Rotec completes innovative remote monitoring system onboard a vessel

As equipment increases in complexity, there is a growing need and advantage to being able to monitor parts of, or a complete system remotely.

With a long held commitment to innovation, Rotec Hydraulics are the first known company in the UK to have designed, installed and commissioned Parker IoT software that remotely monitors a hydraulic system.

With the ability to be installed and remotely monitor any hydraulic system, Parker Internet of Things (IoT) technology allows a user to ensure their assets are working at full functionality by monitoring key performance indicators, such as temperature, pressure and flow.

The remote monitoring technology further benefits the user by providing vital performance feedback for preventative maintenance planning, and can monitor real time and historical data all within a simple web-based interface.

This web-based portal can be accessed worldwide and gives a further benefit of GPS asset tracking and visibility – thus aiding both security of equipment and logistical transport efficiency which in turn, can reduce fuel costs.

The innovative IoT project came to fruition following Rotec being asked by a boat manufacturer to gather information about the performance of the hydraulic system they were fitting to a new fleet of vessels. 

Because of the harsh marine environment, robust equipment was selected that meets high ingress protection. IoT modems are compact and have built in aerials allowing for a sealed solution, meeting strict IP67 ingress protection and wide temperature ranges of -30 to +75 degrees.

Multiple sensors were fitted by Rotec’s engineers to provide feedback of tank levels, oil temperatures, flows and pressures in various parts of the system.

A further enhancement was provided by adding a particle contamination device which monitors and uploads the vessel’s oil cleanliness data to the cloud. Previously hydraulic oil changes were performed on a time expiry basis, whereas adding sophistication of a real time oil contamination device now tells the customer when the oil needs to be changed rather than changing at estimated time intervals. This reduces both the cost for the customer and decreases the impact on the environment because they are now performed only when required.

The customer was particularly impressed as Rotec Hydraulics were able to code unique software and download this remotely to assist with additional logging during sea trials of the vessel before delivery for normal operations at sea. This provided additional information that has not previously been visible due to the nature of the testing preventing personnel being on board monitoring the systems from the bridge. 

The IoT can be connected to an engine ECU using standard j1939 CAN protocol to give live engine data to be able to monitor remotely. This can provide data feedback from various sensors to ensure optimal engine performance and critically, no abuse of the equipment when being used in the field.

Alerts can be set and configured to automatically send emails once thresholds are exceeded, enhancing the effectiveness of automated data upload. 

Built in Bluetooth and WiFi also allows the user to access the password protected modem locally to download logs and further enhance the remote experience. Software updates can be performed remotely over the web or by Bluetooth/WiFi to increase the functionality of the sampling controller or change data collection and upload frequency, allowing for maximum end user flexibility for the customer.

To discuss how Rotec can enhance your system monitoring, contact our Sales Team via 01823 348900 or email sales@rotec.net.

 

Hose Test Rigs for the Motorsport Industry

100% Achilles audit _Rotec Hydraulics Ltd

Rotec Hydraulics Ltd designed, built and commissioned two identical hose test rigs for a UK manufacturer who supplies world-leading racing teams with fluid transfer assemblies, hose and fittings.

UKCA/CE certificated and labelled, the test rigs are designed to provide regular and rigorous testing for a variety of flexible hose assemblies. The rigs were based on an existing design, but updated and improved due to the obsolescence of some of the components.

Measuring over 3 metres in length, the main capabilities of the test rigs include:

  • Testing hoses up to four hoses at a time
  • Testing hoses up to 250bar pressure using water as the medium.
  • An air supply is used to control the hydraulic (water) valves and is used to pressurize the water using a 60:1 air/water intensifier.
  • A low-pressure pump provides a means of flushing and pre-filling the hoses under test.
  • Clean, filtered and dried compressed air supply of guaranteed continuous pressure of 6 bar minimum.
  • Power supply of 240VAC 1 PH 50Hz 16A maximum for UK use.
  • Nominal test sequence, based on existing rigs, (i.e., prefill/flush, test, vent, purge).
100% Achilles audit _Rotec Hydraulics Ltd
100% Achilles audit _Rotec Hydraulics Ltd

Each rig consists of a grade 316 stainless-steel upper half, and a powder coated steel lower half and electrical enclosure.

