Rotec Hydraulics, Author at Rotec Hydraulics Ltd

Rotec Delivers Major Marine Project Clean, Flush and HPU Overhaul in 10 Day Turnaround

100% Achilles audit _Rotec Hydraulics Ltd

Rotec recently successfully completed a complex hydraulic system overhaul for a 430ft long ocean survey vessel. Working in collaboration with a leading ship repair and dry-docking partner in Cornwall, Rotec’s Falmouth-based engineering team executed a comprehensive cleaning, rebuild, and system flush of a critical Controllable Pitch Propeller (CPP) hydraulic system.

The project, which took place in December 2025, was defined by an incredibly demanding 10-day turnaround while the vessel was in dock. Despite the tight window, Rotec’s engineers ensured the system met and exceeded the rigorous standards required for Lloyd’s Register (LR) compliance.

Exceeding Technical Standards

The primary objective was to eliminate foreign object debris (FOD), restore hydraulic cleanliness, and return the CPP circuit to a verifiable condition ready for functional testing. While the client specified a cleanliness standard of NAS 4, Rotec’s advanced mobile flushing and filtration technology, equipped with Parker IQAN real-time data logging, achieved a superior NAS 3 rating.

The scope of work included:

Deep Cleaning: All CPP rod sections and shaft tubes were initially manually cleaned and pigged to remove visible contamination.
Precision Flushing: Each rod and tube section flushed using heated hydraulic oil (at phases of 40°C and 60°C) through multi-stage filtration down to 2 microns.
HPU Restoration: Stripping, cleaning, and flushing the Hydraulic Power Unit (HPU) and associated pipework.
System Rebuild: Full shaft rebuild and system charging in accordance with OEM instructions and surveyor guidance.

The Falmouth depot team worked around the clock to ensure the vessel was hydraulically complete and ready for commissioning. Following the successful venting and oil charging to the header tank, the system was approved by both Ministry and Lloyd’s representatives.

Martin Webber, Rotec’s Falmouth Depot Manager, commented:

“This project was a true testament to the skill and dedication of our Falmouth team. Managing a full CPP shaft and HPU rebuild within a 10-day docking window requires planning and precision. By utilising Rotec’s specialised, custom-designed portable flushing rigs, we didn’t just meet the client’s cleanliness targets—we exceeded them, delivering a NAS 3 standard that ensures long-term system reliability for the vessel.”

Optimise Your Fleet’s Performance

Rotec’s portable flushing rigs with IQAN technology are available for hire, providing live, verifiable data to ensure your hydraulic systems meet the highest international cleanliness standards.

To enquire about our marine engineering services or equipment hire, contact the Rotec team today.

Safety, Compliance, and Performance: The Importance of Accumulator Maintenance

At Rotec, we provide a total life-cycle solution for your hydraulic systems. As the only Parker Certified Accumulator Service Centre in the South West, we are uniquely equipped to keep your operations running safely and efficiently.

What is a Parker Certified Accumulator Centre?

Being a Parker Certified Centre means Rotec has been rigorously audited and approved to provide the highest level of technical service. For our customers, this certification offers several tangible benefits:

Original OEM Parts: We have direct access to genuine spare parts, including Parker, QHP, and Hydac, ensuring your equipment is restored to its original manufacturer specifications.
Expert Recertification: We are authorised to perform full recertifications, including hydrostatic testing and volumetric stretch testing.
Parker Tracking System (PTS): We can use digital tagging to track your assets. This means you can receive automated notifications when an inspection or replacement is due, taking the guesswork out of compliance.
Written Schemes of Examination: We have the expertise to prepare the legally required Written Schemes of Examination (WSE) to ensure you meet UK safety standards.

How Often Does Your Accumulator Need Maintenance?

Under the Pressure Systems Safety Regulations (PSSR) 2000, it is a legal requirement to regularly maintain your hydraulic accumulators. Generally, the following intervals are recommended:

Every 3–6 Months: Visual Inspection & Gas Pre-charge Check

Gas levels naturally permeate over time. Low pre-charge causes the bladder to over-flex, leading to premature failure.

Every 12 Months: External Examination

Checking for corrosion, paint blistering, or mounting issues, especially in harsh marine or construction environments.

Every 5–10 Years: Full Recertification & Internal Inspection

A legal requirement for many systems to verify the structural integrity of the pressure vessel.

Why Choose Rotec Hydraulics?

Maintaining an accumulator is not a DIY task. Opening a pressurized vessel without the correct training and tools can lead to catastrophic accidents, including fluid injection or explosions. Customers choose Rotec because of our:

State-of-the-Art Facilities: Our workshops feature dedicated test rigs capable of testing bladder accumulators from 0.5L up to 54L.
Specialist Accumulator Knowledge: Our engineers are trained by global Fluid Power experts, Parker Hannifin, in all aspects of accumulators.
Sector Experience: We regularly overhaul accumulators from all industries, and can tailor our overhaul accordingly. For example, applying marine-grade coatings to protect against saltwater corrosion for marine accumulators.
Safety First: We ensure your system is fully depressurised and safe before any work begins, protecting your staff and your investment.

