Oresund Dry Docks AB on behalf of the Swedish Coast Guard

Hydraulic lifetime extension for KBV 201 and KBV 202

HydTec developed a common hydraulic lifetime-extension solution for the Swedish Coast Guard vessels KBV 201 and KBV 202. A compact, electrically driven HPU replaced the distributed and weight-intensive supply concept, achieving a substantial reduction in system weight and footprint while enabling a highly accessible, service-friendly installation in the forward section of each vessel.

Challenge:

The existing system on each vessel used eleven hydraulic pumps and seven drive sources distributed across five locations. Extensive piping and conventional drive arrangements created major weight and space penalties, numerous maintenance points, unnecessary energy losses and difficult service access.

Delivery

HydTec assumed full responsibility for engineering, detailed design, manufacturing, complete workshop assembly and pre-delivery checkout. The scope continued onboard with commissioning, system verification, documentation and handover of the complete hydraulic solution.

Results

The new architecture provides up to 800 l/min at 300 bar—equivalent to approximately 400 kW of hydraulic power—while substantially reducing system weight, installation volume and maintenance points. The centralised forward installation provides exceptional accessibility for inspection and service.

GO TO RESULTS
A blue and white ship with yellow accents, marked with the number 202, making way through open water under a clear blue sky.

Initiation

A large blue and yellow industrial ship or vessel photographed in a dry dock, with the hull number 201 visible on the front. The ship is supported by supports on the ground, with another ship and dock structures in the background under a clear blue sky.

Initial assessment

The Swedish Coast Guard vessels KBV 201 and KBV 202 are used for maritime surveillance, environmental response, firefighting, emergency towing and oil-recovery operations. Their hydraulic systems supply numerous operationally critical consumers, including cranes, winches, bow thrusters, fire pumps and oil-handling equipment.

As part of the series’ lifetime-extension programme, the existing hydraulic architecture required comprehensive modernisation. The objective was not simply to replace ageing components, but to establish a common and repeatable system solution that is lighter, more energy-efficient and considerably more service-friendly, supporting the vessels’ continued operation for many years.

Communication

The project required close coordination between HydTec, Oresund Dry Docks, the Swedish Coast Guard and the electrical, mechanical and piping disciplines involved in the vessel upgrades. HydTec retained technical responsibility throughout engineering, manufacturing, onboard integration and commissioning.

The final handover package for each delivery included hydraulic schematics, as-fitted drawings, a detailed bill of materials, operating and maintenance manuals, component documentation, recommended spare parts, flushing and pressure-test records, and commissioning documentation.

Aerial view of a shipyard harbor with multiple large passenger ferries in dry dock, red cranes, industrial buildings, and a distant shoreline with wind turbines under a pale blue sky.

Source: Oresund Drydocks

Process

A person in a black sweater works on a laptop showing a 3D mechanical model on screen, with industrial machinery in the background.

Design & Engineering

HydTec redesigned the hydraulic supply around a central HPU located in the forward section of each vessel. The new architecture replaced multiple distributed pumps and drive sources with two compact Parker GVM permanent-magnet motor-driven main pump assemblies and an auxiliary motor-pump unit for lower-demand and shore-power operation.

Parker GVM permanent-magnet motors provide very high power density and are only a fraction of the size and weight of conventional asynchronous motors with comparable output. Combined with the removal of pumps, drive sources and extensive piping that were no longer needed, this made a substantial reduction in overall system weight and installation volume possible.

Parker PVplus variable-displacement pumps and electronic load-sensing control allow the available pump capacity to be staged according to actual hydraulic demand. The system provides up to 800 l/min at 300 bar, corresponding to approximately 400 kW of hydraulic power.

Engineering also covered system dimensioning, hydraulic schematics, control interfaces, filtration, cooling, pressure monitoring, pipe-sizing principles and integration with the vessels’ numerous existing hydraulic consumers. Particular attention was given to accessibility, component replacement and future service work.

Manufacturing

For each vessel, HydTec completed the detailed engineering, manufacturing, system assembly and pre-delivery checkout at its own facilities. Each customer-specific HPU incorporated a purpose-built tank and structural frame, Parker GVM motor-pump assemblies, an auxiliary pump unit, filtration, cooling equipment, cyclone return units, sensors, valves and custom-designed load-sensing and filter blocks.

Each complete unit was built and assembled as an integrated system before delivery. Mechanical interfaces, component positioning, service access and system functionality could therefore be checked under controlled workshop conditions instead of being resolved during installation onboard.

This approach reduced installation risk and limited the amount of assembly work required inside each vessel. It also allowed HydTec to ensure that every delivered system was correctly configured, documented and prepared for connection to the vessel’s hydraulic, electrical and control interfaces.

A set of custom welded metal exhaust pipes with blue and silver sections, displayed on a workbench in a workshop alongside welding gloves, a helmet, and tools.

Results

A blue industrial hydraulic machine getting loaded onto a large gray semi-truck with its side open. Two men are present near the truck and machine in an outdoor lot.

Installation & commissioning

Each fully assembled HPU was delivered to Oresund Dry Docks for installation in the forward section of the relevant vessel. The shipyard and specialist contractors positioned the unit and completed the required onboard piping and electrical connections in coordination with HydTec.

HydTec then carried out onboard commissioning and system verification for each delivery. The connected hydraulic circuits were flushed and pressure-tested, system functions and control interfaces were checked, and the documentation was updated to reflect the final installed configuration.

Each completed hydraulic system was subsequently handed over together with its operating, maintenance, test and as-fitted documentation.

Follow up & support

The first completed installation established the reference configuration for subsequent applications within the KBV 201 Series. The same fundamental solution can be applied throughout the series, while experience gained during manufacturing, installation and commissioning is incorporated into each follow-on delivery.

HydTec continues to provide technical support, spare-parts guidance and assistance with future service, maintenance and system requirements.

Industrial hydraulic power unit with a prominent black electric motor, blue metal housing, silver filter cylinders, and piping, photographed in a workshop setting.

Want to know more?

About us FAQ