The lower half consists of the water reservoir, an air tank, an intensifier, a low-pressure pump, pneumatically operated hydraulic valves and a pneumatic control system. All the valves, which water flow through, high-pressure pipework & reservoir are made of grade 316 stainless steel to prevent corrosion. There are two lockable hinged doors on the front and three lockable panels on the rear to allow access for maintenance as well as internal led strip lights for enhanced lighting.

Inside the upper enclosure are eight ½” BSP ports (four either end) to which up to four hose assemblies can be installed for testing at up to 250 bar pressure. Bi-fold doors with transparent windows are fitted to enable access to the hoses, the doors are fitted with interlocks to ensure they cannot be opened whilst the hoses are under test. Internal led strip lights are built into the top of the enclosure to provide enhanced lighting. There is also a water filling point and drain which connect to a reservoir in the lower half of the rig.

Attached to the right-hand side of the rig is the Rotec designed lockable electrical enclosure which houses the customers electrical components. On the front face of the enclosure are controls for adjusting the test pressure, starting/stopping the testing cycle as well as an information screen displaying the results of the testing.

2 manually operated panel mountable air regulators were incorporated into the design. One is set and locked at 4.2bar inside the lower area (i.e., beyond the reach of the operator), the other panel mounted in the user control panel. This second unit is fed from the outlet of the former, ensuring the user cannot inadvertently set the test pressure to rise above the setting of the former and thus inadvertently (or intentionally) over-pressurise the system.

Rotec’s customer said:

“I am very pleased with the finished machine. As I expected, everything has been finished to a high standard.”

If you are interested in a similar project or any hydraulic power systems, do not hesitate to contact the team today on 01823 348900 or email sales@rotec.net.

Hydraulic fuel system with integrated pipework solutions carried out by Rotec

Rotec engineers have carried out integration and commissioning of a hydraulic fuel system with pipework solutions on a brand new vessel for a prestigious boatbuilder.

After being let down by another supplier, the client requested Rotec to carry out the works following referrals made by others within the Marine industry who had given Rotec glowing reviews.

A reliable and efficient hydraulic fuel system, built with quality components, aids any vessel engine to run smoothly, avoid unexpected engine failures and ensure passenger safety. Additionally, built and maintained to a high standard, a hydraulic fuel system will be compliant with good practice and environmental regulations.

Rotec’s engineers, whose skills and experience span across multiple engineering disciplines – from hydraulics to electrical – installed and commissioned the hydraulic fuel system in line with the boatbuilder’s schedule of works.

The hydraulic tank design supports 2 hydraulic pumps, driven by 2 engines. The flow rate from each pump (45cc per rev) is estimated at a max 70LPM. The system also supports 2 thrusters, coolers and LS lines.

All pipework solutions used 50mm and 25mm stainless tube with 1.5mm wall thickness. This reduced the number of joints, whilst providing good circulation. Pipework materials centring on the use of rigid tube within the engine machinery space and completion of service points with flexible were employed where required. Finally, pipework was cleaned utilising the pelleting system and flushed.

All hoses were supplied by Rotec and supported by the Parker Tracking System (PTS). This labelling scheme enables a user to quickly scan any asset using a non-subscription, free mobile app. The asset’s technical specifications, including part number are then displayed, enabling efficient and accurate re-ordering of parts when required. App users can also set up service alerts to notify them of when a part’s lifespan is coming to an end.

For more information regarding Rotec’s capabilities, visit www.rotec.net. 

Multi-million pound refurbishment of MS Bolette unveiled

Supported by Rotec’s electrical mechanical services team, a multi-million pound refurbishment of MS Bolette has been unveiled to CLIA and Government officials.

The Bolette entered dry dock for a 13-day refurbishment, including maintenance to the ship’s Azipods and bow thrusters as well a new application of anti-fouling paint. Rotec Hydraulics Ltd, based across the South West of the UK, were responsible for the overhaul of Bolette’s eight thruster fans.

After the fans were electronically and mechanically disconnected, the vessel’s thruster fans were transported by Rotec for a full inspection. Following the inspection of all plate detail and insulation valves, the fans underwent dynamic balancing. The units were then transported back to the shipyard and reconnected, with a full works report supplied to the client.

