Precision HVAC Solution for Vehicle Test Facility at India Nippon Electricals Hosur

Client: India Nippon Electricals Pvt. Ltd.
Location: Hosur, Tamil Nadu
Completion Date: March 2022

Executive Summary

Aqua Chill Systems successfully executed a complex HVAC and utility infrastructure project for India Nippon Electricals’ state-of-the-art vehicle test facility in Hosur. The project demanded tight control of temperature and humidity across a wide operating range. Our team overcame multiple design and commissioning challenges to deliver a robust, precision-controlled environment tailored for vehicle testing.

About the Client

India Nippon Electricals Pvt. Ltd. is a leading manufacturer of ignition systems for two-wheelers, three-wheelers, and general-purpose engines. The company set up a vehicle test facility in Hosur to enhance its R&D and testing capabilities under real-time operating conditions.

Project Scope

Design, supply, installation, and commissioning of the following systems for the test facility:

• HVAC System
• Process Cooling System
• Compressed Air System
• Electrical System

The Challenge

The project posed several critical technical and operational challenges:

• Designing an HVAC system capable of maintaining precise temperature (20°C to 30°C) and humidity (40% to 60%) levels inside the vehicle test cell.
• Ensuring tight control of environmental parameters regardless of the setpoint temperature chosen by the end user.
• The facility was designed for vehicle testing under varying speeds, pressures, and thermal loads, requiring a highly adaptable system.
• Commissioning and validation had to prove consistent performance across all configurations—making this a high-stakes project from both a design and execution standpoint.

Our Solution

To meet the demanding requirements of the test facility, Aqua Chill implemented the following technical strategies:

• Conducted multiple permutations and combinations of heat load calculations to arrive at an optimal HVAC design capable of meeting all operational conditions.
• Selected and integrated high-performance equipment tailored for precision climate control, including:
  • Water-Cooled Screw Chillers
  • Cooling Towers
  • Air Handling Units (AHUs)
  • Advanced Control and Instrumentation Systems
• Designed a fully integrated system architecture to allow real-time monitoring and precise adjustment of environmental conditions based on test requirements.

Outcome

• Achieved stable temperature and humidity control across all operational setpoints as per the client’s requirements.
• The system delivered consistent performance and reliability during and after commissioning.
• Enabled India Nippon to enhance their vehicle testing accuracy, reducing variability caused by environmental factors.

Conclusion

Through advanced engineering, rigorous planning, and high-precision execution, Aqua Chill successfully delivered a turnkey HVAC utility solution for one of India Nippon Electricals’ most critical R&D investments. The project stands as a testament to Aqua Chill’s capabilities in handling complex, high-spec industrial HVAC environments.