Hydraulic Equipment Guide for Oil & Gas Operations
Hydraulic equipment is a mainstay in oil and gas operations, where it provides the power necessary to drive critical oil and gas well components. This equipment includes the following:
- Hydraulic power units (HPUs)
- Hydraulic pumps
- Hydraulic cylinders (rams)
- Hydraulic valves
- Hydraulic hoses and manifolds
- Hydraulic bolting tools (torque wrenches and tensioners)
Success in the field depends on these hydraulic assets being used properly and maintaining them for optimal performance and safety.
Why Hydraulics Matter in Upstream & Midstream Operations
Oil and gas hydraulic equipment plays a critical role in upstream (production) and midstream (transport and storage) operations. In upstream applications, hydraulic systems are responsible for the following:
- Oil rigs – Hydraulic equipment is heavily utilized at drilling sites, where it’s needed to lift and smoothly position equipment into place. This includes pipe-handling equipment, mud pumps and winching systems (drawworks) intended for downhole use.
- Fracking operations – Hydraulic pumps are responsible for delivering frac fluids into the well – a mix of water, mud and chemical additives – at high enough pressures to break rock formations.
- Filter presses – Hydraulic power is needed to circulate drilling fluids through the filter press, where intense pressure separates the drilling mud from solid contaminants. Once filtered, the drilling mud can be reclaimed for downhole use.
- Well control and safety equipment – Hydraulic technology is involved in wellhead safety, primarily in the form of blowout preventers (BOPs). BOPs rely on several redundant hydraulic power units and hydraulic rams to prevent blowout pressures from reaching the drill platform. The kick is redirected through a choke manifold to maintain safe pressures and allow personnel to assert control over the well.
- Offshore operations – In subsea applications, hydraulic power is used to operate subsea control modules (SCMs) via an umbilicus. From their topside control station, operators can utilize SCMs to actuate valves and other subsea hydraulic components.
Oil and gas hydraulic equipment is also featured in midstream applications, where it’s essential for the following:
- Pipeline flow management – Hydraulic actuators are used to manage oil and gas flows through transport pipelines, specifically through controlling valves and boosting flow with technology like hydraulic jet pumps. Hydraulics provide optimal control precision in flow management in midstream applications.
- Pipeline maintenance – Hydraulic equipment like flange spreaders, torque wrenches and bolt tensioners are vital parts of the tool kit for maintenance teams. Flange spreaders provide access to the pipeline, while torque wrenches and bolt tensioners are needed to retorque pipeline fasteners.
- Metering skids – Hydraulic pumps are used to push fluids through metering skids, where flow can be precisely measured for transport or accounting purposes.
- Tanker and storage management – Hydraulic assets are used to power storage and transport machinery, including winches and cranes. Hydraulic reservoirs are needed to maintain ideal fluid pressures and quality by circulating the fluids and removing contamination and excess air.
- Pipeline flow management – Hydraulic actuators are used to manage oil and gas flows through transport pipelines, specifically through controlling valves and boosting flow with technology like hydraulic jet pumps. Hydraulics provide optimal control precision in flow management in midstream applications.
Must-have Hydraulic Equipment for Oil & Gas Operations
Oil and gas companies require a comprehensive array of hydraulic technologies, including the following types of hydraulic equipment:
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- Hydraulic power units – Hydraulic power units (HPUs) consist of a hydraulic pump, motor, reservoir, filters and a valve system. HPUs are self-contained systems that drive the rest of the site’s hydraulic equipment and must be spec’d to the application.
When checking specs on an HPU, you’re looking for a system that lines up with your pressure needs (remember to leave an additional margin for safety), flow rate (pump displacement) and reservoir size. Additional considerations are the HPU’s temperature rating (especially important for Class I, Div I environments), the HPU’s drive technology (electric vs. diesel), corrosion resistance and any contamination controls (high-efficiency filters and a kidney loop in the design).
- Hydraulic cylinders (rams) – Hydraulic rams are actuated by the HPU and are needed to deliver mechanical force where necessary – such as for blowout preventers and for midstream fluid transport. When considering specs on a hydraulic ram, pay attention to its maximum operating pressure, its bore and rod diameter, stroke length and the ram’s construction. Steel body construction and chrome-plated components (the rod and barrel, specifically) provide necessary durability. Also, ensure that your hydraulic ram is designed with the proper mounting hardware, whether it’s a flange, clevis or another mounting style.
- Hydraulic valves – Directional, pressure and flow control valves are all necessary for managing downhole and midstream fluid pressures. Every drilling platform and transport system requires its own valve design. Important spec considerations include the number of flow paths available (2-way, 3-way or 4-way), pressure rating, flow capacity, body and seal construction (look for anti-corrosion materials) and operation method (direct-acting or pilot-operated).
- Hydraulic hoses and manifolds – Your hydraulic hoses and manifolds play a simple, but important role in powering the system’s hydraulic actuators. When selecting hoses and manifolds for your operations, ensure they’re of the proper diameter for your flow demands, and verify that they are temperature-rated for the environment. In addition, select a set of hydraulic hoses and manifolds that come with the right fittings for your existing hydraulic equipment.
