Project Overview
Between June and August 2025, our Marine Department completed a critical replacement project for a marine infrastructure client. Project Manager David Redpath led the effort to remove and replace carbon steel manifolds with copper-nickel (CuNi 9010) alternatives. The project aimed to improve corrosion resistance and extend the system’s lifespan in a harsh marine environment.
Objectives
The main goal was to replace the existing 4” (100NB) carbon steel manifolds with new ones made from CuNi 9010 alloy. This upgrade was essential to improve durability and performance in corrosive conditions.
Project Details
The team began by dismantling and removing the original carbon steel pipework. Next, they created a precise template to ensure accurate replication. Using this template, they fabricated new CuNi 90/10 manifolds. Key steps included cutting and cleaning the pipes and fittings, tack welding with temperature monitoring, and purging to protect weld integrity. They used TIG welding to ensure high-quality joints.
The team faced several challenges. For example, they had to manage material shrinkage during welding and align multiple fittings with precision. Placing a branch on a 90° elbow also required extra care. To overcome these issues, they fabricated the manifolds in smaller sections, applied strict cooling protocols, and performed continuous alignment checks. Additionally, they purged weld areas with inert gas to maintain quality.
Despite the complexity, the team delivered the project on time. They met all milestones and successfully replaced the carbon steel manifolds. As a result, the system now offers improved durability and corrosion resistance.
