Montanhydraulik provides customized hydraulic solutions tailored to the demanding conditions of onshore and offshore drilling. Our products and systems are designed to operate reliably and efficiently under extreme environmental conditions, whether in the Arctic, desert regions, or the open sea.
Renewable energy is opening new opportunities, and Montanhydraulik is seizing them. The company has been investing in this growth market for several years, developing offshore hydraulic systems for the construction of wind power plants. Jack-up platforms and construction vessels, which handle massive loads and require a stable position in water depths of up to 50 meters, are essential for building these wind farms. The demands on hydraulics in these applications are extremely high.
In offshore environments, including ports and the open sea, machinery and structures are frequently exposed to aggressive, salt- and corrosion-rich conditions. Our extensive range of cylinder applications, hydraulic systems, and lifting systems for construction vessels is specifically designed to withstand these harsh environments.
Germany alone plans to install offshore wind farms with a capacity of approximately 25,000 MW by 2030. This requires sophisticated technologies and systems that enable complex operations at sea. Montanhydraulik's expertise in mobile crane construction and extensive global experience in hydraulic steel structures make us one of the most capable partners in this market. Together with our subsidiaries, we develop and manufacture complete hydraulic solutions, ranging from power units and control systems to software and corrosion-resistant hydraulic cylinders.
Oil and gas remain major resources of global significance. The Montanhydraulik Group develops hydraulic drive concepts, including cylinders, hydraulic power units, and control systems, for the oil and gas industry. Ensuring both safety and reliability for personnel while integrating cutting-edge technology on-site is fundamental to the use of hydraulic systems in the oil and gas sector. Whether operating in Arctic temperatures as low as -50°C, desert heat reaching up to 60°C, on land, or at sea, hydraulic functions must be executed precisely, and performance must be optimized at all times.
Our extensive range of cylinder applications and hydraulic drive systems for complete drilling rigs is engineered for these operating conditions. The Smart Rig System offers a turnkey automated lifting solution for masts and substructures of land-based drilling rigs, enabling fully automated, fast, safe, and efficient erection. This system consists of double-acting telescopic cylinders with an integrated position feedback system, load sensor system, computer-controlled control unit, and distribution block.
The development of the Land Drilling Rig Walking System allows drilling rigs to "walk" from one drilling position to the next without requiring disassembly on a pad site. The Montanhydraulik Group designs and supplies the necessary cylinders for this system.
The use of environmentally friendly energy sources is becoming increasingly important, above all in the offshore sector. In particular, the increasing requirements when building offshore wind farms require ever larger and more powerful lifting platforms. The approximately 6,400 t heavy “Thor” can work safely and efficiently in water more than 30 m deep, with a load of 3,300 t, 1,850 m2 free deck surface, and a deck load of 15 t per m2.
For this, the extension of the 70 pontoons in the water, each 40 m in length, is ensured by the hydraulic lifting system, for which Montanhydraulik supplied the necessary hydraulic cylinders. The cylinders are equipped with a magnetostrictive position sensor system. As corrosion protection, the hydraulics company applied a nickel hard chrome coating to the piston rods.
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In order to ease the supply bottleneck when building their own wind farms, a German company for renewable energy placed an order for two special ships of the same design with the Korean shipyard Daewoo Shipbuilding & Marine Engineering.
After completion, the construction ships with a length of 109 m and a beam of 40 m can transport as well as erect up to four offshore wind turbines of megawatt classes 5 and 6, including the foundations, even under rough offshore conditions. This enables the company to gain significant time and cost benefits.
The ships can be positioned at sea with centimetre accuracy by means of satellite. They can work in depths greater than 40 m, and are therefore ideally suited for the installation of the planned offshore wind farms.
For the ships, Montanhydraulik and Muns Techniek jointly supply the complete hydraulic lifting system, consisting of cylinders, bolting units, and guide frames, including the associated electrical controls.
What makes the design of the ships unique are the two synchronously extensible frames for each pillar, whose movement is governed by a synchronous control system developed especially for this order. This makes it possible to raise and lower the four pillars synchronously using the necessary lift, without the platform having to be stopped for the bolting process.
