Hydraulic and Pneumatic Systems - TMT Group - TMT Group - Leading Marine & Offshore Engineering Solutions Provider

Hydraulic and Pneumatic Systems - TMT Group

Expert Fabrication, Installation, and Testing of Power Transmission Systems

TMT Group specializes in the design, fabrication, installation, testing, and commissioning of hydraulic and pneumatic piping network systems for marine and offshore applications. These critical power transmission systems control essential vessel operations including steering, deck machinery, cargo handling equipment, and various automation systems. With experience across 1,395+ vessel projects, we deliver reliable hydraulic and pneumatic solutions that ensure safe and efficient operations.

Hydraulic Systems - Comprehensive Solutions

Hydraulic systems provide powerful, reliable power transmission for critical vessel operations. Our expertise encompasses all aspects of marine hydraulic systems.

Steering Gear Hydraulic Systems

The most critical hydraulic system on any vessel ensures safe maneuvering

Main Steering Gear

Hydraulic power unit (HPU) installation and commissioning
Twin-ram or rotary vane actuator connections
High-pressure piping (up to 250 bar) with seamless steel tubing
Hydraulic fluid reservoirs and expansion tanks
Suction and return line installation
Relief valves and safety devices
Accumulator installations for emergency power
Rudder angle feedback system piping

Emergency Steering Systems

Independent emergency HPU installation
Separate hydraulic power source
Emergency control station piping
Quick-connect emergency power connections
Isolation valves for system segregation
Testing and certification to SOLAS requirements

Steering Control Systems

Autopilot hydraulic control connections
Bridge control unit piping
Telemotor system installation
Follow-up gear hydraulic connections
Non-follow-up control systems
Trick wheel emergency control piping
Hydraulic filters and conditioning equipment

Deck Machinery Hydraulic Systems

Power systems for cargo handling and deck operations

Windlass and Mooring Winches

Anchor windlass hydraulic motor connections
Mooring winch hydraulic power supplies
Warping drum hydraulic circuits
Brake system hydraulic piping
Tension control valve installations
Hydraulic hose reels and cable management
Emergency release systems
Pressure and flow control stations

Cargo Handling Equipment

Crane hydraulic systems (pedestal, knuckle boom, gantry)
Slewing ring hydraulic motor piping
Boom hoist and luffing cylinder connections
Load moment indicator hydraulic interface
Cargo winch hydraulic supplies
Deck crane outrigger stabilizer cylinders
Anti-two-block system hydraulic controls

Hatch Cover Systems

Folding hatch cover hydraulic cylinders
Rolling hatch cover hydraulic motors
Side-rolling cover actuator piping
Pontoon hatch cover systems
Synchronization valve installations
Position sensors and limit switch piping
Emergency manual operation provisions
Seal inflation system piping

Ramp and Door Hydraulic Systems

Systems for vehicle and cargo access

Stern and Side Ramps

Main ramp lifting cylinder piping
Side ramp articulation cylinders
Ramp lowering control circuits
Locking pin hydraulic actuators
Seal compression systems
Ramp position monitoring piping
Emergency lowering systems
Weather-tight door hydraulic operators

Bow Doors and Visors

Visor lifting hydraulic cylinders
Bow door hinge cylinder connections
Locking mechanism hydraulic actuators
Emergency closing systems
Position indication piping
Hydraulic door seal systems
Safety interlock hydraulic circuits

Offshore Hydraulic Systems

Specialized systems for offshore operations

Offshore Crane Hydraulics

Active heave compensation (AHC) hydraulic systems
Motion compensation cylinder installations
High-pressure (350+ bar) piping systems
Accumulator banks for energy storage
Proportional valve manifolds
Redundant hydraulic power supplies
Subsea control pod hydraulic connections

Thruster Hydraulic Systems

Azimuth thruster hydraulic steering
Tunnel thruster blade pitch control
Hydraulic motor drive systems
Slewing mechanism hydraulics
Emergency retraction systems
Shaft sealing hydraulic supplies

Drilling Equipment Hydraulics

Draw-works hydraulic systems
Top drive hydraulic power
Iron roughneck hydraulic connections
Pipe handling equipment hydraulics
BOP hydraulic control systems
Compensator hydraulic cylinders
Riser tensioner hydraulic supplies

Hydraulic Power Units and Distribution

Central hydraulic power generation and distribution

Hydraulic Power Units (HPU)

Main and standby pump installations
Electric motor drive and coupling alignment
Diesel emergency pump installations
Accumulator pre-charging and installation
Reservoir fabrication and installation
Suction strainers and filters
Relief and unloading valves
Pressure switches and transducers
Temperature and level monitoring
Oil coolers and heating systems

Distribution Manifolds

Main distribution valve blocks
Priority and load-sensing valves
Flow dividers and combiners
Pressure reducing and sequence valves
Check valves and pilot-operated check valves
Manifold mounting and piping connections
Hydraulic flushing and cleanliness verification

