The Hidden Workhorse: The Role of Hydraulics in Oil and Gas Production

When it comes to the challenges found in exploration and production of oil and gas resources, there is only one technology that can provide the required force, precision control, and ruggedness to work in the harshest conditions on Earth: hydraulics. When harnessed, hydraulic systems leverage the power of pressurized fluid to become the backbone of drilling operations, safety systems, and heavy machinery for land and marine based applications.

Now, let's delve into how hydraulics are used and why they are critical in the oil and gas sector.

1. The Power Behind the Drill Site - from Rigs to Fracturing

Hydraulics are found in nearly every mechanical function of a drilling rig, whether it is a large offshore platform or a standard land-based rig.

• Drilling Rigs: Hydraulic systems deliver consistent, high-torque power for top drives and drawworks. Top drives rotate the drill string and rely on hydraulic motors to deliver fine control over the speed and torque required for smoother operations and less wear and tear on the equipment.
• Lifting and Movement: Strong hydraulic cylinders and actuators are utilized to lift and move heavy pieces of equipment, such as raising and lowering the derrick, handling casing and operating the Iron Roughneck (the machine that makes up and breaks out pipe connections).
• Hydraulic Fracturing (fracking): This well stimulation process utilizes extremely high pressures, often over 10,000 psi. Hydraulic systems power the specialized frack pumps that inject water, sand, and chemicals deep into the ground to break apart the shale rock and allow gas and oil to escape, which allows the oil and gas to flow, all powered by hydraulics.

2. Guaranteeing Unrivaled Safety: Well Control Systems

In the dynamic context of drilling, preventing the unexpected (a blowout) is first and foremost. Hydraulic systems are the mechanism behind the most important safety apparatuses.

• Blowout Preventers (BOPs): The BOP stack is a configuration of large valves on the wellhead that solely relies on hydraulic power units (HPUs). In a crisis, it is the HPU that provides instantaneous, reliable energy to quickly shut the BOP rams and area off to mitigate catastrophe.
• Control Valves: Throughout the well and processing facilities, many control and safety valves (that control flow, pressure in an effort to maintain system integrity) are operated by hydraulic actuators.

3. Tackling the Deep Sea: Subsea Operations

Offshore and deep-sea drilling present unique challenges of high pressure, corrosive saltwater, and cold temperatures. Hydraulic systems are a natural fit to meet the challenging environment because of their high power density, in compact, sealed units.

• Subsea Blowout Preventers (BOPs): In a subsea rig, the BOP is positioned on the seabed and relies on specialized hydraulic systems, typically water-glycol based, for remote operation, to perform its function at several thousand feet below the surface.
• Hydraulic systems are also utilized in jacking systems for lifting and positioning Mobile Offshore Drilling Units (MODUs) or jack-up rigs, as well as during active moving-position maintenance. Additionally, hydraulic systems are used in compensating for motion, and tensioning the riser and any guidelines on floating rigs, which stabilizes the drill string against waves in the sea.
• Remotely Operated Vehicles (ROVs): Underwater robotic vehicles are used for maintenance and inspection. ROVs utilize complex hydraulic systems for power and control, allowing the robotic arms to perform precise, high-force tasks at depths that humans cannot.

4. The Essential Component of the System: Hydraulic Power Units (HPUs)

The Hydraulic Power Unit (HPU) is the driving force behind the entire hydraulic system. HPUs are self-contained systems that generate and supply the pressurized fluid (hydraulic oil or water-based fluid) through multiple pumps to actuators, motors, and cylinders throughout the rig. HPUs consist of:

• Pumps to pressurize the hydraulic fluid.
• Reservoirs to store and cool the hydraulic fluid.
• Valves to control the direction and pressurization of the hydraulic fluid.
• Accumulators to store energy and provide instant pressure for essential functions such as the BOP.

What's Ahead: Smart and Sustainable Hydraulics

The role of hydraulics is also continuing to evolve, particularly in the areas of safety, efficiency, and environmental stewardship. Innovations are leading to:

• Smart Hydraulics: These hydraulic systems can be integrated with the Internet of Things (IoT), which include smart sensors to monitor the health of hydraulic systems in real-time. Renowned leaders in the industry, such as Baker Hughes and Schlumberger, offer these sensors to help operators mitigate component failure and maximize uptime through predictive maintenance.
• Hybrid Systems: This design marries hydraulic power with electric controls to improve energy efficiency and precise control.
• Eco-Friendly Fluids: Adoption of environmentally responsible and, in many cases, biodegradable hydraulic fluids has greatly increased, especially in offshore applications where there is a higher risk of spill in the marine environment.