Warship Power Units & Reservoir

After 4 months work replacing hydraulic pipework on a warship, Rotec’s engineers needed to flush the pipes to meet the required cleanliness standards. Due to a change in conditions on board the decision was made to design and build modular bespoke power units and a standalone reservoir.

Rotec have a long history working with the defence industry and specialise in bespoke design and manufacture of hydraulic power units for marine applications, amongst others.

Our team designed and built the power units using 55Kw electric motors close coupled to Berarma Vane pumps and included a flowmeter and a pressure gauge. The Berarma pumps are pressure compensated with variable flow rates. This gives the operators the flexibility to tailor flows and pressures thus ensuring turbulent flow conditions are met to maximise the cleaning action.

Electrical control panels are mounted direct to the trollies to allow ease of use

The power units are fitted with castoring braked wheels for easy manoeuvrability in tight spaces. The Rotec team also designed and manufactured a standalone reservoir, suitable for multiple applications and high volume (fluid) displacement, enabling maximum flexibility as design changes can be incorporated or removed as desired. The system includes pressure return filters which help remove any contaminants from the existing system, ensuring the pipes comply with client specified level of cleanliness.

Rotec delivered to the tight deadline, with just 1 week turnover.

Date: 26/09/2019

Author: Sarka Humpolcova

 

Commercial Vehicle Project

Rotec have been contracted to supply hose kits for a UK company manufacturing specialist surface coating removal vehicles, helping them streamline their operations as well as making them safer and more traceable, providing specialist support.

During phase one, all hoses were replaced on a variety of vehicle types, fitting them with the first hose kit in preparation for standardised hose kit supply. This allows the company to order their hose kits from Rotec, instead of manufacturing them in house.

All Rotec hoses are supplied with pressure test certification and can be traced throughout the Parker network using PTS system. Rotec also moved away from the previously used BSP fittings, choosing metric fittings which are more readily available throughout the world and provide a better seal. 

 

Date: 21/08/2019

Author: Sarka Humpolcova

Case Study: Waxing Machine

This unique piece of equipment was recently designed and built at our Taunton depot. The unusual request came as a result of one of our existing existing customers, a well-known candle manufacturer, recommending Rotec to their supplier – a company specialising in the manufacture of candle wicks.

Rotec previously undertook a variety of repairs and control system projects for the candle maker and had also supported the wicks manufacturer’s machinery. Following a successful PLC re-programming project, we were asked to manufacture a waxing machine. Using old conceptual designs left by the previous manufacturer, Rotec produced an up-to-date design, new CAD drawings and a modern control system. Our team of talented engineers then successfully completed the build.

The machine is designed to impregnate and coat a continuous length of wick cord with wax and re-spool onto a new drum. The process involves a multi-pass immersion process through a molten wax reservoir followed by periods of cooling and hardening. The wax is maintained at a constant temperature, indirectly heated by hot water in a vessel located below the wax reservoir. A plc is used to control wax temperature, main drive motor speed and spooling control of the finished product. The machine is now complete and will be installed at the customer’s premises within the next couple of weeks. The machine is capable of producing sufficient finish waxed wick for up to half a million wicks a day, depending on the length of the wick required.

Rotec and the customer are already in discussions about the next project, the design and manufacture of a wicking machine designed to cut the wicks to the desired size and insert the sustainer (the small metal disc sitting at the bottom) ready to be inserted into a candle.

 

Date: 08/04/2019

Author: Sarka Humpolcova

 

Case Study: Cartridge Valve Test Rigs

Roger, Matt and Claire

Rotec were contracted to upgrade a number of cartridge valve test rigs for a valve manufacturer.

The main drive behind the project was employee safety. The manufacturer provided the hydraulic and mechanical design on this occasion, tasking Rotec with the build and installation. This also included the incorporation of electrical software to make the rigs function.

Solid (no-joint) pipework, as can be seen in the photo, was specifically designed with operator safety in mind, replacing the potentially dangerous flexible hoses.

Rotec engineers recently successfully completed a 2nd rig installation, leaving 5 more rigs to go. Roger, Matt and Claire (pictured above) received high praise from the customer:

 “Great job by your team last week to get the2nd rig installed, thank you. “ From James

By Sarka Humpolcova

15/02/2019

Case Study: Beam trawler gets a dose of planned maintenance

Rotec recently completed a thorough service on a beam trawler, as a part of a traditional annual service on one of three local boats.

In addition to remedying the regular list of faults & based on previous experience Rotec suggested expanding the normal work list to include Planned Maintenance work. Typically this would include stripping and checking pumps, motors & valves in addition to addressing any outstanding leaks.

By carrying out Planned Maintenance tasks unexpected breakdowns of hydraulic and pneumatic components can be avoided. This was in a bid to remedy some recurring issues with steering and winching systems.

Rotec serviced the main winching system, removing and overhauling 3 hydraulic pumps, hydraulic motor & gearbox. On inspecting the drive shaft found a worn splined coupling, if this had failed thein it would have stopped the crew from retrieving their nets.

Other work included replacing a large selection of hoses, draining and inspecting the oil tank, supplying and fitting filters and a spare gear box.

 

 The engineers then stripped and repaired the pneumatic engine controls, completing a tricky job due to the controls being obsolete.

All hydraulic and pneumatic issues have been successfully rectified to customer satisfaction. This gives the skipper and his crew the confidence to go back to sea for another year.

Case study: Containerised Flushing Rig

In August 2017, the head of Rotec’s Plymouth Depot, Dave Nance, brought in an interesting enquiry from one of Rotec’s existing customers – an engineering firm specialising in work in Aviation, Land, Marine and Defence sectors.

The firm required a bespoke containerised flushing rig system for marine application. All Design work for the Container, Hydraulic & Electrical was completed in-house by Rotec, followed by a build by a team of Rotec engineers, in-house electrical specialist and a number of subcontracted engineers to help with the workload. The whole team was headed by Andy Rimes and Richard Renfree.

The project took 3 months from start to completion.

Bespoke container:

  • 6000mm long x 2500mm high x 2500mm wide
  • Tunnel design with double doors each end

2x separate Power units installed inside the container:

Each Power unit generally based upon: 4 x 7.5 Kw Motor & Pump sets installed onto a 3000 Litre stainless steel reservoir

 

  • Each Motor & Pump set producing variable flow rates from 70 L/Minute up to 170 L/Min via Electronic Variable speed Motor invertor drive control
  • Each Motor & Pump set provides Bi-Directional flushing control via directional control valves
  • Each Motor & Pump set provides pressure and return line filtration – Filtration ranges from 2 to 10 microns (Depending on filter elements used)
  • Individual contamination monitoring  for each circuit.

Custom made and designed electrical control operating system:

  • Driven via touch screen tablet control
  • Remote operating control also possible