Grain ship-loader replacement electro-hydraulic control system

Thanks to the working relationship spanning many years, Rotec were invited to quote for the replacement of the hydraulic power unit and controls of the grain/feed products ship loader travelling gantry system. The client was faced with reliability and obsolescence issues with the original equipment dating back to the 1980s. It is the only plant capable of this function at the port and is in use constantly.

The ship loader hydraulic functions consist of a dual pumping system and associated hydraulic equipment built into an up-cycled twenty-foot shipping container. The container sits on the machine approximately 20 metres above dock level, which presented some unique access issues.

 Based on the original system design, Rotec designed and manufactured a complete self-contained hydraulic system and associated dedicated electrical control panels which control vertical and horizontal movements of the grain conveyors and loading chute to align over the vessel’s holds as required.

The container was specially modified to accept and fit the hydraulic system. This included full sound and fireproofing, internal full bunding and bespoke flooring and ventilation integration. The hydraulic system consists of a primary pump system driven by a 100KW 3300VAC electric motor and proportionally controlled variable displacement pump with a completely redundant secondary backup system in case of partial or total power loss. This 400VAC backup system is supplied from an external generator and is used to recover the chute off a vessel during a power loss when necessary. The main pump systems are supported by cooling and filtration systems and associated electrical control and monitoring equipment which in turn all interface and interlock to the main ship loader external control system.

21The project initially began in 2017, but project was temporarily halted by Brexit and later on, the outbreak of COVID-19. However, following a major fire one evening whilst in use on a vessel which completely destroyed the old containerised system, surrounding cabling and pipework, the project objectives and target completion date was rapidly brought forward to minimize the client’s downtime.

Due to our very flexible approach and ability to respond to an everchanging priorities list, Rotec was able to pick up and resume the build process quickly and managed to complete and factory test the unit ready for site delivery and install by the end of May. Our on-site engineers in the meantime stripped out and replaced large quantities of fire damaged external fixed stainless and special alloy tubing and replaced all external flexible hoses on the machine. The container unit and system were craned into place, pipework connections completed then flushed thoroughly. The system has now finished its commissioning and setting to work process, on time and on budget, and is ready to serve the port for this vital service for at least another 30 years minimum. The client is completely satisfied with the product and service received by him by our team of design, manufacturing, and field service personnel.

 

Bespoke Winching System for Polaris 1000 HD ATV

Ever considered how Over Head Line maintenance teams get their tools ‘up’ on to pylons to enable them to carry out their work?  One answer is with Rotec Hydraulics’ help.

At Rotec Hydraulics the Team, work on many different projects.  Much of the work undertaken requires the integration of knowledge and skills from across the Rotec team, to deliver all of the elements that make up a client brief.

One such brief was to enable these incredibly gutsy all-terrain Polaris 1000 HD Rangers to help Over Head Line maintenance teams access their tools, whilst working off the beaten track and when needed at height. 

 For one utility company the skilled Rotec team designed, built and installed bespoke hydraulic and electric Capstan Winching Systems to a fleet of all-terrain vehicles, to enable utility staff to ‘winch up’ the items they need, when working at height.

The all-terrain Polaris 1000 HD Rangers are used daily to support overhead line operations in the utilities sector.  The low ground compact build of the Polaris is perfect to access difficult to reach areas when repairing or undertaking planned activity in the utility sector.  Their confined flatbed behind the cab, is ideal to hold and secure Rotec’s bespoke Hydraulic Power Pack, powering the Capstan Winch.  Electricity pylons are by the nature of their role, often positioned off the beaten track and are accessed across all sorts of terrain.

The whole winching system was designed, tested, built and attached to multiple vehicles by Rotec Hydraulics in their large workshop space at the Taunton branch using the skills of the specialist hydraulic Design, Build and Installation team.

The hydraulic and electric winching system ensures when these mighty little vehicles and crew reach challenging locations, they have everything needed to hoist tools up on to a pylon, to carry out overhead cable maintenance and repair work.

When in the middle of nowhere there are times when the utility company over headline maintenance staff will not be beside the winch system to physically push buttons, to engage the winding mechanism.  Therefore, when designing the power sources to operate the Capstan Winch, Rotec ensured the Hydraulic Power Packs could be petrol driven, alongside a battery to enable electric start and a remote electric start option for when personnel are perhaps in position up a pylon. 

An integrated cooling system and roll cage over the whole Capstan winching system unit adds overall protection to the investment as it is transported to site and used.  The complete winching system unit can be fully removed from the vehicle if and when required.

 As a further safety measure, Rotec engineers designed and manufactured a specially designed manually lowered ground anchor, to limit the ability of the vehicle to slide when the winch is engaged in more extreme winching situations.  The power Capstan winching system is designed to pull up to 350kg.

