Case Study 1

Our client has a production department with a number of hydraulic power units driving mixing vessels, 2 of which exhibit the same operating problems - [a] overheating & [b] the mixing vessel stalls/stops when certain products are introduced for manufacture. Our client asked us to investigate and present a solution to both problems.

The first task was to install our electronic monitoring equipment directly into the pipework and monitor the system performance on-load and off-load. Our equipment is capable of monitoring pressure, flow and temperature, during production, in real time, in timescale's down to 1 millisecond [one thousandth of a second]. The information is stored whilst production continues, can be downloaded onto a PC for production of Windows based reports/graphs, and the presentation of a performance report based on objective evidence gained during the production cycle. The analysis enabled us to determine that the mixing vessel was adequate for the task, but that the power unit performance characteristics would require existing pressure and flow settings changing to allow more torque and greater speed.

Benefits:

• These changes were made without installing new equipment thus offering the client further cost

• savings.

• The overheating problem was also eradicated as the power unit performance was now matched to

• production requirements.

• There was an immediate payback through identifying energy savings.
• The diagnosis identified significant contamination levels causing accelerated wear and poor system.
• Established the levels of efficiency of the major system components, and [critically] enable us to

• predict failure.

Where we have a maintenance contract in place, over a period of time we can plot the performance and any trends in advance of sudden failure.



Case Study 2

Our client had a major piece of capital equipment built which is driven by a hydraulic power unit. The hydraulic power system contractors went into liquidation before the equipment was finally commissioned, leaving the system with a series of faults ranging from fluid contamination to electronic signaling problems, and an inability to operate across it's required range. We were asked to identify and resolve the problems, and to also ensure that the capital equipment could perform at the extremes of it's scope.

We first installed the electronic monitoring equipment to identify major fluid contamination, damage to both of the twin hydraulic pumps, electronic signaling and control problems due to the application of unsuitable electrical equipment in a hostile environment.

As the capital equipment was required for daily use against a production timetable, we had to fit in remedial works to suit. Over a period of time we stripped and cleaned the reservoir, replaced both hydraulic pumps, replaced several of the hydraulic valves, replaced several major electrical components, and had the PLC programme reconfigured to reflect the duty requirements.

Benefits:

• The client was able to maintain production and thus avoid commercial penalties.
• There is now a fully reliable, operational piece of capital equipment.
• Ongoing contract maintenance ensures ongoing production.

Case Study 3

Our client has 3 number hydraulic power units whose performance had steadily deteriorated over time, despite their being a maintenance contract in place with another company. We were commissioned to install our diagnostic equipment and to effect any repairs necessary during a 2 week shutdown.

Our initial report identified serious fluid contamination and poor heat exchanger performance leading to excessive fluid temperatures and lacquering of major components. We stripped the equipment, cleaned the reservoirs, replaced the heat exchangers, stripped and cleaned the lacquered components, replaced all oil and filter elements, and refitted the power units within the specified timescale.

Benefits:

• Hydraulic unit performance returned to as new specification.
• Energy savings from using less chilled water.
• 24 x 7 production demands can be reliably achieved.
• Ongoing contract maintenance allows the units to achieve optimum performance and reliability.

Case Study 4

Our Client was contracted to drive a box tunnel through the embankment of a major motorway which could not be closed, and parallel with an existing underpass. The project required minimal disruption to motorway vehicle movements of 112,000 per day, and had to be completed in a 4 week timescale. The concrete box tunnel weighs 3500 tonnes and is pushed through at the rate of 100mm per hour.

Our Remit:

• To fully refurbish the hydraulic power units, all pipework and couplings, the hydraulic cylinders
  

• and valve gear,

• The manufacture of new ancillary equipment.
• The completed works to be pressure tested and certified up to 700 bar working pressure and a
  

• total thrust capability of 10,500 tonnes.

• Timescale for completion one calendar month.
• Completed works to be able to operate continuously for 24 x 7 x 4 weeks without interruption.

All work was completed on time and within budget, enabling the client to confidently complete
the contract and tender for further projects of a similar nature.

Specialist Capabilities:-

• guaranteed leak free hydraulic piping installations.
• pipeline pelleting and pigging.
• camera inspection of pipelines.
• hydraulic pipeline fluid flushing equipment.
• oil sampling & analysis on site.
• pressure testing facilities up to 40,000 psi [2800 bar].
• strain gauge & load testing capacity up to 100 tonnes.
• pressure gauge calibration facility.
• dynamic flow, pressure & temperature monitoring capability, in real time, and down to 1 millisecond

• transients.

• hyper baric chamber capacity to 3000 metre depth.
• accumulator gas charging facility & accumulator stretch test rigs.
• hydraulic proportional valve test equipment.
• breathing air test equipment.