Stroud Engineers Deliver Major Refurbishment Projects at BMW

Rotec engineers carried out a major refurbishment of the Feed Line and Press at a BMW plant in Gloucestershire.

Over 160 hydraulic hoses on the Feed Line, and 66 hoses on the Major Press were removed and new hoses made and fitted.

This was a challenging job due to the complexity of the machinery and included hoses on the Feed Line HPU (hydraulic power unit), Press and Overload/Protection/Lubrication HPUs. Feed Line Pneumatic cylinders, valves and tubings were also supplied and fitted, in addtion to a total of 48 existing hydraulic cylinders on the Feed Line removed and new cylinders fitted.

Further work taken on the Feed Line, Press and Overload/Protection/Lubrication HPUs included:

  • Draining of the working fluid and cleaning of the reservoir.
  • Replacement of pressure and return hydraulic filters, pressure and return.
  • Replacement of pressure and return hydraulic filters, pressure and return.
  • Resealing of duplex filter block.
  • Removal of existing and refitting of new motor pump sets.
  • Thorough cleaning and inspection.
  • Removal of existing and refitting of new air blast coolers.

All refurbishment works were carried out on time, in budget and to the client’s expectations and standards.

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Rotec Deliver Vessel Overhaul at A&P Falmouth

Rotec’s Electrical Mechanical Services team have recently carried out significant maintenance and overhaul works on the vessel Norbay at A&P Falmouth.

Originally built in Rotterdam in 1994, Norbay and her sister Norbank were two of the first of a new generation of ‘super freighters’. The vessel is currently used as a car, passenger and freight ferry in the Irish Sea for P&O Ferries.

Specialists in alternators and generators, Rotec’s Electrical Mechanical engineers have completed a significant overhaul project on the vessel Norbay, on-site at A&P Falmouth. The work included:

  • On-site Aft Bow Thrust Overhaul inc. internal inspection, replacement bearings, rebuild, testing and full works report
  • Port Alternator Clean and Bearing Change
  • Main Vehicle Deck Aft Cargo Fan Overhaul inc. collection from dockside to Rotec workshop inspection, steam clean, re varnish, new bearings, dynamic balancing, testing and reinstall
  • Cargo Fans motors overhaul.

The work carried out will ensure the continued performance and availability of the vessel. Greg Sandy, Business Development Manager and part of Rotec’s Electrical mechanical Services team said:

“Rotec are proud of their strong relationship and partnership with A&P Group in Falmouth, which sees us providing quality services and solutions.

“Our extensive range of services and products, combined with the experience and knowledge of our technical team has given us the well-deserved reputation for being a trusted provider of quality Electrical Mechanical Services.”

Rotec have been trading for over 30 years and take pride in delivering project specific solutions, sustainable results and added value to their clients. For more information on our Electrical Mechanical Services offer, click here.

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Custom made hydraulic winch system for the utilities sector

Rotec Hydraulics Ltd has recently completed works on a custom made hydraulic winch system for the utilities market.

Fitted to a fleet of Ford Ranger vehicles, these bespoke winches have been designed, built, installed and tested by our in-house team of engineers and include a hydraulic system, electronic control system and mechanical components.

The Capstan winch is specifically designed for fast line speeds and has a 350Kg working load limit with a remote electrical foot pedal operation

Safety features include an integral fail safe static brake and integral dynamic braking.

The Capstan winch drum is made of stainless steel and the winch is deployed on a sliding system to allow the operator to move it from stored position to operational position easily.

Our client is one of the world’s largest publicly listed utilities focused on transmission and distribution of electricity and gas. They play a vital role in connecting millions of people to the energy they use safely, reliably and efficiently. Rotec has worked with this organisation for several years and are proud of the strong, effective relationship we share.

At Rotec the team work on many different projects.  Much of the work undertaken requires the integration of knowledge and skills from across the Rotec team, to deliver all of the elements that make up a client brief. For more information on the services we offer, please click here.

 

Custom Designed Winching Systems

Isuzu Dmax

Rotec have been working with the Utility market for the last 20 years – designing and manufacturing winch systems for overhead line teams throughout the UK. Traditional vehicles such as landrovers were deemed the work horse and industry standard. Working with a number of organisation the challenge to replace the landrover centred on certain replacement vehicles – such as the Isuzu DMAX.

