Services - Rotec Hydraulics Ltd

Hydraulic Accumulator Overhaul & Recertification for UK Port

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.

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.

How Rotec Hydraulics Builds Smarter Systems with Parker IQAN Software

As a certified Parker distributor, Rotec Hydraulics is at the forefront of designing and building custom hydraulic systems that are not just powerful, but also smart. By integrating Parker’s IQAN electronic control system, we create solutions that enhance safety, boost efficiency, and provide unprecedented control over your equipment.

What is Parker IQAN and What are the Benefits?

Parker IQAN is a state-of-the-art electronic control system specifically designed for mobile hydraulic applications. It’s an integrated ecosystem of controllers, displays, joysticks, and sensors, all managed by a powerful and user-friendly software suite.

The key benefit of IQAN is its ability to replace complex mechanical and electromechanical systems with a streamlined, totally electronic approach.

Rotec has successfully designed, built, programmed and installed a variety of custom IQAN-enhanced systems. Clients have reported benefits including:

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Enhanced Safety

IQAN controllers enable critical safety features like dual-channel fail-safe circuits and emergency stops which can be operated remotely. This enhances safety – keeping operators out of harm’s way, especially in hazardous environments such as quarries or construction sites.

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Precision & Control

The software allows for precise, proportional control of hydraulic functions. Instead of simple on/off levers, operators can achieve infinite speed control and finely tune movements with joysticks and other input devices. This leads to more accurate and efficient operations.

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Monitoring & Diagnostics

IQAN systems provide real-time monitoring and advanced diagnostics. The software logs events, and can alert operators to potential issues before they cause a breakdown. This proactive approach to maintenance dramatically reduces downtime and lowers repair costs.

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Remote Accessibility

Rotec can build systems that allow for remote monitoring, diagnostics, and even software updates. This means operators can access the system’s data from a laptop or smartphone, diagnose a problem, and potentially resolve it without needing to be on-site.

Customisation

IQAN software is flexible and user-programmable. Rotec Hydraulics’ in-house design team can customize the system to your specific needs, building in tailored functions, adjusting parameters, and creating a user interface on the display that is intuitive for your operators.

Why Choose Rotec?

By choosing Rotec Hydraulics, you’re not just getting a hydraulic system; you’re getting a complete, integrated solution. Our expertise in both hydraulic and electrical mechanical systems, combined with the power of Parker IQAN, allows us to:

Design and Build: Create bespoke hydraulic power units and control systems from the ground up, tailored to your application.
Install and Integrate: Seamlessly integrate new electronic controls with your existing machinery, replacing outdated components with modern, smart technology.
Provide Ongoing Support: Offer remote diagnostics, software updates, and expert maintenance to ensure your system continues to run at peak performance.

Examples of Rotec-designed IQAN systems include a remote control system built for a quarry, which enabled operators to control heavy machinery from a safe distance, drastically improving safety and efficiency. Another project involved the development of a pioneering electric winch system, where Parker IQAN technology was instrumental in achieving precise proportional speed control – a function previously thought impossible for an electric system.

For more information, request a discussion with a member of our Sales Team via sales@rotec.net.

Modernising Ramp Actuators

Mitigating obsolescence and ensuring long-term operational efficiency.

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.

Streamline Your Manufacturing with Rotec’s OEM Kitting Service

In today’s competitive manufacturing landscape, efficiency and cost-effectiveness are paramount. Original Equipment Manufacturers (OEMs) are constantly seeking ways to optimise their operations, reduce lead times, and improve productivity. One solution is Rotec’s bespoke kitting service -streamlining your assembly lines and reducing lead times, it helps improve your time-to-market and gain a competitive advantage.

What is an OEM Kitting Service?

OEM kitting involves assembling all the necessary components for a specific product or sub-assembly into a single, convenient kit. This can include everything from hose assemblies, adaptors, seals, and o-rings, to pumps, valves, oils, and filters – essentially, any component your product requires. Rotec Hydraulics works closely with OEMs to tailor these kits to their exact specifications, ensuring every part is present and accounted for.

How Rotec’s Kitting Service Benefits Your Business:

Our OEM kitting service is designed to be a complete solution, offering a range of value-added services, including:

Customized Kitting: We work with you to understand your specific needs and create kits that perfectly match your requirements. No more searching for individual parts – everything you need arrives in one package.
Comprehensive Component Sourcing: We handle the procurement of all necessary components, saving you time and effort. Our extensive network of suppliers ensures access to high-quality parts at competitive prices.
Value-Added Services: We can include testing, labeling, bagging, and other services to further streamline your production process. Just let us know your requirements, and we’ll take care of the rest.
UK and European Coverage: Rotec Hydraulics serves clients across the UK and mainland Europe, ensuring consistent supply regardless of your location.
Reduced Costs and Improved Efficiency: Kitting can significantly reduce your purchasing activity, speed up goods receipt, and improve productivity. By consolidating your supply chain, you can also reduce the number of suppliers you need to manage, leading to fewer invoices and simplified administration.

“Rotec’s kitting service has streamlined our assembly lines, reducing assembly time and boosting productivity.”

Purchasing Manager

Marine industry

Partner with Rotec Hydraulics:

If you’re looking for a way to optimise your manufacturing processes and improve your bottom line, consider partnering with Rotec Hydraulics for your OEM kitting needs.

Contact us today to discuss your requirements and discover how we can help you achieve your goals. Let us help you build a more efficient and competitive business.

Get in touch

Motor Overhaul for Cruise Ship

Rotec’s Electrical Mechanical Services division completed the overhaul of 21 ship’s motors last month for a leading leisure industry company.

The cruise ship, who carries thousands of passengers each year, voyages throughout the Baltic, Norwegian Fjords, and the Mediterranean. In regular use, our engineers had a strict time limit of 14 days to remove, overhaul and reinstate all 21 motors whilst the ship was in dry dock.

The scope of works included:

Removal and inspection

Safe and efficient electrical and mechanical disconnection of all 21 motors, including the port and starboard anchor winch motors.
Thorough inspection of all plate detail and insulation valves.

Overhaul

Full steam cleaning of the motors and re-varnishing as required.
Baking of the motors in a temperature-controlled oven to ensure proper curing of the varnish and to remove any residual moisture.
New bearings fitted where required.
Repair of worn end-shields by sleeving and machining back to tolerance.
Replacement of brake pad discs with excessive wear.
Insulation tests conducted at 500 volts to ensure electrical safety and integrity.
Dynamic balancing carried out to avoid unnecessary vibrations, reduce noise, prevent mechanical failure, and improve balance and efficiency.
Inspection of all electrical cables for damage.

Reinstallation

Safe and efficient reinstallation of all 21 motors back onto the ship.
Careful reconnection of all electrical and mechanical components.

Report

A detailed report, with images of all motors, was completed and a copy sent to the client upon completion.

All work was completed within the 14 day schedule deadline.

The completed overhaul will significantly improve the reliability and lifespan of the ship’s motors, reducing the risk of unexpected breakdowns and ensuring continued safe and efficient operation.

If you would like more information on Rotec’s Electrical Mechanical capabilities, contact sales@rotec.net or call 01823 348900.

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