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

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. 

 

Rotec Delivers Critical Engineering Solutions for Cruise Ship

Rotec, a leading provider of hydraulic, pneumatic, and electro-mechanical solutions, is proud to announce the successful completion of critical engineering works on a cruise ship at Falmouth Dry Dock. This project follows a successful dry-docking of a sister ship the previous year.

The Challenge

We were asked to carry out essential maintenance requirements on the vessel, specifically focusing on the ship’s main engine combustion fans, supply fans, and exhaust fans.

The scope of work was comprehensive, requiring skilled engineering capabilities. Key objectives included:

  • On-site bearing replacement where feasible.

  • Thorough inspection and pre-recording of electrical readings before disconnection.

  • Safe electrical and mechanical disconnection of units.

  • Post-disconnection inspection and recording of insulation values.

  • Reporting any abnormal findings to the ship’s staff.

  • Cleaning of all necessary areas.

  • Extraction of old bearings and fitting of new, Rotec-supplied bearings.

  • Reinstatement and electrical/mechanical reconnection, including insulation tests.

  • Optional services like dynamic balancing and laser alignment were available.

100% Achilles audit _Rotec Hydraulics Ltd
100% Achilles audit _Rotec Hydraulics Ltd
100% Achilles audit _Rotec Hydraulics Ltd

The Solution

Rotec deployed a team of highly skilled engineers to the dock, who quickly commenced work on the specified fan units. Their methodical approach ensured every step was executed with precision and adherence to safety protocols.

During the process, the team identified several critical issues that required immediate attention:

  • A supply fan, upon removal from its trunking, revealed cracks in its mounting bracket, which were promptly welded for repair.

  • A significant crack was discovered on the lug of the Non-Destructive Examination (N.D.E) endshield. Rotec swiftly sourced and fitted a replacement endshield, adapting it for the absence of a vibration sensor aperture.

  • Both vibration sensors for the bearings were found to be damaged beyond repair, necessitating the sourcing of new replacements.

  • The fan cowl also showed evidence of a previous crack and weld repair.

 Despite these unforeseen challenges, Rotec’s engineers demonstrated exceptional problem-solving skills and adaptability. The fan unit was meticulously reassembled with new, high-quality bearings supplied by Rotec. A rigorous insulation test was performed, yielding a reading greater than 2Ω, confirming the unit’s electrical integrity. Following reassembly and testing, the unit was run to the complete satisfaction of the ship’s staff.

 The Feedback

The client’s Assistant Electrical Manager commented,

“I’d like to personally thank your engineers for their excellent work. As always, they have been a pleasure to work with, delivering the job on time and to a high standard. All work has now been tested and officially signed off by the ship.”

Conclusion

By proactively identifying and resolving complex issues, Rotec ensures that critical marine equipment functions optimally, contributing to the safety and efficiency of global maritime operations. Our engineers carried out the job within the timeframe required – something that is critical to the Marine industry. Rotec looks forward to continuing its partnerships, and further supporting the marine industry within Cornwall, the South West and beyond.

 

100% Achilles audit _Rotec Hydraulics Ltd

Modernising Ramp Actuators

Mitigating obsolescence and ensuring long-term operational efficiency. 

100% Achilles audit _Rotec Hydraulics Ltd

The Challenge: Aging, proprietary ramp actuators (50+ years old) posed maintenance and obsolescence risks, with strict dimensional constraints for replacement.

The Solution: A bespoke engineering solution, developed in collaboration with Landau UK Limited, which delivers a high-performance, modernised replacement using readily available components – reducing obsolescence risks, and extending the serviceable lifespan of the unit.

Key Design Requirements: The new jack was engineered to meet the following critical performance and operational specifications:

  • High Force Capacity (Max pull force: 61,000 kg, max push force: 81,300 kg)
  • Compact Dimensions
  • Fluid Compatibility
  • Weight Optimisation and Manual Handling (Weight reduced from previous jack)
  • Self-Contained System (Integrated design for autonomous operation)
  • Single control interface for intuitive control
  • Manual Backup
  • Over-Pressurization Protection
  • Robust exterior for handling resilience
  • Environmental durability (temp range from -30°C to 48°C, direct saltwater environment)

Manufacturing and Component Strategy: Modern CNC machining techniques employed for manufacturing. Non-machined components, such as o-rings, rod seals, bearings, and fixings, were selected as commercially available products to ensure long-term accessibility.