Hydraulic Piping Installation

Seamless steel tubing (high-pressure)
Hydraulic hose assemblies with crimped fittings
Tube bending to specified radii
Flare and compression fittings
Flanged connections for large bore
Pipe supports and vibration isolation
Fire-resistant hydraulic hose in engine rooms
Identification and labeling per standards

Pneumatic Systems - Compressed Air Solutions

Pneumatic systems provide control air, starting air for engines, and service air throughout the vessel

Compressed Air Generation

Air compressor installations and support systems

Air Compressor Installations

Main air compressor installation and alignment
Emergency air compressor setup
Compressor intake filtration systems
Inter-stage and after-cooler piping
Moisture separator installations
Compressor discharge piping
Safety relief valve installations
Vibration isolation mounting

Air Receiver Installations

Main air receiver positioning and support
Emergency air receiver installation
Pressure vessel certification
Safety valve and drain connections
Pressure gauge and instrumentation taps
Level switches for moisture draining
Internal inspection access provisions

Air Drying Systems

Refrigerated air dryer installation
Desiccant air dryer systems
Moisture separator installations
Condensate drain systems
Dew point monitoring connections
Filter installations (particulate and coalescing)
Bypass piping for maintenance

Starting Air Systems

Critical systems for main and auxiliary engine starting

Main Engine Starting Air

Starting air piping from receivers to engine
Starting air distributor connections
Quick-closing valves with remote shutdown
Starting air line filters
Flame arrestor installations
Pressure reducing valves where required
Branch connections to starting valves
Accumulator installations for additional capacity

Auxiliary Engine Starting Air

Dedicated or shared air receivers
Distribution piping to multiple engines
Automatic start sequencing valve connections
Emergency generator starting air priority
Cross connect valves between systems
Individual engine isolation valves
Moisture traps and drain systems

Air Starting System Components

Pilot air valve connections
Main starting valve pneumatic operators
Air motor starter installations (for diesel-driven pumps)
Turning gear air motor piping
Acoustic monitors air supply
Engine control system air supplies

Control and Instrument Air Systems

Clean, dry air for automation and control

Instrument Air Distribution

Instrument air header piping throughout vessel
Branch connections to control systems
Pressure reducing and regulating stations
Air filters (5 micron and finer)
Coalescing filters for moisture removal
Pressure gauges at distribution points
Isolation valves for maintenance
Backup supply from starting air with conditioning

Pneumatic Control Systems

Pneumatic valve actuator supply piping
Positioner and controller air supplies
Air-operated controller connections
Pneumatic relay and transmitter piping
Air logic system piping
Fail-safe air accumulator installations
Quick exhaust valve installations

Automation Air Supplies

HVAC damper actuator air supplies
Fire damper pneumatic operators
Pneumatic door operators
Watertight door pneumatic actuators
Valve remote operating systems
Pneumatic tool balancer air supplies

Service Air Systems

Utility compressed air throughout vessel

Service Air Distribution

Service air piping to workshops and deck areas
Hose connection points with quick couplers
Pressure reducing stations for tool use
Service air outlets in machinery spaces
Deck wash-down air connections
Tank blowing connections
Emergency blow systems for piping
Air start connections for emergency equipment

Workshop Air Systems

Pneumatic tool supply points
Air filter-regulator-lubricator (FRL) units
Grinder and impact wrench supplies
Painting and blasting air supplies
Tire inflation stations
Compressed air safety coupling

Low-Pressure Air Systems

Utility compressed air throughout vessel

General Alarm and Whistle Air

Air supply to ship's whistle
Fog horn air connections
General alarm pneumatic horns
Air pressure maintaining systems
Moisture trap installations
Adequate receiver volume calculations

Pneumatic Conveying Systems

Hydraulic and Pneumatic Installation Standards

Piping Installation Best Practices

Hydraulic Piping Standards

High-pressure steel tubing per ISO 8434
Hydraulic hose per ISO 18752 or SAE J517
Minimum bend radius (3x outside diameter for tubing)
Proper hose routing avoiding heat sources
Hose strain relief and support
Fire-resistant hose in high-risk areas
Proper tube flaring and torque specifications
Hydraulic tubing cleanliness (NAS 1638 class 7 or better)

Pneumatic Piping Standards

Seamless steel or copper tubing
Galvanized or stainless steel for corrosion resistance
Minimum bend radius for compressed air piping
Slope for moisture drainage (1:100 minimum)
Drain points at low spots
Flexible connections for vibration
Proper thread sealing (PTFE tape or paste)
Air receiver support and anchoring per codes

System Cleanliness and Flushing

Hydraulic System Flushing

Pre-commissioning oil flushing to achieve target cleanliness
High-velocity flushing (minimum 3 m/s)
Inline filter monitoring during flushing
Cleanliness testing per ISO 4406
Target cleanliness codes (typically 18/16/13 or better)
Flush oil disposal or reclamation
System preservation after flushing

Pneumatic System Cleaning

Removal of fabrication debris and scale
Air blowing to remove particulates
Filter element installation after cleaning
Initial condensate draining
Leak testing before commissioning
Moisture removal verification

