Bawal, Haryana
2021
FL Smidth required a complete hydraulic piping solution for four filter press systems at its facility in Haryana.
The scope required the hydraulic piping to be fabricated, assembled, pressure tested and flushed at the customer’s laboratory before being transported to the final installation site.
Cenergy Offshore was selected for the project based on its expertise in hydraulic piping fabrication and non-welded piping technology.
The project involved approximately 350 metres of hydraulic piping across pressure, return, drain and flushing lines, with the system designed for pressures up to 315 bar.
The four filter press systems required a reliable hydraulic piping system that could be accurately fabricated according to the customer’s routing requirements and thoroughly tested before being moved to site.
The project required:
The ability to complete the fabrication and testing under controlled conditions was particularly important to ensure the quality and reliability of the hydraulic system before site installation.
Cenergy Offshore provided an integrated hydraulic piping fabrication and testing solution using Tube-Mac’s 37° Flare Flange non-welded piping technology.
The piping was fabricated according to the customer’s routing requirements using Cenergy Offshore’s in-house machinery and equipment.
The completed pipe spools were then assembled, pressure tested and flushed at the customer’s laboratory in Haryana before being moved to the final site for installation and commissioning.
This approach allowed the hydraulic piping to be thoroughly prepared and validated before site erection.
Cenergy Offshore carried out the complete pipe fabrication using its in-house equipment, including:
The piping was fabricated using the 37° Flare Flange System, eliminating the need for conventional welding of the hydraulic pipe connections.
The system incorporated multiple metric pipe sizes:
Approximately 350 metres of piping were fabricated for the four filter press systems, covering pressure, return, drain and flushing lines.
Following fabrication, the individual pipe sections and components were assembled according to the customer’s specified routing.
The non-welded flare flange connections allowed the piping to be assembled without conventional site welding while providing a controlled and repeatable connection method.
Accurate bending and fabrication ensured that the completed piping could follow the required equipment routing and interface correctly with the filter press systems.
After fabrication and fit-up, the completed hydraulic piping system underwent pressure testing to verify the integrity of the assembled connections and piping.
The system was tested for pressures up to 315 bar using Cenergy Offshore’s in-house pressure testing equipment.
Following successful pressure testing, the piping was flushed using Cenergy Offshore’s in-house flushing equipment.
The flushing process helped remove contaminants introduced during fabrication and assembly and prepared the hydraulic piping for subsequent installation and commissioning.
Both pressure testing and flushing were completed within the customer’s required schedule.
The fabricated and tested pipe spools were prepared for transportation to the final installation site.
Following the successful fabrication, pressure testing and flushing work, the customer entrusted Cenergy Offshore with the additional responsibility of erection and commissioning of the hydraulic piping system at site.
This extended scope reflected the customer’s confidence in Cenergy Offshore’s fabrication quality, testing procedures and hydraulic piping expertise.
Cenergy Offshore successfully fabricated and prepared approximately 350 metres of non-welded hydraulic piping for four filter press systems.
The project demonstrated Cenergy Offshore’s ability to manage the complete hydraulic piping preparation process — from flaring and bending through fit-up, pressure testing and flushing — using its own in-house equipment and expertise.
The piping system was designed for pressures up to 315 bar and was successfully tested and flushed before being moved to site.
The quality and reliability of the completed work were positively acknowledged by the customer, who subsequently entrusted Cenergy Offshore with the erection and commissioning of the hydraulic piping system at the final site.
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