Don’t Leave Your Compliance to Chance

A well-maintained accumulator reduces pump wear, saves energy, and prevents costly downtime. Most importantly, it keeps your team safe.

Is your accumulator due for an inspection? Contact our team today via 01823 348 900 or email sales@rotec.net.

BFPA ‘Q’ Approved Hydraulic Hose Assemblies from Rotec – What this means for you

We are proud to be a BFPA Approved Distributor and ‘Q’ Approved for hydraulic hose assemblies – an assurance of the highest standards in fluid power safety and quality.

What Does This Mean for You?

Choosing a ‘Q’ Approved supplier like Rotec Hydraulics over non-accredited providers delivers critical benefits for your operation:

Guaranteed Safety and Reliability: Our accreditation assures you that every hose assembly is built to an industry-agreed, rigorously audited standard. This significantly reduces the risk of hose failure, injury, and dangerous fluid injection.

Highly Trained & Certified Technicians: All our hose technicians are trained and certified to the BFPA industry standard, ensuring a professional understanding of hose technology and best practice assembly techniques.

Eliminating Dangerous Practices: We are strictly audited to never partake in hazardous practices such as:
- Mixing and Matching components from different manufacturers, which can compromise the integrity and safety of the assembly.
- Re-ending used hose assemblies, a false economy that dramatically increases the risk of failure.

Reduced Downtime and Increased Efficiency: Quality products and expert assembly mean less unexpected failure, less downtime for your machinery, and greater productivity for your business. The ‘Q’ stands for Quality, Efficiency, and Safety.

Commitment to Best Practice: Our facilities, equipment (including swaging machines and test rigs), and stock management are subject to detailed bi-annual technical audits by the BFPA. This ensures continuous adherence to the highest operational standards.

Don’t compromise on safety and quality. Partner with Rotec Hydraulics for your hydraulic hose assembly needs and Choose ‘Q’ for Quality.

For more information, or to place an order call 01823 348 900 or email sales@rotec.net.

Rotec Completes Critical Refurbishment of Canal Lock Lift Bridge System

Rotec Hydraulics, a leading provider of hydraulic engineering solutions, have completed a recent project involving the removal, overhaul, and refitting of two critical hydraulic cylinders for a Canal Lock Lift Bridge.

The project, which also included the fabrication of a new bespoke clevis frame assembly and the replacement of hydraulic hoses, was executed to ensure the continued safe and reliable operation of the waterway infrastructure.

Due to the age and wear on the existing components, the overhaul was critical. Rotec’s work covered the entire lifecycle of the component replacement, from initial isolation to final commissioning:

Cylinder Removal and Preparation: Rotec engineers worked alongside the customer’s team to safely isolate and remove both hydraulic cylinders from the bridge structure, before transporting them to the Rotec workshop for overhaul.
Comprehensive Cylinder Overhaul: Involved stripping the cylinders, removing seized bolts and eyes, manufacturing new 4-inch rods, and performing repairs and refurbishment on the glands and pistons. The cylinder tubes were polished, and new seal kits were supplied and installed before the cylinders were re-assembled and tested.
Reinstallation and Commissioning: Following overhaul, the cylinders were delivered back to the site. Rotec provided installation assistance, topped up the system with new hydraulic oil, and oversaw the final onsite testing to ensure safe and optimal performance.

The project also encompassed the fabrication of a replacement frame for the cylinder base end clevis.

Clevis Frame Assembly: Rotec reverse-engineered measurements from the existing components to design and fabricate a new clevis frame assembly. The new frame was upgraded with larger side plates for increased durability. The fabrication underwent die-penetrant weld testing to confirm structural soundness.
New Components: The project included the machining and supply of a replacement clevis pin and four new pin locating plates.
Hydraulic Hose Assemblies: Rotec supplied and installed four new replacement hydraulic hose assemblies with stainless steel over braid, all of which were pressure tested prior to commissioning.

“Successfully refurbishing these critical cylinders and simultaneously fabricating a key structural component, all while minimising disruption, underscores our commitment to maintaining essential infrastructure,” commented Dale Lockart, Branch Manager of Rotec’s Stroud Service Centre.

The successful completion of the cylinder overhaul and clevis frame replacement ensures the continued operational efficiency and safety of the Canal Lock Lift Bridge for many years to come.

For more information on the services offered by Rotec, contact sales@rotec.net or phone 01823 348900.

Rotec Hydraulics Achieves Cyber Essentials Plus Renewal

We are thrilled to announce that Rotec Hydraulics has successfully renewed our Cyber Essentials Plus certification.

This renewal is a testament to our ongoing commitment to cyber security and protecting our customers and supply chain’s data and privacy.

Achieving Cyber Essentials Plus, the highest level of certification, requires a hands-on technical verification to ensure robust protection against a wide range of common cyber threats. We wish to thank PC Comms for their support in helping us to achieve this.

What this means for you:

Enhanced Security: We maintain rigorous security standards to keep your information safe.
Trust and Confidence: You can be confident that you are dealing with a company that takes data protection seriously.

For more information, contact us via sales@rotec.net or phone 01823 348 900.

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