Testing and Validation: Rigorous factory acceptance testing, utilising a custom 160+ tonne capacity test frame, validated performance under maximum loads.

Delivery and Packaging: Units packaged to stringent Level N Defstan requirements for secure storage and transport.

Outcome: Six units delivered ahead of schedule and fully compliant.

The modernisation provides a sustainable, maintainable solution, mitigating obsolescence and ensuring long-term operational efficiency.

Rotec Hydraulics Set to Exhibit at Seawork 2025

Rotec Hydraulics Ltd, a leading provider of hydraulic, pneumatic, and electrical mechanical solutions, is pleased to announce its participation as an exhibitor at this year’s Seawork, Europe’s largest on-water commercial marine and workboat exhibition. The event will take place from 10th to 12th June 2025, at Mayflower Park in Southampton, UK.

Our team will be on Stand G38 showcasing Rotec’s comprehensive range of products and services tailored for the marine sector – with a particular emphasis on how to work smarter, reducing costs, whilst maximising performance and uptime.

With over 40 years of experience, Rotec is renowned for its expertise in the design, build, supply, installation, and maintenance of fluid power and motion control systems.

Visitors to the Rotec Hydraulics stand will have the opportunity to explore:

  • Bespoke Hydraulic and Pneumatic Systems: Discover Rotec’s capabilities in designing and manufacturing custom power units, flushing rigs, and complex system integrations to meet specific marine requirements.
  • Electrical Mechanical Services (EMS): Learn about their comprehensive EMS offerings, including motor, alternator, generator overhauls, vital for marine vessel operations.
  • PTS (Parker Tracking System): a barcode system that allows you to track assets worldwide and easily order replacements via a web based platform.
  • IQAN: cutting-edge technology allowing for the monitoring and enhancing electrical control systems using the power of IoT.
  • Component Supply: Explore Rotec’s vast stock of high-quality hydraulic and pneumatic components from leading brands such as Parker, Galtech, Heypac, and many more. Their team will be on hand to provide expert advice and technical support.
  • Accumulator Servicing & Parts: Gain insights into stress-free accumulator management and PSSR compliance.
  • OEM Kitting Service: See how Rotec’s custom multi-component kits and hose assemblies can streamline manufacturing processes and improve productivity.

The Rotec team will be available to discuss current projects, offer technical guidance, and explore potential collaborations with industry professionals.

“Seawork is a great event for the commercial marine industry, and we are delighted to be exhibiting again this year,”

says Richard Lang, Sales Director.

“It provides an invaluable platform to connect with our existing clients, forge new relationships, and demonstrate our commitment to delivering innovative and reliable solutions to the marine sector. We look forward to engaging with visitors and showcasing how Rotec can support your operations.”

Rotec invites all attendees to visit their stand at G38, Seawork 2025 to learn more about their capabilities and how they can assist with all fluid power and motion control needs in the marine industry.

Register to attend at: Seawork 2025

100% Achilles audit _Rotec Hydraulics Ltd

Rotec joins Cornwall Marine Network

Rotec Hydraulics Ltd is pleased to be announced as the Cornwall Marine Network’s newest member.

By joining the Cornwall Marine Network and operating from our Falmouth Service Centre, we are strengthening our on-the-ground support for the county’s world-class marine industry.

Building on our existing strong relationships with Cornish customers, our new Falmouth Service Centre, positioned within Falmouth Docks, enables us to offer even greater local support. Our team’s extensive expertise across hydraulic, pneumatic, and electro-mechanical disciplines ensures we can provide comprehensive solutions tailored to the unique demands of the marine sector and beyond.

Heading our Falmouth operation is Martin Webber, whose 25+ years of experience in the marine and shore-based energy sectors bring invaluable industry knowledge and a dedicated passion to our local presence. Martin will be instrumental in forging stronger relationships with businesses throughout Cornwall.

As an ISO 9001 and ISO 14001 certified company, Rotec Hydraulics Ltd maintains the highest standards of quality and environmental responsibility. We offer a comprehensive suite of services, from initial design and installation to ongoing maintenance, repairs, and component supply, providing end-to-end support for our clients.

We understand the specific challenges faced by businesses operating in the marine environment. Our aim is to deliver reliable, efficient, and cost-effective solutions that ensure seamless operational continuity.

We are eager to collaborate with fellow members of the Cornwall Marine Network and contribute to the region’s thriving maritime sector.

To learn more about how Rotec Hydraulics Ltd can support your business, please get in touch via falmouth@rotec.net or phone 01326 653 287.