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.

Kitting Services and Hose Assemblies tailored to your needs

Looking to reduce inefficiency and increase your team’s capacity?

Eliminate non-value added activities and increase your productivity with Rotec’s Bespoke Kitting Service.

 

All components and sub-assemblies are labeled and packaged neatly together with a list detailing parts and quantities for your convenience. 

Whether you need basic to the most complex kits with multiple assemblies, Rotec Hydraulics delivers kit solutions to help you meet performance goals.

Benefits

  • Simplifies Inventory Management: Reduces volume of individual components to stock manage.
  • Increases Productivity: Your team no longer need to pick parts from different areas. Instead they have a kit ready to go so they can get on with the job in hand.
  • Reduces Manufacturing Time: Kits are tailored to your needs and can include pre-assembled items.

Getting Started

  • Establish a Bill of Materials: Identify items and quantities.
  • Identify Packaging Requirements: Define custom tagging/labelling.
  • Specify sub-assemblies: Decide if any pre-assembled items are required.
  • Request Custom Quote: Email sales@rotec.net or phone 01823 348900 to speak to a member of our team. 
It’s that simple!  Get started by clicking the button below and our Sales Team will be in touch to discuss your requirements.
ENQUIRE TODAY

Rotec confirmed as LEEA Full Member

Rotec Hydraulics Ltd are thrilled to announce that following a thorough audit they have achieved full membership status with the Lifting Equipment Engineers Association, better known as the LEEA.

LEEA are a respected organisation dedicated to ensuring safety and quality across lifting equipment materials and supplier integrity. LEEA supports the education and quality procedures to ensure that safe practice is the everyday norm.

To become a full LEEA member, Rotec provided evidence of their activities within the lifting equipment industry and underwent a thorough compliance audit where the business’s processes were examined and assessed on their ability to uphold and maintain the exemplary standards required by LEEA. 

This thorough membership process ensures that only those who provide the highest-quality products and services can attain a membership.

When using a LEEA member, you can be confident that they are compliant to any and all relevant standards and legislation, competent, and are continually raising the standards of practice.

Quality Systems Manager at Rotec Hydraulics Ltd, Josie Chamberlain, commented,

“It is a fantastic achievement to have been confirmed as full LEEA members. Rotec are highly experienced at hydraulic projects for the lifting equipment industry, including being a well-renowned producer of bespoke hydraulic winch systems.

 

“We look forward to continuing our work with LEEA, and ensuring we deliver expertly trained staff to all our clients.”

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. 

How to prevent your hydraulic system overheating

Hydraulic oil temperature beyond 82°C is likely to cause damage to your hydraulic system’s components and accelerate oil degradation.

As one of the most common issues in a hydraulic system, ensuring your hydraulic oil does not overheat is a priority to keep your machines healthy, and avoid costly downtime and repairs.

You can usually tell if the temperature is too high, as the viscosity will be too low for the hydraulic components.

Viscosity can also be negatively affected in temperatures below 82°, depending on the oil’s viscosity index. To ensure a stable oil temperature, the hydraulic system must be able to dissipate heat faster than it is built up.

How to prevent overheating

Reducing hydraulic oil temperature and increasing the rate of heat dissipation are the two most common and effective ways to prevent your system from overheating.

Heat dissipation occurs in the hydraulic reservoir. Check your reservoir to ensure the fluid level is correct. If the fluid level is low, fill it to the recommended level. Whilst you are checking the oil level, make sure there are no obstructions, such as dirt or debris, preventing good air flow into the reservoir.

Heat exchangers

Heat-exchangers rely on the flow-rate and temperature of the hydraulic oil and the coolant in order to disperse heat efficiently. Once again it is critical that you regularly check for any debris or dirt, and ensure the core is not obstructed. If you experience issues with the cooling circuit then they may need to be replaced. Infra-red thermometers that check the performance and oil flow-rate of the heat exchanger can be used and are recommended.

Leakage

Excess heat can be generated when the pressure in a hydraulic system drops. Similarly, overheating can occur if any components are leaking. Check regularly for leaks and fix appropriately.

Rotec achieves Parker Certified Accumulator Service Centre recertification

100% Achilles audit _Rotec Hydraulics Ltd

Rotec is pleased to announce it has been re-certified as a Parker Hannifin Hydraulic Accumulator Service and Technology Centre.

Following successful completion of an audit process for Hydraulic Accumulator Technology and Service Centres, Rotec Hydraulics Ltd has retained its prestige as the only certified Parker Accumulator Service and Technology Centre in the South of the UK.

Parker Certified Accumulator Service Centres were established to enable the combination of industry-leading products with excellent customer service, and to deliver stress-free accumulator management with maximised performance, efficiency, and safety.

The benefits of being a Parker certified centre, in addition to Rotec’s status as a Parker Hydraulic Technology Centre, enables Rotec Hydraulics to provide integrated solutions that combine products, services and technologies. Rotec’s access to original spare parts provides tangible benefits to clients, including shorter inspection time and the reduction of complexity help to lower cost and to save time.

As added value to customers, the Rotec Hydraulics Ltd Service Centre is able to utilise the Parker Tracking System (PTS) which helps schedule accumulator maintenance, providing automated notifications on inspections and replacement parts.

Rotec Hydraulics have the knowledge, expertise and capabilities to deliver a comprehensive range of accumulator services including:

Regulatory compliance and certification

  • Hydraulic accumulator re-certification
  • Provision of tracking systems, data monitoring and recording
  • Optimising customer documentation to fulfil regulatory requirements
  • Local pressure vessel regulation
  • Audits, scheduled inspections and replacement parts

Hydraulic accumulator maintenance and pre-charging

  • Full service for just in time solutions and breakdown repairs
  • Full service for replacement and planned/preventative maintenance
  • Commissioning/testing (on-site)
  • Bladder and piston seal replacement
  • Gas pre-charge control and re-charge

System Optimisation

  • System design and improvement (including Hydraulic Power Units (HPUs) and Accumulator Racks, calculation, training and measurement)
  • Accumulator replacement

Asset Management

  • Energy and efficiency audits
  • Risk assessment and servicing of safety equipment
  • Asset condition monitoring and prognostics (sensors)
  • Legal conformity and insurance cover
  • Enabling customers to exploit the potential of Condition Monitoring and the use of Internet of Things (IoT) technology.

For more information on Rotec’s ramge of Accumulator services, contact our team.