Transmission shaft manufactured by reverse engineering
Manufacture of a transmission shaft for discontinued equipment, worked up from the fractured component with no manufacturer drawing available.
Read the case studyHPU · Marine
Overhaul of a steering gear HPU
Full recovery of the hydraulic power unit driving the rudder, with pump replacement and contamination brought back within specification.
Execution
The sequence applied and the engineering decisions taken
The order below reproduces how the work was actually carried out, including the points where the condition found required a change of scope.
- Pressure, flow and temperature readings taken in operation to characterise the fault before strip-down.
- Fluid analysis, which showed a contamination level far above that specified for the system's proportional valves.
- Strip-down of the HPU with photographic records and identification of every component and connection.
- Dimensional inspection of the piston pumps, which showed wear on the valve plate and slippers.
- Recovery of the actuator cylinders: tubes honed, rods ground and re-chromed, seal sets fully replaced.
- Replacement of the main pumps and overhaul of the proportional valve block.
- Flushing of the lines until the specified cleanliness class was reached, tracked by sampling.
- Reassembly, leak testing and commissioning, with response times verified to port and starboard.
Comparison
Condition before and after the intervention
Drag the slider to switch between the two recorded conditions.
- Before
- Slow rudder response, fluid above working temperature and contamination outside the specified class.
- After
- Response time to design specification, temperature stabilised and fluid within the required cleanliness class.
Result
What the intervention delivered
The system was handed back within the response time specified in the design and with the working temperature stabilised in the normal band. The work was completed before the docking window closed, releasing the vessel on schedule.
11
days on the job
100%
within the docking window
2
cylinders recovered
Photographic record
Job gallery
The photographic record forms part of the technical report handed to the client and feeds the equipment history.
Portfolio
Other completed projects
Full overhaul of a mooring winch
Complete overhaul of a mooring winch with drum recovery, hydraulic drive overhaul and load testing.
Read the case studyRecovery of a cargo pump losing efficiency
Internal clearances recovered and wear rings manufactured, with the duty curve restored and proven on the test bench.
Read the case studyTechnical support
Need to bring a piece of equipment back into service?
Tell us the condition of the equipment and the window you have available. Our engineering team will come back with an assessment and a preliminary scope of work.