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Through the hydraulic lowering of four movable legs with a length of 90 m and a diameter of 4.80 m, the ship becomes a lifting platform. The lifting system raises a total weight of 25,000 t from the water. It consists of 48 corrosion-resistant cylinders from Montanhydraulik, the necessary bolting units and guide frames, and the associated electrical controls.
The hydraulic design is distinguished by two extensible opposed guide frames for each leg. Their movement is governed by a synchronous controller. Muns Techniek developed the controller in order to ensure synchronous raising and lowering of the four legs using the necessary lift, without the platform having to be stopped for the bolting process.
The legs of the jack-up ship are lowered to the sea bed with a stroke speed of 1 m/min. For this, the hydraulic system provides not only the stroke function, but also gives the ship a high imperviousness to impacts. As soon as all four legs make contact with solid ground, the ship lifts itself out of the water.
The special jack-up ship, with a length of 136.5 m and a beam of 41 m travels at a speed up to 12 kn, and can transport up to 6,500 t. A 1,200 t crane forms part of the essential equipment for assembly and installation of the foundations and wind turbines for setting up offshore wind farms.
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The LHM product range includes flexibly operable mobile harbour cranes designed for various applications, ranging from container transfer to the transport of containers, bulk materials, and general cargo. The largest mobile crane in the range, the LHM 800, lifts heavy loads of up to 308 tons.
The LHM consists of a slewing boom crane equipped with a chassis, and can perform the three main movements: Slewing, luffing, and lifting. The boom is powered by a hydraulic differential cylinder.
A further special feature, which specifically fulfils the safety requirements of the crane manufacturer, is the position of the luffing cylinder. This is positioned above the boom. This prevents cylinder damage which could arise from swinging loads or from high-stacked containers on board. Here too, the cylinder technology comes from Montanhydraulik.
Technical data for LHM 800:
Pin and unpin mast and sub-structure raising cylinder
Positioning of the mast and sub-structure raising cylinder
For various hydraulic applications
Programmable logic controllers (PLCs)
The construction of maritime platforms and power plants increasingly requires new concepts, suitable special equipment, and ever more powerful types of ships.
Together with various subsidiaries, Montanhydraulik develops and manufactures complete hydraulic systems for onshore and offshore applications (e.g. jack-up ships and jack-up drilling rigs).
In compliance with customer requirements, the system components – from hydraulic aggregates, to control systems and software, to corrosion-resistant hydraulic cylinders – are dimensioned and matched to each other. The complete installation and commissioning of the components rounds out the range of services offered by Montanhydraulik.
For Montanhydraulik, the outstanding quality of our own products is a permanent and ever-present goal. In order to be able to fulfil this requirement at all times, Montanhydraulik possesses extensive test and quality inspection capacities, as well as the necessary expertise of our employees.
The test and quality inspection capacities include two combinable 25 ton cranes, sufficient working space to turn and test 30 metre long cylinders, and stable structures for optimum working and storage conditions. In addition, glass windows in walls and ceiling provide effective natural lighting.
In addition, the available capacities and equipment allow us to be very flexible, in order to perform final acceptance for very large lot sizes (for example 16 offshore cylinders in a single acceptance test). Here, the final acceptance takes place through the approval and fulfilment of the test standards of DNV, ABS, China Classification Society, Lloyd’s Register, Bureau Veritas, RINA and/or TüV.
In addition, Montanhydraulik has developed and built its own test rig, which enables vertical testing of friction-sensitive cylinder systems. Especially for cylinders used in the offshore sector, this method of quality inspection represents an important and meaningful test process for quality inspection.
Our modern controllers ensure problem-free and exact coordination of all drive functions. All system components are controlled by local PLC controllers, each in a control cabinet, and started by soft starter when required.
Instructions from the command bridge are executed by the PLC after local safety checks. In addition, the PLC collects and archives all data required for the operation of the hydraulic system, and sends it to the ship’s performance system and/or to the dynamic positioning system.
Designed to the most varied customer requirements, and fulfilling the specifications of the classification companies, we manufacture fully piped and tested hydraulic aggregates.
The electro-hydraulic high-performance aggregates for jack-up ships are equipped with soft starters and controlled by means of a PLC.
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