Case Study: : Maruti Suzuki Vehicle Simulation Lab:
Project No: 1733
Chase Resource has recently executed a Hydraulic Piping / Hardline project in a state of the art simulation and R&D facility for Maruti Suzuki India Ltd out of Rohtak, Haryana in India. The Project was awarded on merit based on international best practices and project executions carried by TMI / Chase Resource. One of the leading Testing & Sensing Equipment OEM’s was providing all the necessary Test equipment’s and the same was to be integrated viz. the HPUs and Actuators.
The Project key points are as follows:
- Implementation of Non Weld Hydraulic / High Pressure / Hardline Piping system for the
Vehicle Simulation Actuators.
Issuance of all the drawings prior to installation. The installation process was based on pre- designed & pre-fabricated Hardline Pipe spools.
Pipes were pre-fabricated and they were carefully laid out in a defined space - meeting the
design & schematic layout criteria.
Carrying out piping in an environment which demanded high standards of cleanliness.
Installation of wide range of components like special type valves and accumulators.
The various steps involved were as follows
- Design / Engineering: Since this was a project involving Hardline Piping for a simulation lab,
prior design could be carried out. The End-User sharedus preliminary information like
hydraulic schematic drawing, equipment connection details based on which we could arrive
on the configuration for Hardline like pipe size, wall thickness, connections, and layout of
different components like valves & accumulators, etc. The design was entirely carried out
in-house based on necessary information like Hydraulic Schematic Drawing, Civil Layout, and
RC Detail Drawing. The designing process took a considerable amount of time since it
required co-ordination with both the End-User as well as the OEM and also with a lot of
requests for change / modification. Finally the Hardline Piping design was successfully
issued and was accepted by the End-User with the confirmation of the OEM to suit the final
Fabrication: The Hardline Piping involved in this project were all pre-designed and prefabricated
since site layout details were accurately available at our end. All the spools were
pre-fabricated, cleaned, painted in TMI facility in Canada and shipped to the site. By stating
“cleaned” we mean that the Spools / Hardline system do not get contaminated by dirt, dust,
rust, pollution, and chemical contamination during transportation & handling, which could
hamper the final Hydraulic application. All hoses were fabricated / crimped at site using
portable hose crimper.
Erection: All the Hardline Piping was erected under the supervision of TMI Field Technicians
and using Chase Resource Technicians. The erection had to be carried out carefully since the
cleanliness requirement at the lab was very high. All hoses were installed using the right
Flushing: All the Hardline and Hose connections were looped and the system flushed. We
achieved a “NAS 0” cleanliness level which was applauded by the End-User and also by the
OEM. It hardly took half a day to achieve the above cleanliness level which clearly
demonstrates the merit of using Non Weld for such particular Testing Applications.
Pressure Testing: The Hardline had to be pressure / proof tested up to 4500 psi. The above
pressure rating was subjected on the Hardline and was held for 30 min (standard states hold
time of 15 mins is sufficient).
Commissioning : After the installation phase the Hardline was ready to be commissioned.
All the Simulation actuators / equipment’s were tested successfully to full capacity and to
the complete satisfaction of the OEM and End-User.
Hand Over: After successful commissioning, all the spares, documentation, reports were
handed over to the End-User and a copy was kept with TMI / Chase Resource for future
reference & traceability. The same was provided in digital format for easy access.
The Project was completed in half the time allotted to us which was positively acknowledged by the End-User and by the OEM i.e. the Testing / Sensing Equipment Provider. TMI / Chase Resource will soon be carrying out Project II or Phase 2 of the Project shortly.