FLEX Test Bench (Coslada Factory)

Design, Prefabrication and Installation of High-Pressure Hydraulic Test Bench Piping Systems

Description

Project

Flowserve Spain entrusted CADE with the development and execution of the complete modernization of the piping system of the FLEX Test Bench, a key facility for the validation and testing of high-performance industrial equipment.

The project encompassed the fabrication, supply, assembly, and quality control of all service lines, ensuring optimal performance under extreme pressure and temperature conditions.

Execution integrated engineering, workshop prefabrication, specialized painting, and on-site mechanical installation, all performed under the highest standards of safety, quality, and sustainability.

Thanks to its comprehensive EPC (Engineering, Procurement & Construction) approach, CADE managed the entire project scope—from detailed engineering to workshop fabrication, industrial coating, transport, and final site installation—meeting the most demanding quality, safety, and environmental standards.

main test and return lines

of fabricated and installed steel

0 m²

of protected piping and supports

components (elbows, flanges, tees, valves, fittings, instrumentation)

The

Challenge

The FLEX Test Bench at Flowserve’s Coslada plant is a critical facility for validating and testing high-performance industrial equipment.
Modernizing its piping system represented a technically and operationally complex challenge.

The new design had to ensure a piping and conduit network capable of operating under high pressure and flow conditions, with total reliability and no efficiency losses.
Moreover, the installation had to be completed without interrupting plant operations, coordinating each phase of prefabrication, transport, and assembly with extreme precision.

The industrial environment imposed strict technical and operational requirements, including:

Limited space and maneuverability, requiring detailed planning and specific lifting equipment.
High standards in welding and painting quality, essential to ensure durability and leak-tightness in every line.
Strict compliance with safety and environmental regulations, due to the nature of the fluids and testing procedures involved.

CADE tackled this challenge through an integrated EPC methodology, applying its expertise in complex industrial projects to minimize downtime, optimize technical traceability, and deliver results that fully met Flowserve’s requirements and international standards.

To successfully deliver the project, CADE deployed a comprehensive EPC approach, combining its engineering know-how with its in-house fabrication and assembly capabilities.

Engineering and Planning:
The technical team reviewed the base documentation and defined the construction drawings, Material Take-Off (MTO) lists, and 3D models of the system.
This allowed early detection of interferences, optimized assembly routes, and ensured a smooth, deviation-free workflow.
Fabrication and Prefabrication:
Over 1,200 meters of piping and 9 tons of steel supports were manufactured in CADE’s workshops, using qualified welding procedures and precise dimensional controls.
Industrial Coating and Protection:
A high-durability coating system was applied, consisting of epoxy primer and PPG polyurethane finish, ensuring resistance to corrosion and intensive testing conditions.
Assembly and Quality Control:
Mechanical installation was carried out on-site using specialized lifting and alignment equipment, under continuous supervision by CADE’s site manager.
Non-destructive testing (NDT) was performed, and a full quality and traceability dossier was delivered upon completion.

The result was a smooth, coordinated, and incident-free process, meeting both schedule and technical specifications agreed with the client.

CADE´s

Solution

Results

The new FLEX Test Bench now operates with a fully renovated, efficient, and safe piping system, capable of withstanding the highest levels of performance demand during valve and hydraulic component testing.

Main achievements include:

Significant improvement in operational reliability and reduced maintenance downtime.
Optimized hydraulic performance and enhanced leak control.
Full compliance with safety, quality, and environmental regulations.
On-time, incident-free execution within a 12-week schedule.
Seamless integration of the new system into the existing facility without affecting production.

This project reinforces CADE’s position as a trusted technical partner for industrial EPC projects, where the combination of engineering expertise, experience, and execution excellence ensures tangible and sustainable results.