The bespoke system includes the following:

  • Electro-hydraulic PTO (Power Take Off) for the pump
  • Custom designed hydraulic manifold assembly, which uses an electronic proportional directional control valve
  • Dual pressure control which allows for pressure selection
  • Custom made hydraulic reservoir
  • Custom electronic control system, including a remote pendant with joystick control as well as a 2nd joystick located in the cab
  • Integrated electronic hand throttle for the engine
  • Quality winch and Parker hydraulic hose supplied with pressure test certification which can be traced throughout the Parker network using PTS system

The system operates in two work modes:

  • Lifting mode: capable of lifting up to 1550 Kg (SWL)
  • Self – recovery: capable of pulling 3600 Kg

The bespoke system is designed and manufactured completely in-house, fully – tested prior to despatch.

Grain ship-loader replacement electro-hydraulic control system

Thanks to the working relationship spanning many years, Rotec were invited to quote for the replacement of the hydraulic power unit and controls of the grain/feed products ship loader travelling gantry system. The client was faced with reliability and obsolescence issues with the original equipment dating back to the 1980s. It is the only plant capable of this function at the port and is in use constantly.

The ship loader hydraulic functions consist of a dual pumping system and associated hydraulic equipment built into an up-cycled twenty-foot shipping container. The container sits on the machine approximately 20 metres above dock level, which presented some unique access issues.

 Based on the original system design, Rotec designed and manufactured a complete self-contained hydraulic system and associated dedicated electrical control panels which control vertical and horizontal movements of the grain conveyors and loading chute to align over the vessel’s holds as required.

The container was specially modified to accept and fit the hydraulic system. This included full sound and fireproofing, internal full bunding and bespoke flooring and ventilation integration. The hydraulic system consists of a primary pump system driven by a 100KW 3300VAC electric motor and proportionally controlled variable displacement pump with a completely redundant secondary backup system in case of partial or total power loss. This 400VAC backup system is supplied from an external generator and is used to recover the chute off a vessel during a power loss when necessary. The main pump systems are supported by cooling and filtration systems and associated electrical control and monitoring equipment which in turn all interface and interlock to the main ship loader external control system.

21The project initially began in 2017, but project was temporarily halted by Brexit and later on, the outbreak of COVID-19. However, following a major fire one evening whilst in use on a vessel which completely destroyed the old containerised system, surrounding cabling and pipework, the project objectives and target completion date was rapidly brought forward to minimize the client’s downtime.

Due to our very flexible approach and ability to respond to an everchanging priorities list, Rotec was able to pick up and resume the build process quickly and managed to complete and factory test the unit ready for site delivery and install by the end of May. Our on-site engineers in the meantime stripped out and replaced large quantities of fire damaged external fixed stainless and special alloy tubing and replaced all external flexible hoses on the machine. The container unit and system were craned into place, pipework connections completed then flushed thoroughly. The system has now finished its commissioning and setting to work process, on time and on budget, and is ready to serve the port for this vital service for at least another 30 years minimum. The client is completely satisfied with the product and service received by him by our team of design, manufacturing, and field service personnel.

 

Portable Flushing Units

The Rotec Portable Flushing Unit performs a function that’s important for any hydraulic system: It flushes out and filters build-up of contaminants, leaving the system ready for use in minutes. It is crucial for maintenance, extends system lifetime, helps avoid repair costs and downtime. The unit can also be adjusted for fuel filtration and can be used for filling the system (filtering all the while).

This versatile unit is built into a trolley frame which makes it easily manoeuvrable and can often be found on keysides, decks or factory floors. The flushing unit is suitable for use in a variety of applications, including but not limited to: marine, industrial & off-shore.

The system is bespoke and can be tailored to your needs for use with a range of water-based control fluids or hydraulic mineral oils.

Technical Information of the system pictured:

  • Use: localised flushing on marine applications
  • Filtration: 10Q micron
  • Motor: 1.5Kw, 110v
  • Flow: 20 l/min
  • Pressure: up to 28 bar
  • Supplied with 5 metre suction and delivery hoses