- Hydraulic torque wrenches and flange spreaders – Hydraulic bolting tools (torque wrenches and tensioners) and flange spreaders are primarily used in maintenance applications. Select bolting tools that can provide the level of torque your fasteners require and consider access as some hydraulic torque wrenches are designed for limited access applications, and this is a common obstacle for field maintenance teams.
- Hydraulic power units – Hydraulic power units (HPUs) consist of a hydraulic pump, motor, reservoir, filters and a valve system. HPUs are self-contained systems that drive the rest of the site’s hydraulic equipment and must be spec’d to the application.
Safety in Class I Division I Areas When Using Hydraulic Equipment
Class I, Div I sites are characterized by an elevated risk of fire and explosion, typically due to the presence of flammable gases or vapors. Additional safety measures are necessary to protect workers in Class I, Div I settings, and that starts with the right hydraulic equipment.
If you’re selecting oil and gas equipment intended for Class I, Div I worksites, consider the following:
- Choose hydraulic equipment that’s rated for Class I, Div I sites – Hydraulic pumps, cylinders, valves and other hydraulic components can be hardened and sealed against explosions and fire. If certified for Class I, Div I applications, your hydraulic equipment will not ignite flammable gases present in the environment.
- Choose hydraulic equipment with bonded metallic components – When bonding metallic components, any electrical gradients between metal parts are minimized. This protects against spark or arc paths and minimizes the chances of ignition as a result. The use of bonding jumpers is one way to supply this protection.
- Choose hydraulic fluid that is resistant to fire and ignition – Certain types of hydraulic fluid, such as water-glycol for example, are less likely to ignite and are therefore recommended for any electrically powered hydraulic equipment that’s not in use or is used in an enclosed setting.
- Test your hydraulic valves for excessive pressure build ups – Excessive pressure is a risk factor in Class I, Div I environments, so it’s important for field personnel to regularly test relief valves and hydraulic accumulators for pressure build ups. Attach pressure relief devices to your accumulators to protect against sudden pressure shocks, which can spark ignition.
- Train your personnel in the use of Class I, Div I rated equipment – And finally, your field personnel should be aware and practiced in the installation and use of Class I, Div I rated equipment. Consider implementing emergency drills to train personnel in leak and fire response.
- Choose hydraulic equipment that’s rated for Class I, Div I sites – Hydraulic pumps, cylinders, valves and other hydraulic components can be hardened and sealed against explosions and fire. If certified for Class I, Div I applications, your hydraulic equipment will not ignite flammable gases present in the environment.
Preventative Maintenance and Contamination Control for Oil & Gas Hydraulic Equipment
In the oil and gas industry, hydraulic equipment maintenance and contamination control are essential to ensure efficient, safe operations. If you’re partnered with a hydraulic equipment supplier and service partner, you’ll have access to expert preventative maintenance that includes:
- Hydraulic fluid inspections and replacement – Hydraulic fluid quality and quantity are essential maintenance considerations. Maintaining proper fluid levels is easy enough, but an expert hydraulic technician can also perform chemical analysis to identify contamination before it can be seen by the human eye. If contamination is present, action can be taken to minimize its impact on your oil and gas equipment.
- Full hydraulic equipment inspections – Equipment breakdowns and inspections are only recommended if there are performance issues or other emerging problems with your hydraulic equipment, as there’s always the risk of introducing contamination into the system while the equipment is opened up. However, expert hydraulic technicians are skilled in proper disassembly and reassembly and can therefore minimize this risk. During a full system inspection, your hydraulic technician will check for component wear, corrosion, leaks and issues with system configuration.
- Hydraulic component replacement – If worn hydraulic components are identified during an inspection, these can be replaced to restore system integrity. Seals, gears and bushings are the most common examples, but your hydraulic technician can also check for damage or wear to any parts in the flow path that may be caused by overheating, cavitation or another serious system issue.
- Hydraulic system repairs – If your hydraulic technology does experience a breakdown and downtime in the field, you’ll return that equipment to action faster if you can send it off to your hydraulic service partner. Your technician can troubleshoot and isolate the problem and recommend the right maintenance or replacement option.
- Hydraulic fluid inspections and replacement – Hydraulic fluid quality and quantity are essential maintenance considerations. Maintaining proper fluid levels is easy enough, but an expert hydraulic technician can also perform chemical analysis to identify contamination before it can be seen by the human eye. If contamination is present, action can be taken to minimize its impact on your oil and gas equipment.
Selecting Suppliers and Service Partners for Your Hydraulic Equipment
Oil and gas companies do not accept downtime for any of their critical hydraulic systems. To avoid downtime, every component should be well maintained, and every system should be backed up with redundant equipment that can be switched in as necessary. This approach to upstream and midstream management guarantees maximum productivity and profitability.
To ensure your hydraulic equipment is calibrated and maintained according to spec and best practices, many oil and gas companies partner with an experienced hydraulic equipment supplier and service expert, like Flickinger Machine. Establishing this partnership will ensure your field teams have access to the right hydraulic equipment and on-point maintenance when it’s needed.