Hydraulic power units save space in oil & gas industry

Developed on behalf of Saipem (part of the ENI group and also based in Italy), these power units have been designed to contribute to powering machinery that will lay methane gas pipes at the bottom of the Caspian Sea in Kazakhstan.

One of the key objectives of Power Hydraulik’s HPU project is helping customers in the oil and gas industry save space and time. In oil and gas applications, space and time can make the difference in terms of transport, logistics and management costs. It is for this reason that Power Hydraulik became involved in building smaller power units that were pre-assembled and ready to use, without having to hold back on power or autonomy. To achieve these multiple requirements, Power Hydraulik teamed-up Eaton.

“We believe in Eaton and believe in their technical skills,” says Lorenzo Merzari, CEO at Power Hydraulik. “By listening to what we need, they select the components best suited for our HPUs.”

Choosing Eaton as a partner was also dictated by the need to provide a reliable and quick after-sales service anywhere around the world. “Having an international partner like Eaton is fundamental in a sector such as the gas industry where rapid support can really make a difference in terms of efficiency and productivity” explains Merzari.

The support provided by Eaton was fundamental in selecting the most appropriate components for smaller HPUs capable of delivering maximum reliability under extreme operating conditions. Power Hydraulik opted to fit its power units with Eaton valves, including KB Series proportional valves, logic elements and directional valves.

 “The Eaton components we used for our HPUs are particularly well-suited to confined spaces,” explains Merzari, “so they definitely helped us reduce the dimensions.”

As well as having to reduce the size of the HPUs, it was also necessary to build units capable of withstanding the extreme temperature ranges of Kazakhstan, where harsh winters and scorching summers are the norm. To tackle these extreme climatic conditions, Power Hydraulik fitted the HPUs with pumps to cool the oil with water, as air cooling would have been insufficient. An internal air-conditioning system (heaters and fans) was also fitted to protect the unit from sub-zero temperatures.

To ensure the correct operation of this innovative, complex hydraulic system, Power Hydraulik also chose Eaton valves specifically for their ability to guarantee reliability under difficult operating conditions. Furthermore, as Merzari explains, “We chose the KB Series proportional valves as they guarantee optimal control under low-flow conditions.”

The synergy between Power Hydraulik and Eaton has paid off in terms of results. Power Hydraulik has developed a 480kW HPU that is 30 percent smaller than HPUs with similar power. Furthermore, all of the unit’s components (converters and fire protection system, etc.) have been placed in a 20 foot container; this means that the HPUs can be “stacked” during transport, thus reducing the area required for the HPU less. Thanks to this innovative, self-contained design, Power Hydraulik’s HPU will also be delivered to the customer pre-assembled and ready to use.

The results achieved by Power Hydraulik have far exceeded expectations in various areas. It enabled them to include diesel and oil tanks that are more capacious than initially planned, guaranteeing fuel autonomy.

Merzari summarises: “We are very happy with our cooperation with Eaton’s hydraulics business. We believe that Eaton’s approach is different from its competitors in the field, who tend to tell you what to do rather than listen to what you actually need. Our partnership with Eaton has always been and continues to focus on innovation.”