Chennai
2017
Following the successful completion of the hydraulic hardline piping for Ashok Leyland’s New Component Test Lab – Bay 1, Ashok Leyland expanded the facility with a second test bay and again entrusted Cenergy Offshore with the hydraulic piping requirement. The expansion required an extension of the non-welded hydraulic hardline system to support additional test equipment, including HPUs and actuators supplied by a leading testing and sensing equipment OEM.
Building on the solution implemented for Bay 1, Cenergy Offshore designed and delivered a large-bore, high-pressure, non-welded hydraulic hardline piping system for the new Component Test Lab – Bay 2. The project included engineering, pre-fabrication, installation, flushing, pressure testing, commissioning and handover.
The Bay 2 expansion required the new hydraulic piping system to integrate with the test equipment and hydraulic power units while fitting within the defined laboratory layout.
The testing machines also generated significant vibration, requiring the hardline piping and its supporting structure to withstand vibration frequencies of up to 50 Hz.
As with Bay 1, cleanliness was a critical requirement because the hydraulic system was connected directly to precision test equipment and actuators.
The piping therefore had to be installed without compromising the cleanliness of the hydraulic circuit while also meeting the customer’s hydraulic schematic and space constraints.
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 successfully delivered the hydraulic hardline piping expansion for Ashok Leyland’s Component Test Lab – Bay 2, building on the successful implementation of the system for Bay 1.
The project provided the additional hydraulic infrastructure required to integrate the test equipment, HPUs and actuators while addressing the demanding vibration and cleanliness requirements of the laboratory.
The use of pre-fabricated non-welded hardline piping helped maintain installation quality and minimise contamination risks associated with conventional site-fabricated hydraulic piping.
The completed system achieved the specified cleanliness requirement, was pressure tested to 4,500 psi with a 30-minute hold, successfully commissioned and handed over to Ashok Leyland.
Hydraulic hardline expansion for Ashok Leyland Component Test Lab – Bay 2
Large-bore non-welded high-pressure hydraulic piping
Designed for testing machine vibrations up to 50 Hz
Integration with HPUs and test actuators
Complete in-house piping design and engineering
General Arrangement and detailed piping drawings issued before installation
Pre-fabricated pipe spools manufactured at TMI, Canada
Controlled fabrication, cleaning and painting to minimise contamination
NAS 0 cleanliness level reported after flushing
Cleanliness achieved in approximately half a day
Pressure/proof testing up to 4,500 psi
Final pressure held for 30 minutes
Complete installation, flushing, testing, commissioning and handover by Cenergy Offshore
Follow-on project awarded after successful completion of Component Test Lab – Bay 1
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