Chennai
2018
After successfully completing hydraulic hardline piping for Ashok Leyland’s New Component Test Lab – Bay 1 and Bay 2, Cenergy Offshore was selected for another critical application: the conversion of the existing 6 Poster Lab into an 8 Poster Lab.
The project involved replacing the existing hydraulic hardline piping and developing a new piping system for the test actuators. Unlike a conventional hydraulic piping installation, the new system had to accommodate significant vibration generated by the testing equipment, particularly at the actuator tap-off points.
Ashok Leyland required a piping and support system that could withstand these dynamic conditions while maintaining the required hydraulic performance, cleanliness and reliability. Cenergy Offshore was also tasked with carrying out Finite Element Analysis (FEA) of the piping supports and Computational Fluid Dynamics (CFD) analysis of the piping system as part of the engineering validation.
The primary challenge was the high level of vibration associated with the test machines and actuator connections.
The piping and its supporting structure had to withstand vibrations of up to 50 Hz without compromising the integrity of the hydraulic system. Particular attention was required at the actuator tap-off points, where vibration could be transferred directly into the hydraulic piping.
The project therefore required more than simply replacing the existing hardline. The piping layout, support arrangement and hydraulic flow characteristics had to be engineered for the actual operating conditions of the 8 Poster Lab.
Cenergy Offshore designed and executed a large-bore, non-welded hydraulic hardline piping system for the Component Test Lab actuators.
The complete solution was engineered in-house using the available hydraulic schematics, civil layouts and equipment information. The piping layout and support arrangement were developed specifically for the laboratory environment and the dynamic loads generated by the testing machines.
To ensure that the system could withstand the demanding operating conditions, Cenergy Offshore carried out:
This engineering-led approach allowed the piping system to be validated before fabrication and installation rather than relying on adjustments at site.
Once the design was finalised, the piping was pre-designed and pre-fabricated into individual pipe spools.
The spools were cleaned and prepared before being transported to site, helping maintain the cleanliness required for a high-performance hydraulic test laboratory.
Pre-fabrication also allowed the installation to follow the approved 3D model and drawings, reducing site fabrication and ensuring that the piping could be installed within the defined laboratory space.
Cenergy Offshore supervisors and technicians carried out the erection of the hardline piping at site.
Because the installation was being performed inside a test laboratory, maintaining hydraulic cleanliness during handling and installation was a key requirement.
After installation, the piping system was flushed using Cenergy Offshore flushing components and achieved a NAS 6 cleanliness level.
The completed hardline was subsequently pressure tested up to 4,500 psi, with the pressure held for 30 minutes to verify the integrity of the installed system.
Following successful testing and commissioning, the laboratory was handed over to Ashok Leyland along with the required documentation, reports and spares.
The completed hydraulic hardline system enabled Ashok Leyland to upgrade its existing 6 Poster Lab to an 8 Poster Lab, providing the required hydraulic infrastructure for the additional testing capability.
More importantly, the system was engineered specifically around the vibration conditions of the test equipment. The FEA-validated support structure and engineered piping layout provided a robust solution for the high-vibration environment, while CFD analysis supported the hydraulic design.
The project demonstrated Cenergy Offshore’s ability to take on complex hydraulic piping requirements where dynamic loads, hydraulic performance, cleanliness and installation constraints all need to be considered together.
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