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.

Boost Efficiency and Safety: Rotec Hydraulics is Your Parker Approved Accumulator Service Centre

Accumulators play a vital role in all industries, ensuring smooth and reliable hydraulic system performance. However, maintaining and servicing these critical components can be complex.

That’s where Rotec Hydraulics comes in. As a Parker Approved Accumulator Service Center (ASC), we possess the in-depth knowledge, experience and test rig facilities to provide comprehensive accumulator services, including: 

  • Product Range: We stock and sell accumulator products of all brands, sizes, and types.
  • Test Rig Facility: Our state-of-the-art test rig enables the testing of bladder type accumulators from 0.5 litres up to 54 litres.
  • Maintenance & Recertification: Our skilled engineers meticulously maintain and recertify your accumulators, ensuring optimal performance and extending their lifespan.
  • Pre-Charging & Audits: We pre-charge accumulators and conduct thorough audits to identify potential issues and prevent costly downtime.
  • Scheduled Inspections & Replacements: We offer customised inspection schedules and recommend replacements when necessary, proactively safeguarding your hydraulic systems.

Benefits of Choosing Rotec Hydraulics:

  • Enhanced Safety: Minimize accident risks and protect your employees with our expert service, adhering to all relevant safety regulations.
  • Regulatory Compliance: Ensure your operations comply with Pressure Systems Safety Regulations (PSSR) 2000 by adhering to recertification, data monitoring, and scheduled inspections.
  • Increased Productivity:
    • Boost Efficiency: Optimize system performance and reduce energy consumption with accumulator replacement, maintenance, and pre-charging.
    • Reduced Downtime: Minimize downtime and maximize productivity through warranty validation, preventative maintenance, and optimized performance.
  • Extensive Inventory of Accumulator Parts:
    • Bladder Kits
    • Charging Kits
    • Saddle Clamp Assembly
    • Relief Valves
    • Safety Blocks
    • Accumulator Flange Adaptors

Ready to optimize your accumulator management?

Contact us to schedule an initial consultation and discover how Rotec Hydraulics can help you enhance efficiency, improve safety, and minimise downtime.

Email sales@rotec.net or call 01823 348900.

Rotec completes innovative remote monitoring system onboard a vessel

As equipment increases in complexity, there is a growing need and advantage to being able to monitor parts of, or a complete system remotely.

With a long held commitment to innovation, Rotec Hydraulics are the first known company in the UK to have designed, installed and commissioned Parker IoT software that remotely monitors a hydraulic system.

With the ability to be installed and remotely monitor any hydraulic system, Parker Internet of Things (IoT) technology allows a user to ensure their assets are working at full functionality by monitoring key performance indicators, such as temperature, pressure and flow.

The remote monitoring technology further benefits the user by providing vital performance feedback for preventative maintenance planning, and can monitor real time and historical data all within a simple web-based interface.

This web-based portal can be accessed worldwide and gives a further benefit of GPS asset tracking and visibility – thus aiding both security of equipment and logistical transport efficiency which in turn, can reduce fuel costs.

The innovative IoT project came to fruition following Rotec being asked by a boat manufacturer to gather information about the performance of the hydraulic system they were fitting to a new fleet of vessels. 

Because of the harsh marine environment, robust equipment was selected that meets high ingress protection. IoT modems are compact and have built in aerials allowing for a sealed solution, meeting strict IP67 ingress protection and wide temperature ranges of -30 to +75 degrees.

Multiple sensors were fitted by Rotec’s engineers to provide feedback of tank levels, oil temperatures, flows and pressures in various parts of the system.

A further enhancement was provided by adding a particle contamination device which monitors and uploads the vessel’s oil cleanliness data to the cloud. Previously hydraulic oil changes were performed on a time expiry basis, whereas adding sophistication of a real time oil contamination device now tells the customer when the oil needs to be changed rather than changing at estimated time intervals. This reduces both the cost for the customer and decreases the impact on the environment because they are now performed only when required.

The customer was particularly impressed as Rotec Hydraulics were able to code unique software and download this remotely to assist with additional logging during sea trials of the vessel before delivery for normal operations at sea. This provided additional information that has not previously been visible due to the nature of the testing preventing personnel being on board monitoring the systems from the bridge. 

The IoT can be connected to an engine ECU using standard j1939 CAN protocol to give live engine data to be able to monitor remotely. This can provide data feedback from various sensors to ensure optimal engine performance and critically, no abuse of the equipment when being used in the field.

Alerts can be set and configured to automatically send emails once thresholds are exceeded, enhancing the effectiveness of automated data upload. 

Built in Bluetooth and WiFi also allows the user to access the password protected modem locally to download logs and further enhance the remote experience. Software updates can be performed remotely over the web or by Bluetooth/WiFi to increase the functionality of the sampling controller or change data collection and upload frequency, allowing for maximum end user flexibility for the customer.

To discuss how Rotec can enhance your system monitoring, contact our Sales Team via 01823 348900 or email sales@rotec.net.

 

Minimising Downtime: Manufacturing Press Tube Replacement

Rotec’s technical team researched and implemented an innovative method to complete replacement tube pipework whilst keeping downtime to a minimum at a large car manufacturing plant in Gloucestershire.

