HYDRAULICS Hydraulic power units (HPUs) remain fundamental to industrial and mobile equipment, delivering controlled force and motion across a wide range of applications. While hydraulic principles are well established, modern systems increasingly demand higher levels of efficiency, integration, reliability and control. Hydrastore and Related Fluid Power, working in conjunction with DCA as a dedicated technical and applications partner, explain that HPU development is approached from a system perspective. Rather than focusing solely on component supply, the emphasis is placed on understanding the full application context—operating conditions, duty cycles, environmental constraints and control requirements—and translating these into a complete, engineered solution. Julian Lee, Director at DCA Ltd, explains that his company plays a key role at the front end of this process, working directly with customers to define system requirements and control philosophy. This structured approach ensures that hydraulic, mechanical and electrical elements are aligned from the outset, reducing integration risk and improving overall system performance. Energy efficiency and operational visibility are increasingly central to HPU design. Systems are developed to make effective use of power through the correct pump control application, optimised hydraulic layouts and, where appropriate, variable speed drive technology. These approaches reduce energy consumption while maintaining required performance levels. Hydrastore and Related Fluid Power say they combine practical application experience with component-level expertise to ensure appropriate selection of pumps, valves, filtration and cooling systems. Thermal management and fluid conditioning are considered early in the design process to maintain system stability and extend component life. Integration with modern control environments is also a key requirement. HPU systems are routinely supplied with sensors and instrumentation to monitor pressure, flow and temperature, alongside control interfaces that support PLC integration or standalone operation. All companies support the development of control software, considering safety, automation and remote communication capability where required. Space constraints, mobility and environmental conditions are increasingly influential in system design. Related Fluid Power focuses on compact and modular HPU configurations suited to space-limited, while Hydrastore delivers larger industrial units designed for robustness, maintainability and compliance with relevant standards. Across both areas, systems are engineered for ease of installation and integration, whether as part of new equipment or retrofit into existing plant. This includes consideration of mounting arrangements, connection points and accessibility for service and maintenance. Full equipment lifecycle is also a key aspect considered by Hydrastore, Related Fluid Power and DCA, says Lee. This includes initial specification and design, system build, testing and commissioning, as well as ongoing service, modification and technical support. By combining application knowledge with engineering and integration expertise, complete HPU systems can be delivered that are aligned to the specific operational demands of each project. This approach reduces complexity for the end user while supporting reliable, efficient and maintainable hydraulic systems. Hydraulic power units require more than effective component selection; they depend on coordinated system design, integration and control. Lee concludes that, through the combined capabilities of Hydrastore, Related Fluid Power and DCA, HPUs are developed as complete, application-specific systems that address performance, efficiency and integration requirements in demanding industrial and mobile environments. 16 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk A system approach to hydraulic power unit design Subsea Wellhead Abandonment System A complete HPU and control system was developed for the operation of subsea wellhead abandonment equipment in a marine environment. The unit was engineered for offshore deployment, incorporating stainless steel construction and marine-grade coating systems to ensure durability. The HPU was mounted within a transportable frame suitable for installation inside a standard shipping container, supporting deployment flexibility. Dual motor-pump units (15 kW load-sensing piston pumps) were incorporated to provide operational redundancy. The system supported 22 hydraulic work functions, with additional spare capacity. Instrumentation included distributed pressure and flow sensors, enabling system-wide monitoring. An integrated control console with touchscreen interface provided operator control and diagnostic feedback. The control system, developed inhouse via Hydrastore control team, included data logging of all work functions and sensor outputs, software-based safety interlocks and remote communication capability, allowing monitoring and operation from a remote location if required. Manual override of valve functions was also incorporated at panel level. The unit was supplied fully documented, including operational guidance and spares support, and underwent full factory acceptance testing prior to delivery. For further information please visit: https://www.dca-ltd.com
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