Testing and Commissioning

Hydraulic System Testing

Pressure Testing

Hydrostatic pressure test at 1.5x design pressure
Test duration per classification society rules
Leak detection at all connections
Hose and tubing inspection under pressure
Pressure relief valve set point verification
Accumulator pre-charge pressure verification
System draining after test

Functional Testing

Hydraulic pump performance testing
Flow rate and pressure verification
Actuator stroke and timing verification
Control valve response testing
Relief valve cracking pressure test
System response time measurement
Load testing under operational conditions
Emergency system functionality verification

Performance Verification

Fluid cleanliness verification (particle count)
System operating temperature monitoring
Pressure drop across filters
Flow rate verification at multiple points
Noise and vibration measurement
Leakage rate measurement
Power consumption measurement
Efficiency calculations

Pneumatic System Testing

Pressure and Leak Testing

Pneumatic test at working pressure
Soap solution leak detection
Pressure decay test (allowable leakage verification)
Safety valve lift pressure verification
Pressure switch calibration verification
Emergency shutdown system testing
- Starting air system functional test

Functional Testing

Air compressor performance test
Air dryer dew point verification
Pressure regulator set point verification
Instrument air quality testing (ISO 8573-1)
Valve actuator stroke time measurement
Starting air system capacity test
Control system response verification

Hydraulic Fluid and Air Quality Management

Hydraulic Fluid Selection and Management

Fluid Types and Selection

Mineral oil hydraulic fluids (most common)
Biodegradable hydraulic fluids (ester-based, vegetable oil)
Fire-resistant fluids (water-glycol, phosphate ester)
Selection based on operating conditions and equipment
Compatibility with seals and components
Environmental considerations

Fluid Condition Monitoring

Regular oil sampling and analysis
Particle contamination monitoring
Water content measurement
Viscosity and additive depletion checks
Acid number (TAN) trending
Filter condition monitoring
Oil change intervals based on condition

Compressed Air Quality

Air Quality Standards

ISO 8573-1 compressed air purity classes
Instrument air: Class 1.4.1 or better (particulate, moisture, oil)
Starting air: Class 2.4.2 acceptable
Control air requirements per equipment specifications
Regular air quality testing
Filter element replacement scheduling

Safety Considerations

Hydraulic System Safety

High-Pressure Hazards

Injection injury prevention training
Pressure isolation during maintenance
Hydraulic hose inspection and replacement schedules
Burst protection and hose restraints
Pinhole leak detection (use cardboard, never hands)
Personal protective equipment requirements

Hydraulic Fluid Hazards

Fire risk with mineral oils near hot surfaces
Slip hazards from leaks and spills
Environmental contamination prevention
Spill containment and cleanup procedures
Proper disposal of used hydraulic fluid
Safety data sheet (SDS) accessibility

Pneumatic System Safety

Compressed Air Hazards

Rapid decompression risks
Air blast injury prevention
Noise exposure from air leaks and exhausts
Flying debris from air jets
Freezing from rapid expansion
Proper lockout/tagout during maintenance
Safe depressurization procedures

Regulatory Compliance and Standards

International Standards

ISO 4413 – Hydraulic fluid power systems
ISO 4414 – Pneumatic fluid power systems
ISO 5598 – Fluid power vocabulary
ASTM Standards for hydraulic fluids
ISO 8434 – Tube fittings and connections
ASME B31.3 – Process piping (adapted for hydraulic)
Classification Society Rules (Lloyd's, DNV, ABS, etc.)

Quality and Certification

ISO 9001 Quality Management compliance
Certified hydraulic fitters and pipefitters
Welder qualifications for hydraulic tubing
Equipment type approvals and certifications
Pressure vessel certifications for accumulators and receivers
Hose assembly certifications and traceability

Industries and Applications

Our hydraulic and pneumatic services support

Merchant Vessels :
Offshore Platforms :
Ro-Pax Ferries :
Container Ships :
Tankers :
Dredgers :
Offshore Wind :
Naval Vessels :

Steering, windlass, cargo handling
Cranes, BOP control, drilling equipment
Ramp and door operations, vehicle handling
Hatch covers, lashing systems, cargo cranes
Cargo pumps, hydraulic mooring, valve remote operation
Cutter head hydraulics, spud hydraulics, dredge pumps
Jack-up systems, crane hydraulics, motion compensation
Weapon systems, specialized deck equipment

Why Choose TMT Group for Hydraulic and Pneumatic Systems?

Specialized Expertise :
Complete Solutions :
Quality Fabrication :
Certified Technicians :
System Integration :
Testing Capabilities :
Global Experience :
Safety Focus :

Dedicated hydraulic and pneumatic engineers
Design review through commissioning
Precision tube bending and hose assembly
Trained fitters from TMSTI facility
Coordination with electrical and control systems
Complete pressure testing and performance verification
Projects across 1,395+ vessels worldwide
Rigorous safety protocols for high-pressure systems

Get Started with Your Hydraulic or Pneumatic Project

Our experienced team is ready to deliver reliable, efficient hydraulic and pneumatic systems for your vessel or offshore installation. Contact us today to discuss your requirements.