Following damage occurrence on one of their press lines, the world-leading manufacturer required replacement Ø75×12.5 carbon steel tubes.

Traditionally, engineers would be required to remove the damaged tube in order to gather accurate measurements before being able to provide and fit replacements. The removal and installation processes would require manufacturer to shut down the machine during these times.

Downtime for a large manufacturer in the automotive industry can have huge implications operationally and financially. Always keeping the customer at the forefront of projects, Rotec’s technical team suggested using a 3D laser scanner to measure the pipework, in order to minimise downtime.

The 3D laser scanner not only meant that the machine no longer had to be turned off, but the measurements collected were incredibly accurate and minimised the influence of human error. Furthermore, the time required for Rotec engineers to be onsite removing pipes and then measuring them would be dramatically reduced – saving the customer costs due to reduced labour costs.

Once measured accurately, the design for new tubes created using CAD design software in-house at Rotec. In total, the measuring and design process was complete within 2 days.

Continuing Rotec’s commitment to utilising technologies, the tube ends were formed using the Parker HPF system, which eliminates the need for welding of the tube. Bespoke flanges were also machined to suit the formed profile of the Ø75mm tube and accommodate the bolt pattern of the existing connections. 

For more information visit www.rotec.net.

Rotec’s repair and overhaul service reduces running costs by 10% at leading manufacturer

Machine prior to overhaul
Overhaul completed, outer door refitted and ready for re-paint

Following a major failure during operation, a large flooring, MDF and OSB manufacturer asked Rotec to carry out extensive repairs on an industrial wood chipper.

Owing to the failure occurring whilst the machine was in use, the Maier Wood Chipper machine had suffered severe damage internally and so required a thorough repair and overhaul service.

After Rotec engineers stripped the machine and checked all components, it became apparent that the shaft bearing sleeves had failed, worn the housing and as the blades had come away during the failure, many internal parts were damaged and required either replacement or upgrading.

As the customer had issues with levelling up the impellor blades, Rotec checked the laser alignment and then ‘clocked’ the rear datum locating ring support pads on the machine. The support pads were found to have a 0.7mm difference in their positioning which, may have been a contributing factor to the issues leading to the initial failure. On discussion with the client, it was decided to build up the lower blocks and design and build a tool for machining the pads in-situ.

Once the chipper had been repaired, overhauled, re-painted and fitted back onsite at the customer’s facility, the client was so pleased with Rotec’s workmanship and project management that Rotec have now taken delivery of another unit from the same workshop for a complete overhaul.

The Engineering Managing of the flooring, MDF and OSB manufacturer has since reported that the overhaul and rebalancing of the machine is so good that the company is achieving a higher output rate and saving 10% on the machine’s previous running cost.

Laurence White, Business Development Manager for Rotec Hydraulics Ltd, commented;

“It has been a pleasure to be part of this thorough overhaul and repair service. Our team take pride in knowing that we have delivered a high level of workmanship and have not only helped to increase efficiency, but also have helped to reduce running costs for our client. We look forward to a long lasting relationship with our customer.”

For more information regarding Rotec’s capabilities, including the overhaul and repair service, contact sales@rotec.net or phone 01823 348900.

Chipper unit prior to Rotec overhaul

Damage caused by external conveyor belt

Damage to internal shaft

Internal damage caused during failure of blades

Modifications to front lower section to allow for outer adjustment on longer support sections, manufactured and fitted support bars

Die penetration checks on welding

Special support structure manufactured for accurate machining of the rear ring support pads

Inner bladed impellor fitted and clocked to ensure true

Outer door refitted on chipper

Chipper Completed unit back onsite at customer’s facility

Rotec Completes Machine Overhaul with the ‘Wow’ Factor

Rotec Hydraulics Ltd have delivered a machine refurbishment project with the ‘wow’ factor.

A leading manufacturer of high quality, precision tubes asked the Rotec team to assess and quote for the refurbishment of an old tube manipulation machine. The unit which had been in situ for many years, required a complete overhaul to improve efficiency and to provide quality and robust workmanship, due to regularly working with the toughest specifications in high performance alloys (including stainless steel, titanium and nickel alloys).

After removing the unit and transporting it to Rotec’s Plymouth service centre in Devon, the tube manipulation machine was stripped and inspected. Following the quoting process and being awarded the contract to proceed, Rotec’s skilled engineers carried out a thorough overhaul of the hydraulics, mechanical and electrical control system.

On completion, Rotec engineers attended the client’s site and re-commissioned the unit. All of the works carried out by Rotec were project managed by an assigned manager, as with all our projects. This allows for quality client-supplier relationships and improves communications.

Following the re-commissioning, the customer stated that they are very happy with the unit and they are impressed with the workmanship and quality of the overhaul.

Established in 1979, Rotec Hydraulics is a leading fluid power expert; providing quality design, build, installation and maintenance of hydraulic, pneumatic, electrical mechanical and electronic components and solutions to the Aerospace, Agriculture, Defence, Industrial, Marine, Transport and Utilities sectors throughout the UK and internationally. ISO 9001 and ISO 14001 certified, Rotec Hydraulics prides themselves on high operational standards.

For more information, visit www.rotec.net.