Chennai
2016
Ashok Leyland, India’s leading commercial vehicle manufacturers, was setting up a new Component Test Lab at its Technical Centre in Chennai.
The existing test laboratory had experienced repeated issues and downtime associated with welded hydraulic hardline piping. For the new facility, Ashok Leyland was therefore looking for a more reliable, maintainable and installation-efficient alternative to conventional welded piping.
Based on Cenergy Offshore’s experience in implementing non-welded hydraulic hardline systems for Maruti Suzuki Test Labs, Ashok Leyland selected Cenergy Offshore to deliver the hydraulic piping system for the new Component Test Lab.
The project involved the design, pre-fabrication, installation, flushing, pressure testing and commissioning of a large-bore, high-pressure non-welded hydraulic hardline piping system serving the test lab actuators.
The new Component Test Lab required a hydraulic piping system capable of supplying multiple test actuators while fitting within a defined trench layout.
The project presented several engineering and execution challenges:
Ashok Leyland therefore required a solution that could combine high-pressure hydraulic performance, vibration resistance, installation efficiency and cleanliness.
Cenergy Offshore implemented a large-bore, non-welded hydraulic hardline piping system designed specifically for the Component Test Lab.
Instead of fabricating the entire piping system at site, the system was designed and manufactured as pre-fabricated pipe spools. This approach reduced site fabrication and allowed the installation to progress quickly once the laboratory trench and supports were ready.
The design incorporated the customer’s hydraulic requirements, laboratory layout and equipment information to develop a piping system suited to the actual operating conditions.
The piping system had to be installed within a trench, making accurate site measurements critical to the design.
Cenergy Offshore carried out a site inspection and survey to establish the trench dimensions, support plate locations and other relevant installation details. The survey information was used as an input for the detailed piping design.
The customer provided key design information including:
Cenergy Offshore worked with the customer through multiple design discussions to evaluate different piping approaches and arrive at the final approved layout.
Based on the required flow capacity and actuator demand, a 6-inch SCH XXS pressure header was selected for the main hydraulic circuit.
The tap-off piping was also designed to accommodate the expected 60 Hz vibration frequency at the test actuators.
Following approval of the piping design, the hardline was manufactured as pre-fabricated pipe spools.
The required components, including clamps and O-rings, were also sourced and prepared as part of the project.
Due to the scale of the installation, the material was shipped in two lots. The first shipment contained the piping and components required to begin installation and complete a substantial portion of the first stage while the second shipment was being prepared.
This phased delivery approach helped maintain project progress while reducing the impact of transportation and logistics on the installation schedule.
The support brackets were welded to the support plates along the trench walls before the pre-fabricated hardline spools were positioned and installed.
Cenergy Offshore deployed a dedicated site team comprising two supervisors and four workers, supported by two cranes, to carry out the installation.
The pre-fabricated nature of the piping allowed the team to focus on positioning, assembly and connection rather than carrying out extensive pipe fabrication at site.
All flange connections were assembled and tightened to the specified torque requirements to ensure the integrity of the high-pressure piping system.
Before hydraulic flushing, a pneumatic pressure test was carried out to verify that the joints had been correctly assembled and tightened.
The hydraulic hardline was then looped at each actuator tap-off using hoses and flushed until a NAS 5 cleanliness level was achieved.
Following successful flushing, the system underwent hydraulic pressure testing in three stages:
The final pressure of 315 bar was held for 15 minutes to verify the integrity of the system and check for leaks or pressure drops.
After the successful test was witnessed by the client, the pressure was safely released and the hardline was connected to the HPUs and test actuators.
The flushing and pressure testing certificates were subsequently signed by the client for project records.
The completed hydraulic system was commissioned by Ashok Leyland with support from Cenergy Offshore technicians.
The system was tested and confirmed to operate to the customer’s requirements. Upon successful completion, Cenergy Offshore prepared the project documentation and project report, which was reviewed and signed by the client, formally completing the project.
Cenergy Offshore delivered a large-scale non-welded hydraulic hardline piping system for Ashok Leyland’s new Component Test Lab, replacing the limitations associated with conventional welded hydraulic piping.
The approximately 2 km piping network, serving 79 actuator points across two stages, was designed, pre-fabricated and installed to suit the laboratory’s hydraulic and spatial requirements.
The use of pre-fabricated non-welded hardline helped minimise site fabrication and installation time, while the engineered tap-off arrangement addressed the demanding vibration conditions of the test equipment.
The completed system was flushed to NAS 5 cleanliness, pressure tested up to 315 bar, commissioned and handed over successfully to Ashok Leyland.
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