Case Studies

Overcoming the Challenges of Welding in Subterranean Tunnels

Inside tunnel view of Samruddi Mahamarg Tunnel where PreFiS non-welded piping technology is used for water mist systems
Installing kilometres of high-pressure stainless-steel piping inside a confined tunnel environment presents unique challenges. Conventional welding can introduce risks related to material integrity, hot-work safety and post-weld quality requirements. This case study explores how a non-welded cold-press piping solution was used for the Samruddhi Mahamarg Tunnel’s high-pressure water mist network, helping address these challenges while improving installation efficiency and reducing total installed cost.

Eliminating Hot Work in a Marine Hydraulic Piping Retrofit

stainless steel non-welded tube-mac piping connected to thruster
Mubarak Marine, Dubai, undertook the modernisation of the hydraulic piping connecting Thrustmaster thruster units to deck-mounted hydraulic power packs. The system needed to withstand high cyclic pressures, mechanical vibration and demanding marine conditions. Traditional welded piping introduced hot-work requirements, inspection requirements and the risk of internal contamination. The retrofit therefore adopted a zero-welding approach for the structural hydraulic runs between the thruster wells and deck infrastructure.

20 km Fire Suppression Piping Deployment in Less Than 8 Weeks

Cenergy Offshore Technician Crimping Pyplok® for Water Mist System on Cherry Picker in Dwarka Tunnel.
The Dwarka Expressway Tunnel project in Delhi, India, involved the installation of a high-pressure fire suppression piping network designed to protect a critical tunnel infrastructure. Cenergy Offshore Pvt. Ltd. served as the system installer, with the network comprising approximately 20 km of 22 mm stainless-steel tubing and around 4,000 PYPLOK® fittings. The system operates at 120 bar and was hydrostatically tested at 180 bar.

Steel Plant Shutdown reduction by 60 Hrs

The Hydraulic Exit Valve Stand-3 replacement demonstrated the use of Pyplok® non-welded cold-swage technology in high-pressure hydraulic maintenance. The work was completed in 36 hours instead of 96, recovering 60 hours of production time

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