Rohtak, Haryana
2016
Following the successful execution of its earlier hydraulic hardline project for Maruti Suzuki’s R&D and simulation facility in Rohtak, Cenergy Offshore was selected to deliver a second hydraulic piping project for the facility — this time for the Strength Lab.
The project involved implementing a high-pressure, non-welded hydraulic hardline piping system for the Strength Lab actuators and integrating the system with hydraulic power units and test equipment supplied by a leading testing and sensing equipment OEM.
The project was awarded based on Cenergy Offshore’s experience with international best practices and its successful execution of previous hydraulic hardline projects for Maruti Suzuki.
The Strength Lab required a reliable high-pressure hydraulic piping system to connect the test equipment and actuators while meeting the demanding requirements of a controlled testing environment.
The project involved several key requirements:
The solution therefore needed to provide hydraulic reliability while maintaining precise installation and stringent cleanliness standards.
Cenergy Offshore implemented a pre-designed and pre-fabricated non-welded hydraulic hardline piping system for the Strength Lab.
The complete piping system was engineered before installation, allowing the pipe spools to be manufactured in advance and installed according to the approved layout.
This approach reduced site fabrication and helped maintain the cleanliness of the hydraulic system while ensuring that the piping, valves, accumulators and hose connections could be accurately integrated with the test equipment.
The design was developed in-house using information provided by Maruti Suzuki and the testing equipment OEM.
Key design inputs included:
The design process involved close coordination between Cenergy Offshore, Maruti Suzuki and the equipment OEM.
Multiple design reviews and modifications were undertaken to accommodate the requirements of the end user and the testing equipment supplier.
Once finalised, the complete hardline piping design was issued and approved by the end user with confirmation from the OEM.
Following design approval, the hardline piping was pre-fabricated at the Tube-Mac Industries (TMI) facility in Canada.
The pipe spools were fabricated, cleaned and painted under controlled conditions before being shipped to site.
Cleaning the spools before transportation helped minimise the risk of contamination from dirt, dust, rust, pollution and other contaminants that could affect the final hydraulic application.
The pre-fabricated approach also allowed the site team to install the piping according to the approved design with minimal fabrication work inside the laboratory.
Hydraulic hoses were fabricated and crimped at site using portable hose-crimping equipment.
The pre-fabricated hardline piping was installed under the supervision of Cenergy Offshore supervisors and technicians.
The pipe spools were carefully positioned within the defined laboratory space and assembled according to the approved piping layout and hydraulic schematic.
Because the Strength Lab required a high level of hydraulic cleanliness, particular attention was given to handling, assembly and installation practices.
The associated hydraulic hoses were also installed using appropriate practices to ensure reliable connections between the hardline, HPUs and test actuators.
After installation, the hardline and hose connections were looped and the complete hydraulic system was flushed.
The system achieved a reported NAS 0 cleanliness level, which was positively acknowledged by both the end user and the equipment OEM.
The required cleanliness level was achieved in approximately half a day, demonstrating the benefits of using pre-fabricated non-welded piping in controlled hydraulic testing applications.
Following flushing, the hardline underwent pressure/proof testing up to 4,500 psi.
The final test pressure was held for 30 minutes, exceeding the standard 15-minute hold period, to verify the integrity of the piping system and check for leaks or pressure loss.
Following successful installation, flushing and pressure testing, the hydraulic hardline was commissioned.
The Strength Lab simulation actuators and associated equipment were successfully tested to their required operating capacity, with the system performing to the satisfaction of both Maruti Suzuki and the equipment OEM.
After successful commissioning, all required spares, documentation and reports were handed over to the end user. Digital copies were also provided for easy access and future traceability.
Cenergy Offshore successfully delivered the hydraulic hardline system for Maruti Suzuki’s Strength Lab at its Rohtak R&D facility.
Building on the success of the previous project at the facility, the second project demonstrated Cenergy Offshore’s ability to deliver repeat hydraulic infrastructure for demanding automotive testing applications.
The use of pre-fabricated non-welded hardline piping enabled accurate installation within the defined laboratory space while reducing site fabrication and supporting the stringent cleanliness requirements of the facility.
The completed system achieved a reported NAS 0 cleanliness level, was pressure tested to 4,500 psi with a 30-minute hold, successfully commissioned and handed over.
The project was completed within the allotted schedule, earning positive acknowledgement from both the end user and the testing equipment OEM.
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