Rohtak, Haryana
2015
Cenergy Offshore was selected to deliver a turnkey hydraulic piping and hardline system for Maruti Suzuki India’s state-of-the-art R&D and Vehicle Simulation facility in Rohtak, Haryana.
The project involved approximately 500 metres of hydraulic hardline piping connecting the 4 Poster and 2 Poster Vehicle Simulation Labs and their associated test actuators.
The hydraulic system had to integrate with the HPUs and test equipment supplied by a leading testing and sensing equipment OEM. The project therefore required close coordination between Maruti Suzuki, the equipment OEM and Cenergy Offshore throughout the design and installation process.
Cenergy Offshore was awarded the project based on its experience with international best practices and previous project execution in non-welded hydraulic piping systems.
he Vehicle Simulation Lab required a high-pressure hydraulic piping system capable of reliably supplying the simulation actuators while meeting the stringent requirements of a controlled testing environment.
The project presented several challenges:
The solution therefore needed to combine hydraulic performance, installation accuracy, cleanliness and speed of execution.
Cenergy Offshore implemented a non-welded, high-pressure hydraulic hardline piping system for the Vehicle Simulation Actuators.
Rather than carrying out extensive pipe fabrication at site, the system was designed and manufactured as pre-fabricated pipe spools. This allowed the installation to follow the approved piping layout and significantly reduced site fabrication activities.
The complete solution included piping, valves, accumulators and hydraulic hose connections required to integrate the hardline system with the simulation equipment.
The hydraulic piping system was designed in-house based on the technical information provided by Maruti Suzuki and the testing equipment OEM.
The design inputs included:
The design had to accommodate the interface requirements of both the end user and the equipment OEM.
Multiple design reviews and modifications were carried out during the engineering phase before the final piping arrangement was approved.
The completed design established the pipe sizes, wall thicknesses, connections, routing and positioning of hydraulic components required for the final application.
General Arrangement and other required drawings were issued before installation, providing the basis for the manufacture and installation of the pre-fabricated pipe spools.
Once the design was approved, the hardline piping was pre-fabricated at the Tube-Mac Industries (TMI) facility in Canada.
The pipe spools were fabricated, cleaned and painted before being shipped to India.
Controlled fabrication and cleaning helped protect the internal hydraulic surfaces from contamination by dirt, dust, rust, pollution and other contaminants during fabrication, transportation and handling.
The pre-fabricated approach also allowed the site team to install the piping according to the approved design without extensive pipe fabrication inside the testing facility.
Hydraulic hoses were fabricated and crimped at site using portable hose-crimping equipment.
The pre-fabricated hardline was installed under the supervision of TMI field technicians with support from Cenergy Offshore 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 facility required stringent cleanliness standards, particular attention was given to handling, assembly and installation practices.
The hydraulic hoses were also installed using appropriate assembly practices to ensure reliable connections between the hardline system and the test equipment.
Following installation, the hardline and hose connections were looped and the complete 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 pre-fabricated non-welded piping for controlled hydraulic testing applications.
Following flushing, the hydraulic hardline was pressure/proof tested up to 4,500 psi.
The final pressure was held for 30 minutes, exceeding the standard 15-minute hold period, to verify the integrity of the system and check for leaks or pressure loss.
After successful installation, flushing and pressure testing, the hydraulic hardline was commissioned.
The Vehicle Simulation Lab actuators and associated equipment were successfully tested to their required operating capacity, with the system performing to the satisfaction of both the equipment OEM and Maruti Suzuki.
Following 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 approximately 500 metres of non-welded hydraulic hardline piping connecting Maruti Suzuki’s 4 Poster and 2 Poster Vehicle Simulation Labs at its Rohtak R&D facility.
The system integrated the hydraulic power units, actuators, valves, accumulators and associated equipment while meeting the stringent cleanliness requirements of the testing environment.
The use of pre-fabricated non-welded hardline piping enabled the system to be installed efficiently with minimal site fabrication. The completed system achieved the required hydraulic cleanliness and successfully passed pressure testing up to 4,500 psi.
Most significantly, the project was completed in approximately half of the allotted project time, earning positive acknowledgement from both Maruti Suzuki and the testing equipment OEM.
The successful execution also led to the planned continuation of the project through a subsequent Phase 2.
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