Home / Applications / Thrusters

Piping for Thrusters

Hydraulic thrusters are critical to the manoeuvrability and positioning of marine vessels, requiring reliable hydraulic piping connections between the Hydraulic Power Unit (HPU) and the thruster assembly. Tube-Mac® non-welded piping technology provides an alternative to conventional welded hydraulic piping for thruster systems, combining high-pressure piping with mechanically connected fittings and, where required, flexible hose connections. The technology has been applied to bow and stern thrusters, retractable thrusters and associated hydraulic systems across marine and offshore projects.

Challenge

Hydraulic piping for marine thrusters presents several installation and operational challenges:

Reliability

High-pressure hydraulic systems require reliable piping connections.

Space Constraints

Limited space around thruster and HPU installations can make conventional routing difficult.

Complexity

Tight-radius elbows can result in complex piping arrangements and additional connection point

Hot Work

Marine and offshore environments can make hot-work activities more challenging.

Flexible Connections

Thruster systems may require flexible connections to accommodate equipment movement and installation constraints.

Solution : Tube-Mac® Non-Welded Piping for Marine Thrusters

Tube-Mac® provides a non-welded approach to hydraulic piping between HPUs, valves and marine thruster units.

The system can combine different connection technologies according to pipe size and system requirements, including:

37° Flare Flange System for high-pressure hydraulic piping
Pyplok® for mechanically swaged pipe connections
Retain Ring Flange System for larger high-pressure piping
Flexible hoses for HPU-to-thruster connections where flexibility is required

Pipe bending can also be incorporated into the routing to reduce the need for tight-radius elbows and unnecessary fittings. This approach was used in the M/Y NAVTILVS yacht project, where 2″ Sch 80 piping operating at 3,000 psi was installed using 37° Flare Flange and Pyplok® connections.

For a separate offshore supply vessel project, Tube-Mac® technologies were used for hydraulic piping connecting the HPUs to four retractable thrusters, with system pressures up to 2,640 psi and approximately 3,000 m of piping using 37° Flare Flange and Pyplok® systems.

Bow & Stern Thrusters

Hydraulic piping connections between HPUs and bow & stern thruster systems for vessel manoeuvrability.

Retractable Thrusters

High-pressure hydraulic piping for retractable thruster systems used on offshore and marine vessels.

Thruster HPU Connections

Hardline and flexible connections between hydraulic power units and thruster equipment.

Thruster Steering Systems

Hydraulic piping for steering circuits associated with marine thruster assemblies.

Thruster Lift Systems

Hydraulic piping for raising and lowering retractable thruster units.

Thruster Case Drain Lines

Piping connections for draining hydraulic fluid from thruster housings and associated systems.

Marine Refit & Piping Replacement

Replacement of existing welded hydraulic piping with non-welded piping during vessel refurbishment and modification projects.

Benefits of Tube-Mac® Non-Welded Piping

Tube-Mac® non-welded piping provides practical advantages for hydraulic thruster installations, particularly where high-pressure connections, routing flexibility and marine installation constraints need to be considered. The system can simplify installation while supporting reliable hydraulic connections between HPUs and thruster assemblies.

Reduced Hot Work

Non-welded connections eliminate welding at the fitting connection, providing an alternative where hot-work activities need to be minimized.

Efficient Piping Installation

Mechanical connection systems and portable installation tooling can simplify and accelerate hydraulic piping installation.

Flexible Routing

Pipe bending can be used to achieve smoother routing and reduce dependence on tight-radius elbows and additional fittings.

High-Pressure Capability

Tube-Mac® connection technologies can be configured for high-pressure hydraulic thruster systems, with the referenced projects operating at pressures up to 3,000 psi.

Suitable for Marine Refit

Non-welded piping can be used when replacing existing welded hydraulic piping on vessels, while working within existing equipment layouts.

Flexible Equipment Connections

Flexible hoses can be incorporated between HPUs and thrusters where required by equipment configuration and available space. The offshore project reference specifically included flexible hose connections as part of the HPU/thruster piping installation.

Industries Served

Offshore Vessels

Hydraulic piping for thrusters used in offshore supply and support vessels.

