are available anywhere and at any time.

Service-Center at a glance: www.zf.com/service-center

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DigitalizationAs a continuous innovator, ZF is preparing for the next genera-tion of off-road transmissions and intelligent connection solutions that will further improve productivity and efficiency for different segments and markets. Extending high-performance mechanical systems with digital services opens up new potential to optimize the productivity of oil and gas operations.

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Real time diagnosis

Global status monitoring

Online error management

Vision of intelligent driveline management ZF develops a concept of the “Driveline of the Future” as a contributor to the overall vision of “Intelligent Mechanical Systems”.

New technologies

Innovation efforts are driven by mega-trends as well as by key trends in the energy market and are focused on contributing to all aspects of maximizing return on invest-ment. Key areas of innovation are seen in the develop-ment of technologies to increase the transmission torque density, mobile and digital solutions, alternative driveline concepts and optimal system behavior of the transmis-sion in its surrounding structure.

As a technology company, ZF dedicates considerable effort to innovative approaches in all its product fields. ZF anticipates that one of the current big mega-trends, the trend toward “digitalization”, will not turn out to be just a show-item, but that the high rate of innovation will soon lead to stronger demand. As such, ZF accepts this challenge and combines mechanics, electronics and digital technologies for industrial applications. High performance mechanical systems are turned into smart systems by using ZF’s digital know-how and electronics competence. Through their connectivity features these “Intelligent Mechanics” will enable performance optimi-zation of the overall system.

CLOUD

Example of intelligent transmission technologyRegistered by sensors, operational data of the pump trailer will be transmitted via the Internet to an evaluation portal. Other relevant partners for optimal operation also provide data to deter-mine the best time for maintenance. So unnecessary or costly downtimes are avoided.

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ZF Friedrichshafen AGIndustrial Technology Marine & Special Driveline TechnologyEhlersstr. 50 88046 Friedrichshafen / GermanyPhone +49 7541 77-3246Fax +49 7541 77-961797special-transmission@zf.com

Get to know more about our transmissions for special applications:

www.zf.com/special-transmission

www.zf.com/8tx