As part of the design and testing process Rotec also undertook the Finite Element Analysis (FEA) in support of the Lifting Operations & Lifting Equipment Regulations (LOLER).  Rotec ensures we provide the additional evidence within our design to ensure the vehicle conversion is strong, reliable and suited to the challenging environments in which it is designed to operate. 

The Rotec team is thrilled they enable others to reliably undertake time critical repairs and planned activity, all year round, in any conditions, at any height, to keep key utility services across the country operating. 

Are you looking for an alternative option to get something from A to B in a controlled way?  Rotec Hydraulics experienced team of Hydraulic, Pneumatic, Mechanical and Electrical engineers can help.  Please contact any of our locations across the south west for more information or assistance.

 

Date: 24/02/2020  Revised   Author: Carly Warren 

 

Defence Hose Assemblies

Hose Assemblies forJackal HMT

The Jackal HMT series is a supremely versatile platform with unparalleled cross‑country performance.

 Already well-proven in the harsh terrain of the Afghanistan battlefield, the 400 has a unique air suspension system that allows the selection of a variable ride height to match the terrain and also, enable internal loading within CH-47 Chinook.

 Rotec supported Babcock (DML) in 2009 with production of hose assemblies for the Jackal.

Rotec’s technical expertise, infrastructure and ability to utilise Parker technologies enabled the supply of the specialist hose kits suitable for hydraulic and auxiliary services. Kits were supplied fully assembled and tested.

Propeller Press

A customer who we have a longstanding relationship with requested a propeller press    re-fit for us ein the marine industry.

The customer supplied the framework, into which we incorporated a new valve block, fabricated a weld on bracket for gauge and a pressure relief valve and fit custom made hydraulic hoses as per technical drawings supplied by Rotec.

This bespoke piece of kit is going to Indonesia for use with straightening propeller shafts, to check propeller shafts are true.

Contact us today to see if we can assist you with your fluid power project: sales@rotec.net or 01823 348 900

Date: 8/10/19

Author: Sarka Humpolcova

 

Warship Power Units & Reservoir

After 4 months work replacing hydraulic pipework on a warship, Rotec’s engineers needed to flush the pipes to meet the required cleanliness standards. Due to a change in conditions on board the decision was made to design and build modular bespoke power units and a standalone reservoir.

Rotec have a long history working with the defence industry and specialise in bespoke design and manufacture of hydraulic power units for marine applications, amongst others.

Our team designed and built the power units using 55Kw electric motors close coupled to Berarma Vane pumps and included a flowmeter and a pressure gauge. The Berarma pumps are pressure compensated with variable flow rates. This gives the operators the flexibility to tailor flows and pressures thus ensuring turbulent flow conditions are met to maximise the cleaning action.

Electrical control panels are mounted direct to the trollies to allow ease of use

The power units are fitted with castoring braked wheels for easy manoeuvrability in tight spaces. The Rotec team also designed and manufactured a standalone reservoir, suitable for multiple applications and high volume (fluid) displacement, enabling maximum flexibility as design changes can be incorporated or removed as desired. The system includes pressure return filters which help remove any contaminants from the existing system, ensuring the pipes comply with client specified level of cleanliness.

Rotec delivered to the tight deadline, with just 1 week turnover.

Date: 26/09/2019

Author: Sarka Humpolcova

 

Case Study: Waxing Machine

This unique piece of equipment was recently designed and built at our Taunton depot. The unusual request came as a result of one of our existing existing customers, a well-known candle manufacturer, recommending Rotec to their supplier – a company specialising in the manufacture of candle wicks.

Rotec previously undertook a variety of repairs and control system projects for the candle maker and had also supported the wicks manufacturer’s machinery. Following a successful PLC re-programming project, we were asked to manufacture a waxing machine. Using old conceptual designs left by the previous manufacturer, Rotec produced an up-to-date design, new CAD drawings and a modern control system. Our team of talented engineers then successfully completed the build.

The machine is designed to impregnate and coat a continuous length of wick cord with wax and re-spool onto a new drum. The process involves a multi-pass immersion process through a molten wax reservoir followed by periods of cooling and hardening. The wax is maintained at a constant temperature, indirectly heated by hot water in a vessel located below the wax reservoir. A plc is used to control wax temperature, main drive motor speed and spooling control of the finished product. The machine is now complete and will be installed at the customer’s premises within the next couple of weeks. The machine is capable of producing sufficient finish waxed wick for up to half a million wicks a day, depending on the length of the wick required.

Rotec and the customer are already in discussions about the next project, the design and manufacture of a wicking machine designed to cut the wicks to the desired size and insert the sustainer (the small metal disc sitting at the bottom) ready to be inserted into a candle.

 

Date: 08/04/2019

Author: Sarka Humpolcova