Rotec Hydraulics Powers F1 Performance with Remote-Monitored HPU & Flushing Rig

100% Achilles audit _Rotec Hydraulics Ltd

Rotec Hydraulics, a leader in high-performance fluid power solutions, has engineered a custom Hydraulic Power Unit (HPU) and Flushing Rig for a global F1 team, tackling the challenge of delivering safe, precise, and reliable pressure while ensuring optimal system longevity.

Race car hydraulic systems demand meticulous maintenance, including regular flushing to prevent contamination—the primary cause of system failure. Traditional, bulky on-site equipment often leads to logistical issues and unwanted downtime. Rotec’s innovative solution merges two critical functions into one compact, portable unit.

The custom 3 kW HPU is designed to deliver 200 Bar of pressure at 8 Liters per Minute (LPM) to power race car hydraulic components. More crucially, it features an integrated flushing rig and particle counter, enabling technicians to maintain pristine oil cleanliness.

A key differentiator is the integration of remote diagnostics via Parker IQAN technology. The HPU utilises Bluetooth connectivity to allow remote monitoring and control via a tablet or smartphone. This provides instant, detailed data on sensor and output states, including pressure, temperature, flow, and contamination levels.

Jesse Cherry, Business Development Manager at Rotec Hydraulics commented,

“This project showcases Rotec’s ability to deliver bespoke, high-performance hydraulic solutions that directly address challenges. We understood the critical need for a reliable, safe, and mobile solution. The integration of remote diagnostics streamlines operations and provides a great benefit to our client.”

The dual-functionality, combined with remote diagnostic capabilities, transforms maintenance from reactive repairs to proactive system health management. This compact, maneuverable rig minimizes maintenance time, boosts operational efficiency, and significantly reduces the risk of critical hydraulic failures—a crucial competitive edge in the high-stakes world of Formula 1.

Discover Rotec’s full capabilities via their website www.rotec.net or call 01823 348900 to discuss your requirements.

Servicing Hydraulic Systems for Harbour Authority

At Rotec Hydraulics, we believe that a well-maintained hydraulic system is the backbone of efficient and reliable operations. We recently carried out essential hydraulic power unit (HPU) servicing for a returning customer – a major harbour authority in Devon.

Our experienced engineers carried out a thorough service of the client’s HPU, including:

  • HPU Draining & Oil Replacement: We began by draining the old hydraulic oil from the HPU, preparing the system for a fresh start.
  • Critical Hose Replacements: The project required the replacement of two steering system “severe rated” hydraulic hose assemblies. Our engineers manufactured new hoses, making them 150mm longer to allow for better routing around a tie-rod. This small modification significantly reduces wear and tear and extends the life of the hoses. We also identified and replaced two additional hose assemblies with damaged outer sleeving, preventing potential future failures.
  • Component Inspection & Servicing: We removed and inspected the slow stow adjuster and its associated solenoid. This step involved servicing, cleaning, and replacing seals as needed, ensuring these components operate flawlessly.
  • System Flushing & Filtration: To guarantee a clean system, we installed a temporary hydraulic filter in the Man Overboard (MOB) system. We then refilled the tank with BIO ISO-32 oil and ran the system through, directing the flow of oil through the pressure filter to effectively flush out any contaminants.
  • Final Commissioning: After the flushing process, we reinstated the system, carefully bled the lines, and performed a comprehensive commissioning to ensure everything was functioning correctly. We also performed fault-finding on the MOB system, addressing any issues proactively.
  • Site Clean-up: We believe a job isn’t complete until the site is left clean and tidy, a final touch that underscores our professionalism and respect for our client’s workspace.

 If you are looking to secure the longevity and reliability of your hydraulic systems, a proactive maintenance plan is a wise investment. Contact Rotec Hydraulics today to learn how our team can help you safeguard your operations via sales@rotec.net or phone 01823 348900.

100% Achilles audit _Rotec Hydraulics Ltd

Preventative Maintenance for Hydraulic Pumps to Boost Efficiency and Reduce Downtime

At Rotec Hydraulics, a Parker Certified Hydraulic Technology Centre with over 45 years of experience, we advocate businesses to adopt a proactive approach to hydraulic pump maintenance.

Preventative care is far more cost-effective than reactive repairs, which is why we offer flexible preventative maintenance service contracts to help clients avoid costly and unexpected system failures.

Proactive Hydraulic Pump Maintenance

Hydraulic pumps are at the heart of hydraulic systems. However, without regular maintenance, their performance can quickly degrade, leading to inefficiency, increased energy consumption, and catastrophic failures.

Routine maintenance and inspection are crucial because:

  • They prevent expensive breakdowns: A small, easily fixed issue, like a worn seal or contaminated fluid, can escalate into a complete pump failure, requiring a full and costly replacement.

  • They extend equipment life: Regular servicing and timely replacement of components—such as seals, bearings, and filters—significantly extend the operational life of the pump.

  • They improve efficiency: Clean, well-maintained pumps operate at peak performance, reducing energy waste and ensuring the system performs as designed.

A thorough strip-down and inspection is recommended every 2,000 to 4,000 operating hours or as indicated by the manufacturer. This may also be reduced if operating in a particularly harsh environment. Rotec’s in-depth service allows technicians to identify internal wear and tear that isn’t visible during routine checks.

The Rotec Hydraulics Advantage

Choosing the right service provider is paramount. Rotec Hydraulics is uniquely positioned to offer superior hydraulic maintenance services.

  • Parker Certified Hydraulic Technology Centre: As the only accredited Parker Hydraulic Technology Centre in the South of the UK, Rotec guarantees services performed to the highest industry standards.

  • Decades of Expertise: With over 45 years in the industry, Rotec has a deep, hands-on understanding of hydraulic systems across various sectors, from industrial and marine to defense and agriculture. This extensive experience ensures accurate diagnostics and effective, long-lasting repairs.

  • Preventative Maintenance Service Contracts: Rotec offers customised service contracts tailored to a business’s specific needs. These contracts schedule regular inspections and maintenance, taking the guesswork out of pump care and ensuring a system’s health is always a priority. This approach not only minimizes downtime but also provides a detailed service history for audit purposes and offers emergency support.

“We believe in helping our clients shift from a reactive to a proactive maintenance strategy,” says Mark Conniff, Operations Manager. “Our goal is to ensure their hydraulic systems are reliable, safe, and efficient. With our Parker certification and extensive experience, we take pride in our level of service and expertise.”

For more information on our preventative maintenance services or to schedule a consultation, please phone 01823 348900 or email sales@rotec.net.

Hydraulic Accumulator Overhaul & Recertification for UK Port

100% Achilles audit _Rotec Hydraulics Ltd
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.