Rotec Hydraulics, Author at Rotec Hydraulics Ltd

Hydraulic Accumulator Overhaul & Recertification for UK Port

100% Achilles audit _Rotec Hydraulics Ltd

The Challenge:

Our client – a major UK port offering shipping, logistics, and cargo handling services for industries worldwide – needed a critical service for their 10-litre and 20-litre, 135 bar hydraulic accumulators. These components, vital for port machinery, operate in a harsh, submerged saltwater environment, which had led to significant corrosion and wear. The accumulators required a full overhaul and recertification to ensure safety and continued operation.

Our Solution:

The Rotec Hydraulics team performed a comprehensive service to restore the accumulators to a like-new condition.

Full Overhaul: We disassembled the units, replaced all internal bladders and seals, and prepared the shells for a new protective coating.
Corrosion Treatment: To combat the effects of saltwater, we shotblasted the accumulators to remove all rust and old paint, creating a clean surface.
Protective Coating: We applied a durable, high-performance marine-grade paint system designed to withstand the harsh conditions of their working environment.
Recertification: Finally, each accumulator was recertified through rigorous pressure and leak testing, ensuring they met all safety standards and operational requirements.

The Result:

The accumulators were returned to the customer fully overhauled, recertified, and protected against future corrosion. Our work extended the lifespan of these critical assets, minimizing downtime and ensuring the continued reliability of their port operations.

Rotec Hydraulics are the only certified Parker Hannifin Accumulator Recertification Centre in the South West of the UK – servicing and re-certifying accumulators of all brands.

For reliable hydraulic solutions in challenging environments, contact Rotec Hydraulics via 01823 348900 or email sales@rotec.net.

Managing Hydraulic Systems in High-Temperature Environments

High temperatures pose a significant threat to the performance and longevity of hydraulic systems. Elevated heat can lead to a rapid decline in fluid quality, premature component wear, and potential system failure. We’ve summarised some proactive maintenance measures you can take to mitigate these risks and maintain operational reliability.

Fluid Temperature Monitoring

Regularly monitoring hydraulic fluid temperature is critical. The ideal operating range for most systems is 40°C to 60°C (104°F to 140°F). Temperatures exceeding this range accelerate fluid degradation. Systems should be equipped with a reliable temperature gauge to provide accurate and continuous readings. A significant increase in temperature from a known baseline indicates a potential issue requiring immediate attention.

Hydraulic Fluid Selection and Management

The viscosity of hydraulic fluid is directly affected by temperature. As the temperature rises, viscosity decreases, reducing the fluid’s ability to lubricate components effectively.

Adherence to specifications: Always use the hydraulic fluid recommended by the manufacturer. This fluid is designed to maintain optimal performance within the specified operating parameters.
Viscosity Index: In consistently hot environments, a fluid with a higher viscosity index (VI) may be considered, but only after consultation with a hydraulics expert or the equipment manufacturer. A higher VI indicates less change in viscosity with temperature fluctuations.
Fluid levels: Maintain correct fluid levels to prevent cavitation, which occurs when air bubbles form and collapse, causing damage to pumps and other components.

Cooling System Maintenance

The hydraulic cooler is vital for dissipating heat. Its efficiency is paramount in high-temperature conditions.

Regular cleaning: The cooler’s fins must be kept free of debris, such as dust, dirt, and leaves, which can restrict airflow. Use compressed air or a soft brush to clean the surface regularly.
Inspection: Inspect the cooler for any damage, such as bent fins, that could impede heat exchange.
Fan operation: For forced-air coolers, verify that the fan is operating correctly and is free from any obstructions or electrical faults.

Operational Practices

Operational practices can significantly influence a system’s thermal load.

Duty cycles: Avoid continuous, high-load operation during the hottest periods of the day. Scheduling demanding tasks for cooler hours can reduce thermal stress on the system.
Load management: Where possible, reduce the load on the equipment to decrease the amount of heat generated.

Component Integrity Checks

High temperatures can degrade seals and hoses, leading to leaks and component failure.

Leak inspection: Regularly inspect all hoses, seals, and connections for signs of leaks. Heat can cause materials to harden and crack, compromising their integrity.
Physical inspection: Check hoses and seals for signs of blistering, cracking, or other physical deterioration.
Connection integrity: Ensure all connections are properly tightened to prevent leaks caused by vibration and thermal expansion.

By implementing these preventative maintenance measures, system operators can ensure the long-term health and efficiency of their hydraulic equipment, even under the stress of high-temperature conditions.

Rotec Delivers Critical Engineering Solutions for Cruise Ship

Rotec, a leading provider of hydraulic, pneumatic, and electro-mechanical solutions, is proud to announce the successful completion of critical engineering works on a cruise ship at Falmouth Dry Dock. This project follows a successful dry-docking of a sister ship the previous year.

The Challenge

We were asked to carry out essential maintenance requirements on the vessel, specifically focusing on the ship’s main engine combustion fans, supply fans, and exhaust fans.

The scope of work was comprehensive, requiring skilled engineering capabilities. Key objectives included:

On-site bearing replacement where feasible.
Thorough inspection and pre-recording of electrical readings before disconnection.
Safe electrical and mechanical disconnection of units.
Post-disconnection inspection and recording of insulation values.
Reporting any abnormal findings to the ship’s staff.
Cleaning of all necessary areas.
Extraction of old bearings and fitting of new, Rotec-supplied bearings.
Reinstatement and electrical/mechanical reconnection, including insulation tests.
Optional services like dynamic balancing and laser alignment were available.