The turnaround for the project was a mere 8 days from the ship arriving in the UK shipyard to Bolette setting sail again on 7th March. To ensure the tight deadline was met, Rotec engineers went above and beyond, working a 24/7 split shift pattern. Unplanned and additional emergent works which occurred, were quickly responded to by the Rotec team. Following the works, Mark Terrell, Electrical & Maintenance Manager at A&P Falmouth commented on Rotec’s service delivery:

“I would like to take the opportunity to thank you for the support. The Rotec response was great and by Monday 16:00 (less than 24 hours later) the ship had passed off all 8 fans as complete and ready to return to service. Special mention must go to [your engineers] for sticking with the job through Sunday night and well into Monday!”

MS Bolette has now sailed to Newcastle to complete its spring/summer season operating in Europe. Owned and operated by Fred. Olsen Cruise Lines, Bolette was formerly named Amsterdam and was the last ship of the four Rotterdam class (R class) cruise vessels.

For more information on Rotec’s Electrical Mechanical Services visit www.rotec.net.

 

Image: Aerial view of A&P Falmouth, where refurbishment of MS Bolette took place. Image source: https://www.cruiseandferry.net/

Minimising Downtime: Manufacturing Press Tube Replacement

Rotec’s technical team researched and implemented an innovative method to complete replacement tube pipework whilst keeping downtime to a minimum at a large car manufacturing plant in Gloucestershire.

Following damage occurrence on one of their press lines, the world-leading manufacturer required replacement Ø75×12.5 carbon steel tubes.

Traditionally, engineers would be required to remove the damaged tube in order to gather accurate measurements before being able to provide and fit replacements. The removal and installation processes would require manufacturer to shut down the machine during these times.

Downtime for a large manufacturer in the automotive industry can have huge implications operationally and financially. Always keeping the customer at the forefront of projects, Rotec’s technical team suggested using a 3D laser scanner to measure the pipework, in order to minimise downtime.

The 3D laser scanner not only meant that the machine no longer had to be turned off, but the measurements collected were incredibly accurate and minimised the influence of human error. Furthermore, the time required for Rotec engineers to be onsite removing pipes and then measuring them would be dramatically reduced – saving the customer costs due to reduced labour costs.

Once measured accurately, the design for new tubes created using CAD design software in-house at Rotec. In total, the measuring and design process was complete within 2 days.

Continuing Rotec’s commitment to utilising technologies, the tube ends were formed using the Parker HPF system, which eliminates the need for welding of the tube. Bespoke flanges were also machined to suit the formed profile of the Ø75mm tube and accommodate the bolt pattern of the existing connections. 

For more information visit www.rotec.net.

Rotec Completes Machine Overhaul with the ‘Wow’ Factor

Rotec Hydraulics Ltd have delivered a machine refurbishment project with the ‘wow’ factor.

A leading manufacturer of high quality, precision tubes asked the Rotec team to assess and quote for the refurbishment of an old tube manipulation machine. The unit which had been in situ for many years, required a complete overhaul to improve efficiency and to provide quality and robust workmanship, due to regularly working with the toughest specifications in high performance alloys (including stainless steel, titanium and nickel alloys).

After removing the unit and transporting it to Rotec’s Plymouth service centre in Devon, the tube manipulation machine was stripped and inspected. Following the quoting process and being awarded the contract to proceed, Rotec’s skilled engineers carried out a thorough overhaul of the hydraulics, mechanical and electrical control system.

On completion, Rotec engineers attended the client’s site and re-commissioned the unit. All of the works carried out by Rotec were project managed by an assigned manager, as with all our projects. This allows for quality client-supplier relationships and improves communications.

Following the re-commissioning, the customer stated that they are very happy with the unit and they are impressed with the workmanship and quality of the overhaul.

Established in 1979, Rotec Hydraulics is a leading fluid power expert; providing quality design, build, installation and maintenance of hydraulic, pneumatic, electrical mechanical and electronic components and solutions to the Aerospace, Agriculture, Defence, Industrial, Marine, Transport and Utilities sectors throughout the UK and internationally. ISO 9001 and ISO 14001 certified, Rotec Hydraulics prides themselves on high operational standards.

For more information, visit www.rotec.net.