Taloja, Navi Mumbai
2018
Owens Corning was constructing a state-of-the-art 80,000-ton glass melter facility at its existing plant in Taloja, Mumbai. With a tight project schedule and a shortage of skilled welders, Owens Corning needed a piping installation method that could accelerate construction while reducing dependence on conventional welding manpower.
Having previously used PYPLOK® mechanical pipe joining technology at its facilities in the USA, Owens Corning selected the same technology for the Mumbai project. Cenergy Offshore was engaged to supply approximately 2,000 PYPLOK® fittings, along with the required installation tools and trained technicians, for piping in the binder area and utility lines.
The new glass melter facility had to be completed within a demanding schedule, while the availability of suitably skilled welders was limited.
Using conventional welded pipe connections would have required significant welding manpower and associated activities, potentially affecting the project schedule.
The piping installation also covered a range of materials and sizes, requiring a joining solution that could be applied consistently across the facility.
The project therefore required a solution that could:
Reduce dependence on skilled welding manpower
Accelerate piping installation
Minimise hot-work requirements
Provide reliable mechanical pipe connections
Accommodate both stainless-steel and carbon-steel piping
Cover pipe sizes from 1/2-inch to 2-inch NPS
Cenergy Offshore supplied approximately 2,000 PYPLOK® fittings for the binder area and utility piping lines.
The PYPLOK® mechanical joining system provided an alternative to conventional welded connections, allowing the piping to be assembled using dedicated installation tooling rather than welding.
Cenergy Offshore also supplied the required PYPLOK® installation tools and trained technicians to support the customer during installation.
This combination of mechanical joining technology, specialised tooling and experienced installation personnel enabled Owens Corning to increase installation efficiency while addressing the shortage of skilled welders.
The PYPLOK® system was used across the binder area and utility piping lines.
The installation covered:
Cenergy Offshore technicians worked alongside the project team to install and crimp the PYPLOK® fittings using the appropriate tooling.
The mechanical installation process eliminated the need to weld each pipe connection, reducing hot-work activities and allowing the piping installation to progress without relying entirely on specialist welding manpower.
The main reason Owens Corning selected PYPLOK® was its ability to reduce installation time and manpower requirements.
Each mechanical connection could be completed using a controlled tooling process rather than requiring conventional welding, welding preparation and associated hot-work activities.
This was particularly valuable during the construction of the glass melter facility, where the project schedule was compressed and the availability of skilled welders was limited.
The technology therefore allowed the customer to continue progressing the piping installation while addressing one of the key constraints affecting the construction schedule.
Cenergy Offshore’s involvement extended beyond the supply of fittings.
The company provided:
The combination of equipment and technical expertise helped the customer implement the mechanical joining technology effectively across the project.
Cenergy Offshore supported Owens Corning in addressing two critical construction constraints at its Taloja glass melter project: limited availability of skilled welders and the need for faster piping installation.
Approximately 2,000 PYPLOK® fittings were supplied and installed across stainless-steel and carbon-steel binder and utility piping ranging from 1/2-inch to 2-inch NPS.
By replacing conventional welded connections with mechanical PYPLOK® fittings, the project reduced dependence on welding manpower and hot-work activities, helping the piping installation progress more efficiently within the demanding construction schedule.
The successful application also demonstrated how mechanical pipe joining technology can provide a practical solution when project timelines and skilled welding manpower are major constraints.
Piping installation for an 80,000-ton glass melter facility
Project location: Taloja, Mumbai
Approximately 2,000 PYPLOK® fittings
Binder area and utility piping
Stainless-steel and carbon-steel piping
Pipe sizes from 1/2-inch to 2-inch NPS
Mechanical pipe joining without conventional welding
Reduced dependence on skilled welders
Reduced hot-work requirements
Faster piping installation
PYPLOK® tools supplied by Cenergy Offshore
Trained Cenergy Offshore technicians provided for installation
Technology selected based on Owens Corning's previous experience with PYPLOK® in the USA
Solution implemented to address tight project timelines and shortage of skilled welders
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