TPT July 2024

TUBE SOFTWARE & CONTROL SYSTEMS

Smart fabrication: streamlining pipe spool pre-fabrication

Real-time monitoring: machines on the production line automatically report to 3R’s central database upon completing a production step. Operators can also confirm completion, reporting the status to the central database. This allows for real-time tracking of all production steps, identification and correction of potential bottlenecks and comprehensive documentation for each spool or joint. Mechanised and automated fabrication: despite the high mix/low volume nature of the oil & gas industry, where many different spool shapes are fabricated only a few times, automation is still possible for individual aspects of fabrication, such as cutting, edge preparation and welding of fittings to straight pipes. This automation results in significant time savings, greater accuracy and reduced risk of errors. Quality control ensures that all components meet the design specifications and industry standards. Advanced techniques like 3D laser scanning and automated inspection systems detect deviations with high precision, minimising errors and rework. Feedback loop: smart fabrication streamlines the feedback loop between the workshop and the design team. If a drawing is revised, the design team can check whether fabrication has started. If not, work orders are updated immediately; otherwise, the software alerts operators to stop working on an obsolete design. This agile approach reduces delays and costs associated with rework. Smart fabrication offers numerous benefits:

PIPE SPOOL fabrication is crucial across various industries, including petrochemicals, power generation and shipbuilding. Traditionally, this process has heavily depended on manual inputs and human expertise. However, with technological advancements, the fabrication of pipe spools has evolved to embrace smarter, automated solutions. This evolution introduces the concept of smart fabrication, effectively bridging the gap between engineering designs and workshop execution. Smart fabrication integrates advanced technologies and intelligent systems into the fabrication process. These technologies include advanced software solutions, such as those developed by 3R solutions, which streamline planning, monitoring and documenting workshop activities, as well as automated handling systems and sophisticated processing machines. When applied to pipe spool fabrication, this results in a seamless, more efficient and error-free production process. One of the primary challenges in pipe spool fabrication has been the disconnect between the engineering design phase and actual workshop production. Traditionally, engineers would create designs, convert 3D models into isometric drawings and pass these onto the workshop. Skilled workers would then interpret the drawings and manually fabricate the spools, often leading to errors, misinterpretations and inefficiencies. Smart fabrication aims to minimise, if not eliminate, this disconnect through: Digital integration: the 3R software enables engineers to automatically generate isometric drawings, perform weld mapping and split spools based on customer-specific parameters. The required data for CNC machines is generated and transferred through direct interfaces, eliminating the need for manual input and ensuring perfect alignment between the fabricated product and the design. Material optimisation reduces waste and costs by calculating precise material needs. Integrating with warehouse and ERP systems enhances this process by providing real-time inventory tracking and automated procurement.

Efficiency: automated processes lead to quicker production cycles, reducing what once took days to mere hours. Accuracy: digital integration and advanced fabrication methods significantly reduce the margin for error, ensuring products adhere closely to specifications, reducing rework and enhancing client satisfaction. Safety: automation reduces the risk of workplace injuries. Cost savings: while the initial investment in smart fabrication technologies may be substantial, the long-term savings in reduced need for skilled labour, less wastage, quicker turnaround times and fewer errors generally justify the expense. As industries worldwide strive to modernise their processes, particularly due to the growing scarcity of qualified workers and operators, pipe spool fabrication is no exception. Smart fabrication, with its combination of advanced software solutions, automated handling systems and sophisticated CNC machines, paves the way for more efficient, accurate and cost-effective production processes. By effectively bridging the gap between engineering and the workshop, smart fabrication not only streamlines operations but also sets a new standard for future advancements in the field.

3R solutions www.3r.de

Smart fabrication, with its combination of advanced software solutions, automated handling systems and sophisticated CNC machines, paves the way for more efficient, accurate and cost-effective production processes

27

www.read-tpt.com

JULY 2024