Passing the test

21 March, 2017

Previously, Hydrotechnik had typically supplied components to either systems integrators or end users within design engineering departments, who would use them to build rigs and systems to perform a broad range of hydraulic and hydrostatic tests. While the business was successful simply selling components, its potential to add value was limited. At the same time, across the various markets that Hydrotechnik served, in-house engineering departments were disappearing amid efficiency drives and the company’s end user customers were increasingly outsourcing the design and build of test rigs to systems integrators.

The move wasn’t without its challenges and risks, however. A significant amount of new skills and knowledge was needed to manufacture turnkey systems. But it wasn’t long before the company started to develop a reputation for its work and enquiries began to grow; quickly turning in to orders.

Rail project

Price reflects that some of these test rig projects can create enormous challenges; the biggest of which so far has been for a company in the rail sector. The business in question overhauls rolling stock and part of that process requires large cylinders used in braking systems to be pressure-tested to ensure their integrity. It is a safety-critical part of the process, which results in certification for the component.

Before Hydrotechnik even got to the stage of designing the system, the size of the company presented challenges that had to be overcome. Identifying the right people and departments to communicate with wasn’t easy. Then, the health & safety requirements for getting on site were far from straightforward too.

Plumbing, heating & engineering

Another case study example saw Hydrotechnik design, built and commission an advanced burst testing rig for a UK-based plumbing, heating & engineering product manufacturer that distributes its products worldwide.

Regular and rigorous burst testing ensures that their products are developed to meet the demanding standards within hydraulic applications. The custom-built test rig is installed within a sophisticated workshop and is an integral part of their development testing. The test rig main capabilities are:

• Manual pressure build up with course, fine & super fine pressure adjustments.

• Real time accurate reading and logging of pressure.

• Complete logging and archiving of all results for future reference.

Hydraulic motors

Another case study example saw Hydrotechnik design and custom-build a hydraulic testing rig for KPEC capable of testing the efficiency of a wide range of hydraulic motors commonly fitted onto forklifts and other hydraulic machinery. Having built up a loyal customer base over the past 20 years repairing and re-selling motors, KPEC wanted to improve its testing facilities. The company required its motors to go through extensive testing under specific conditions to understand the performance of the refurbished motor.

KPEC wanted a user-operated testing system with variable flows up to 100 litres per minute at a maximum settable pressure of 300 bar with a torque load of up to 1100Nm. During the test the user needs to be able to control the direction (both clockwise or anti-clockwise) flow rate, loading pressure, temperature and system pressure. On top of this, the user needs to be able to read displays on the control panel in real time.

A variety of pump accessories were supplied from UK Flowtechnik such as bellhousings, damping elements, foot brackets to improve the noise levels, oil cooler to keep systems running smoothly and spider couplings all helping to sustain the life of the pump and test piece.

So, Hydrotechnik is an excellent example of a UK business that has diversified, not in its product offering, but in its reach across its value chain.

www.hydrotechnik.co.uk