The Solution

Rotec deployed a team of highly skilled engineers to the dock, who quickly commenced work on the specified fan units. Their methodical approach ensured every step was executed with precision and adherence to safety protocols.

During the process, the team identified several critical issues that required immediate attention:

A supply fan, upon removal from its trunking, revealed cracks in its mounting bracket, which were promptly welded for repair.
A significant crack was discovered on the lug of the Non-Destructive Examination (N.D.E) endshield. Rotec swiftly sourced and fitted a replacement endshield, adapting it for the absence of a vibration sensor aperture.
Both vibration sensors for the bearings were found to be damaged beyond repair, necessitating the sourcing of new replacements.
The fan cowl also showed evidence of a previous crack and weld repair.

Despite these unforeseen challenges, Rotec’s engineers demonstrated exceptional problem-solving skills and adaptability. The fan unit was meticulously reassembled with new, high-quality bearings supplied by Rotec. A rigorous insulation test was performed, yielding a reading greater than 2Ω, confirming the unit’s electrical integrity. Following reassembly and testing, the unit was run to the complete satisfaction of the ship’s staff.

The Feedback

The client’s Assistant Electrical Manager commented,

“I’d like to personally thank your engineers for their excellent work. As always, they have been a pleasure to work with, delivering the job on time and to a high standard. All work has now been tested and officially signed off by the ship.”

Conclusion

By proactively identifying and resolving complex issues, Rotec ensures that critical marine equipment functions optimally, contributing to the safety and efficiency of global maritime operations. Our engineers carried out the job within the timeframe required – something that is critical to the Marine industry. Rotec looks forward to continuing its partnerships, and further supporting the marine industry within Cornwall, the South West and beyond.

Reliable Component Supply Enhances Productivity

As a company we at Rotec Hydraulics have worked alongside a gas turbine specialist providing them with a reliable supply of parts after a previous supplier let them down.

Rotec provides them with a range of products including; hose assemblies, pumps , valves , fittings and metal cutting compounds. The on-time delivery of these products enable the client’s production line to run efficiently, reducing downtime and boosting productivity.

Rotec have assigned a dedicated account manager who holds regular review meetings with the customer to ensure their hydraulic requirements are met without fail.

The supply includes a number of Parker products. Parker, as the global leader of motion control products, are the gold standard for reliability and quality. As a leading distributer for Parker, Rotec is able to also bring a Parker representative to these meetings.

Rotec sales director Richard Lang comments,

“We are pleased to offer our OEM customers a reliable product supply service that enhances their productivity. We are committed to building long lasting working relationships with valued customers.”

If you are in need of a reliable product supply call 01823 348900 to discuss how Rotec Hydraulics can help you.

How Rotec Hydraulics Builds Smarter Systems with Parker IQAN Software

As a certified Parker distributor, Rotec Hydraulics is at the forefront of designing and building custom hydraulic systems that are not just powerful, but also smart. By integrating Parker’s IQAN electronic control system, we create solutions that enhance safety, boost efficiency, and provide unprecedented control over your equipment.

What is Parker IQAN and What are the Benefits?

Parker IQAN is a state-of-the-art electronic control system specifically designed for mobile hydraulic applications. It’s an integrated ecosystem of controllers, displays, joysticks, and sensors, all managed by a powerful and user-friendly software suite.

The key benefit of IQAN is its ability to replace complex mechanical and electromechanical systems with a streamlined, totally electronic approach.

Rotec has successfully designed, built, programmed and installed a variety of custom IQAN-enhanced systems. Clients have reported benefits including:

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Enhanced Safety

IQAN controllers enable critical safety features like dual-channel fail-safe circuits and emergency stops which can be operated remotely. This enhances safety – keeping operators out of harm’s way, especially in hazardous environments such as quarries or construction sites.

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Precision & Control

The software allows for precise, proportional control of hydraulic functions. Instead of simple on/off levers, operators can achieve infinite speed control and finely tune movements with joysticks and other input devices. This leads to more accurate and efficient operations.

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Monitoring & Diagnostics

IQAN systems provide real-time monitoring and advanced diagnostics. The software logs events, and can alert operators to potential issues before they cause a breakdown. This proactive approach to maintenance dramatically reduces downtime and lowers repair costs.

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Remote Accessibility

Rotec can build systems that allow for remote monitoring, diagnostics, and even software updates. This means operators can access the system’s data from a laptop or smartphone, diagnose a problem, and potentially resolve it without needing to be on-site.

Customisation

IQAN software is flexible and user-programmable. Rotec Hydraulics’ in-house design team can customize the system to your specific needs, building in tailored functions, adjusting parameters, and creating a user interface on the display that is intuitive for your operators.

Why Choose Rotec?

By choosing Rotec Hydraulics, you’re not just getting a hydraulic system; you’re getting a complete, integrated solution. Our expertise in both hydraulic and electrical mechanical systems, combined with the power of Parker IQAN, allows us to:

Design and Build: Create bespoke hydraulic power units and control systems from the ground up, tailored to your application.
Install and Integrate: Seamlessly integrate new electronic controls with your existing machinery, replacing outdated components with modern, smart technology.
Provide Ongoing Support: Offer remote diagnostics, software updates, and expert maintenance to ensure your system continues to run at peak performance.

Examples of Rotec-designed IQAN systems include a remote control system built for a quarry, which enabled operators to control heavy machinery from a safe distance, drastically improving safety and efficiency. Another project involved the development of a pioneering electric winch system, where Parker IQAN technology was instrumental in achieving precise proportional speed control – a function previously thought impossible for an electric system.

For more information, request a discussion with a member of our Sales Team via sales@rotec.net.

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