Modular HPUs reduce delivery time and cost

By Peter Doesburg
Head of Sales M&O Benelux at Bosch Rexroth

Traditionally, high-end hydraulic power units (HPU systems), capable of powering large equipment such as lifting and handling systems on offshore vessels and dredgers, are unique. Made to meet the specific requirements of each customer and application, the ‘engineer-to-order’ approach as applied remains important. However, there are many similarities in HPU design, offering opportunities to cut design costs and delivery times.

Drawing on its experience in this field and expertise gained in making modular HPUs for all kinds of power systems, Bosch Rexroth has designed a modular HPU (MHPU) for high flow, high power systems. “We analysed the similarities of our customer-specific HPUs to help us develop a standardized system,” said Pierre Wouters, responsible for detail engineering of HPU in Boxtel, the Netherlands. “By taking into account all the technical specifications and different customer requirements, we have developed a system made up of standardized modules that can be easily adapted to solve the challenges faced by a variety of customers.

“By carefully designing our components and how they interact and interconnect, we have built a modular platform based on proven technology. We have also developed a set of standard mounting frames to facilitate this modular approach. Of course, there will always be some items which have to be purpose-made to meet a specific requirement – valve blocks, steering, cylinders, and so forth. However, we have achieved considerable standardization. In this way, our new MHPU can really be thought of as the first ‘off-the-shelf’ alternative for marine and offshore markets.”

Customer satisfaction

Offering anything from 300 kW to 3000 kW installed power and handling flows up to 5750 l/min with 350 bars pressure, the new modular HPUs offer customers numerous benefits.

Layout designers no longer have to wait before beginning to plan the layout. Now they can start drawing immediately. Once the MHPU has been chosen, layout design (of the engine room) can begin directly as the dimensions, weight, footprint and specifications of the parts are pre-defined. The layout can also be optimized for a specific function or to make best use of the available space.

It is expected that customers will be delighted about the time they can save. As HPU design and time-to-delivery are significantly reduced, the time from design to operation is very short. After discussing the particular system requirements with a Bosch Rexroth representative, customers will quickly receive a design proposal as, being modular, a lot of the design work is already done.

Assembly of the MHPU system is similarly very efficient. As only a small proportion of the system needs to be designed and built from scratch, the MHPU can be ready for installation and operation in a much shorter time than a full custom design. Obviously, saving time can save costs as well as helping to meet design, installation time on board and production deadlines.

Qualified for dependability

Bosch Rexroth has put significant efforts into ensuring its modular HPUs deliver the highest quality performance. All components in the platform are based on technologies already proven in the field. This combines with the modular design’s inherently low risk to safeguard reliability.

Verification of design and applied standards of the MHPU systems comes from the world’s most reputable independent institutions. Lloyd’s Register of Shipping Type Approval has been awarded for the complete MHPU system. Lloyd’s comprehensive Type Approval comprises tests included electrics and hydraulics and covers all modular options. Type approval from DNV GL is also pending and is expected in the very near future. The MHPU systems also comply to the latest ISO standards.

“We can integrate components to perform today’s tasks as well as the innovative technologies necessary for achieving tomorrow’s operations,” said Pierre Wouters. “For example, we are already working on ‘digital connectivity’ units to complement the MHPU as part of our Industry 4.0 initiative and world-wide standards.”

Digital data and communication capabilities are at the core of the emerging ‘smart world’, which promises, among other things, greater efficiency and accuracy in the workplace as well as distance monitoring. “Our MHPUs will soon offer this capability making them ready for companies moving to digitize their operations and include functionality like condition monitoring with sensors,” adds Wouters.

System components

The MHPU comprises the following main modules:

• A highly flexible set-up that meets most requirements in the Marine & Offshore industry
• Reservoir – oil reservoir capacities from 6,000 to 30,000 liters
• Pump motor group – with up to 2 electric motors
• Hydraulic pump – single- or double-units, 2 different types and sizes
• Manifold block – together with adjustable pressure filter and pulse damper (optional)
• Electrical controls cabinet – with optional Plug-n-Play capability
• Deep filtration and cooling set – oil conditioning and monitoring

The list of MHPU parts includes several optional parts which used to be considered ‘add-ons’. “We managed to extend the modular design to incorporate previous add-on components,” said Pierre Wouters “This makes them readily-available options that can be easily integrated into the system, giving customers more choice and flexibility.”

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