Services - Rotec Hydraulics Ltd

Rotec Completes Critical Refurbishment of Canal Lock Lift Bridge System

100% Achilles audit _Rotec Hydraulics Ltd

Rotec Hydraulics, a leading provider of hydraulic engineering solutions, have completed a recent project involving the removal, overhaul, and refitting of two critical hydraulic cylinders for a Canal Lock Lift Bridge.

The project, which also included the fabrication of a new bespoke clevis frame assembly and the replacement of hydraulic hoses, was executed to ensure the continued safe and reliable operation of the waterway infrastructure.

Due to the age and wear on the existing components, the overhaul was critical. Rotec’s work covered the entire lifecycle of the component replacement, from initial isolation to final commissioning:

Cylinder Removal and Preparation: Rotec engineers worked alongside the customer’s team to safely isolate and remove both hydraulic cylinders from the bridge structure, before transporting them to the Rotec workshop for overhaul.
Comprehensive Cylinder Overhaul: Involved stripping the cylinders, removing seized bolts and eyes, manufacturing new 4-inch rods, and performing repairs and refurbishment on the glands and pistons. The cylinder tubes were polished, and new seal kits were supplied and installed before the cylinders were re-assembled and tested.
Reinstallation and Commissioning: Following overhaul, the cylinders were delivered back to the site. Rotec provided installation assistance, topped up the system with new hydraulic oil, and oversaw the final onsite testing to ensure safe and optimal performance.

The project also encompassed the fabrication of a replacement frame for the cylinder base end clevis.

Clevis Frame Assembly: Rotec reverse-engineered measurements from the existing components to design and fabricate a new clevis frame assembly. The new frame was upgraded with larger side plates for increased durability. The fabrication underwent die-penetrant weld testing to confirm structural soundness.
New Components: The project included the machining and supply of a replacement clevis pin and four new pin locating plates.
Hydraulic Hose Assemblies: Rotec supplied and installed four new replacement hydraulic hose assemblies with stainless steel over braid, all of which were pressure tested prior to commissioning.

“Successfully refurbishing these critical cylinders and simultaneously fabricating a key structural component, all while minimising disruption, underscores our commitment to maintaining essential infrastructure,” commented Dale Lockart, Branch Manager of Rotec’s Stroud Service Centre.

The successful completion of the cylinder overhaul and clevis frame replacement ensures the continued operational efficiency and safety of the Canal Lock Lift Bridge for many years to come.

For more information on the services offered by Rotec, contact sales@rotec.net or phone 01823 348900.

Rotec Hydraulics Powers F1 Performance with Remote-Monitored HPU & Flushing Rig

Rotec Hydraulics, a leader in high-performance fluid power solutions, has engineered a custom Hydraulic Power Unit (HPU) and Flushing Rig for a global F1 team, tackling the challenge of delivering safe, precise, and reliable pressure while ensuring optimal system longevity.

Race car hydraulic systems demand meticulous maintenance, including regular flushing to prevent contamination—the primary cause of system failure. Traditional, bulky on-site equipment often leads to logistical issues and unwanted downtime. Rotec’s innovative solution merges two critical functions into one compact, portable unit.

The custom 3 kW HPU is designed to deliver 200 Bar of pressure at 8 Liters per Minute (LPM) to power race car hydraulic components. More crucially, it features an integrated flushing rig and particle counter, enabling technicians to maintain pristine oil cleanliness.

A key differentiator is the integration of remote diagnostics via Parker IQAN technology. The HPU utilises Bluetooth connectivity to allow remote monitoring and control via a tablet or smartphone. This provides instant, detailed data on sensor and output states, including pressure, temperature, flow, and contamination levels.

Jesse Cherry, Business Development Manager at Rotec Hydraulics commented,

“This project showcases Rotec’s ability to deliver bespoke, high-performance hydraulic solutions that directly address challenges. We understood the critical need for a reliable, safe, and mobile solution. The integration of remote diagnostics streamlines operations and provides a great benefit to our client.”

The dual-functionality, combined with remote diagnostic capabilities, transforms maintenance from reactive repairs to proactive system health management. This compact, maneuverable rig minimizes maintenance time, boosts operational efficiency, and significantly reduces the risk of critical hydraulic failures—a crucial competitive edge in the high-stakes world of Formula 1.

Discover Rotec’s full capabilities via their website www.rotec.net or call 01823 348900 to discuss your requirements.

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.

Preventative Maintenance for Hydraulic Pumps to Boost Efficiency and Reduce Downtime

At Rotec Hydraulics, a Parker Certified Hydraulic Technology Centre with over 45 years of experience, we advocate businesses to adopt a proactive approach to hydraulic pump maintenance.

Preventative care is far more cost-effective than reactive repairs, which is why we offer flexible preventative maintenance service contracts to help clients avoid costly and unexpected system failures.

Proactive Hydraulic Pump Maintenance

Hydraulic pumps are at the heart of hydraulic systems. However, without regular maintenance, their performance can quickly degrade, leading to inefficiency, increased energy consumption, and catastrophic failures.

Routine maintenance and inspection are crucial because:

They prevent expensive breakdowns: A small, easily fixed issue, like a worn seal or contaminated fluid, can escalate into a complete pump failure, requiring a full and costly replacement.
They extend equipment life: Regular servicing and timely replacement of components—such as seals, bearings, and filters—significantly extend the operational life of the pump.
They improve efficiency: Clean, well-maintained pumps operate at peak performance, reducing energy waste and ensuring the system performs as designed.

A thorough strip-down and inspection is recommended every 2,000 to 4,000 operating hours or as indicated by the manufacturer. This may also be reduced if operating in a particularly harsh environment. Rotec’s in-depth service allows technicians to identify internal wear and tear that isn’t visible during routine checks.

The Rotec Hydraulics Advantage

Choosing the right service provider is paramount. Rotec Hydraulics is uniquely positioned to offer superior hydraulic maintenance services.

Parker Certified Hydraulic Technology Centre: As the only accredited Parker Hydraulic Technology Centre in the South of the UK, Rotec guarantees services performed to the highest industry standards.
Decades of Expertise: With over 45 years in the industry, Rotec has a deep, hands-on understanding of hydraulic systems across various sectors, from industrial and marine to defense and agriculture. This extensive experience ensures accurate diagnostics and effective, long-lasting repairs.
Preventative Maintenance Service Contracts: Rotec offers customised service contracts tailored to a business’s specific needs. These contracts schedule regular inspections and maintenance, taking the guesswork out of pump care and ensuring a system’s health is always a priority. This approach not only minimizes downtime but also provides a detailed service history for audit purposes and offers emergency support.

“We believe in helping our clients shift from a reactive to a proactive maintenance strategy,” says Mark Conniff, Operations Manager. “Our goal is to ensure their hydraulic systems are reliable, safe, and efficient. With our Parker certification and extensive experience, we take pride in our level of service and expertise.”

For more information on our preventative maintenance services or to schedule a consultation, please phone 01823 348900 or email sales@rotec.net.

Hydraulic Accumulator Overhaul & Recertification for UK Port

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.

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.

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