Yachts & Superyachts

Compact hydraulic piping systems for bow and stern thrusters in yacht construction and refit projects.

Marine & Shipbuilding

Non-welded hydraulic piping for propulsion, manoeuvring and auxiliary marine systems.

Offshore Construction Vessels

High-pressure hydraulic piping for positioning and manoeuvring equipment on specialized offshore vessels.

Engineered for Marine Thruster Applications

At Cenergy Offshore, we provide engineered Tube-Mac® non-welded piping solutions for marine and offshore hydraulic applications. Our solutions can cover the piping requirements between HPUs, valves, control systems and thruster units, with connection technologies selected according to pipe size, pressure and equipment requirements.

Our technical approach includes piping engineering, routing, material selection, pipe fabrication, installation guidance, pressure testing and flushing, helping integrate the non-welded piping system into new-build and vessel-refit projects. With applications ranging from yacht bow and stern thrusters to large retractable thruster systems on offshore vessels, non-welded piping provides a practical approach to complex marine hydraulic installations.

Talk to our engineering team about your piping requirements and find the right solution for your application.

Also read

Marine Heating Coil Repair : Traditional Welding vs. Pyplok® Cold Work

Piping for Water Mist System in Dwarka Expressway

PYPLOK® fittings enabled rapid installation of a high-pressure fire suppression system in the Dwarka Expressway Tunnel. J Kumar Infraprojects Limited along with Cenergy Offshore completed 20 km of stainless steel tubing in under 8 weeks, improving safety, reducing welding risks, and accelerating infrastructure delivery for 40,000 daily commuters.

Hydraulic Piping for Filter Press (FL Smidth)

Fabrication of hydraulic piping for four filter press systems, including flaring, bending, pressure testing, and flushing. Using non-welded 37° flare flange technology, the project handled up to 315 bar pressure across 350 meters of piping. Fabrication and testing were completed in-house in Haryana, ensuring high quality, reliability, and timely delivery for industrial hydraulic piping systems.

Tubing for Fuel & Mine Research Lab (CIMFR)

Installation of 1300+ meters of 1/4” SS316L tubing for multiple gases including Nitrogen, Oxygen, Hydrogen, and Helium was completed using advanced PYPLOK® non-welded technology for a high-precision lab project at the CSIR-Central Institute for Mining and Fuel Research. The system ensured leak-proof performance, faster installation, and long-term reliability, with successful pressure testing up to 12 bar.

Binder Area Piping for Glass Melter Facility (Owens Corning)

Owens Corning’s Mumbai facility faced tight timelines and a shortage of skilled welders during the construction of an 80,000-ton glass melter. To accelerate progress, they adopted the Pyplok® piping solution, proven in their USA operations for fast and reliable installation. Cenergy Offshore supplied 2000 Pyplok® fittings, along with tools and skilled technicians, enabling efficient installation across binder area and utility piping lines in stainless steel and carbon steel, ranging from 1/2” to 2” NPS.

Hydraulic Piping for Granulator in JSPL Sinter Plant

Jindal Steel & Power (JSPL) expanded its Angul plant with a state-of-the-art Sinter Plant built by Primetals, Austria. To ensure high-performance hydraulic systems, Tube-Mac non-welded piping technology was selected for the granulator hardline. The pre-fabricated piping system was manufactured in Austria and installed in Odisha under expert supervision. Designed for 315 bar pressure and spanning 350 meters, the system enabled faster installation, reduced welding dependency, and improved reliability. This project highlights advanced piping engineering and efficient manpower execution in India’s steel industry, contributing to the plant’s successful commissioning and ongoing operations.

Drill Hydraulics Piping for GTRV (Fugro Voyager)

Fugro N.V.’s geotechnical research vessel at TEBMA Shipyards, Udupi, featured advanced non-welded hydraulic piping by TMI and Cenergy Offshore. Using Pyplok® and flare flange systems, the project ensured precision, cleanliness, and reliability. Successfully installed, flushed, and pressure tested, the system was completed in record time, earning repeat orders and client appreciation.