100%
45%
Marine hydraulic piping presents challenges that go beyond simply creating a pressure-tight connection. The thruster hydraulic circuits operate under intense cyclic pressures and significant mechanical vibration, while the confined spaces around the thruster units make hot work particularly demanding.
Traditional welded piping introduced several additional requirements:
The project therefore required a piping solution that could provide:
High-pressure integrity + vibration resistance + internal cleanliness + rapid installation — without welding.
Rather than relying on a single connection technology, the piping system was engineered using three complementary Tube-Mac technologies, selected according to pipe size, pressure requirements and available installation space.
Used on medium-to-large high-pressure feed lines from ½” to 2″ nominal pipe.
Pipe ends were mechanically cold-flared to a 37° profile using portable hydraulic tooling. An internal cone with elastomeric O-ring sealing was then assembled into a leak-tight mechanical connection rated up to 420 bar (6,000 PSI).
Used on larger-bore, heavy-wall piping from 2″ to 4″ and above, including low-pressure return and high-volume suction lines.
A precision-machined groove on the pipe accommodated a heavy-duty split retain ring, creating a mechanical shoulder for the sliding flange while maintaining the pipe’s full wall thickness without heat exposure.
Used for small-bore control loops, instrumentation and pilot lines, particularly in compact spaces around the Thrustmaster valve blocks.
The fittings were cold-swaged onto the pipe using specialised hydraulic pressing equipment, creating a permanent, maintenance-free connection without introducing heat into the piping.
One of the major advantages of the approach was that the specialised preparation equipment could be brought directly to the work location.
The piping could therefore be prepared and assembled in situ, without removing sections for off-site fabrication or obtaining hot-work authorisations.
Pipes were cut, deburred and mechanically flared directly within the thruster space using compact electro-hydraulic flaring equipment.
Portable high-torque grooving tools created the required external profiles on larger-diameter return piping without heat input or alteration of the pipe’s structural metallurgy.
Each PYPLOK® fitting was pressed using specialised hydraulic tooling and subsequently checked with a Go/No-Go inspection gauge, providing immediate verification of the connection.
The completed installation demonstrated the practical advantages of replacing welded hydraulic connections with cold-formed mechanical technologies. The hydraulic integration was 100% hot-work-free, eliminating associated permits and safety controls, while flushing and commissioning timelines were reduced by more than 45% compared with welded configurations. The TMI 37° Flare Flange system provides a maximum rated pressure of 420 bar (6,000 PSI), and hydrostatic testing recorded zero pressure drops or weeping across the mechanical connections..
The project demonstrated that high-performance marine hydraulic piping does not necessarily require conventional welded construction.
By combining 37° Flare Flanges, Retain Ring Flanges and PYPLOK® Permanent Press Fittings, the installation eliminated hot work while addressing three critical requirements of marine hydraulic systems:
The Mubarak Marine project demonstrates how non-welded piping technologies can transform hydraulic system installation in demanding marine environments.
By removing hot work, reducing contamination risks and accelerating commissioning, the approach provides a practical alternative for marine propulsion systems, vessel retrofits and new-build hydraulic installations.
20 km Fire Suppression Piping Deployment in Less Than 8 Weeks
20 km Fire Suppression Piping Deployment in Less Than 8 Weeks
Steel Plant Shutdown reduction by 60 Hrs
Steel Plant Shutdown reduction by 60 Hrs
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