Enhance the Value of Pre-fabricated Piping with Source Inspection

Understanding the cost differences between welding pipe in an off-site shop versus in the field, including labor, equipment, and rework, is essential for project managers to make informed decisions that optimize project budgets and quality outcomes.

Welding in a controlled shop environment in an upright position on a rotary table produces a higher-quality weld because you're not fighting the wind, weather, or tight spaces. Owner-operators often increase the percentage of non-destructive testing for field welds due to the higher likelihood of error. Field radiography is also more expensive, and the more welds are rejected, the more welds must be inspected, which can significantly increase costs, sometimes doubling inspection expenses. Scaffolding, heat treatment, and hardness testing all cost more in the field due to remote locations, limited infrastructure, and increased hazards.

Yet, some believe field-fabricating pipe is more efficient. Last year, a project found that at least 70% of prefabricated spools failed to meet specifications, resulting in costly rework and delays. These non-conformances were due to poor quality control at the fabrication shop, not to off-site construction itself. Implementing Source Inspection programs and hiring third-party inspectors can ensure spools meet project specifications, preventing costly non-conformances before acceptance.

Designing piping systems to be 'spooled' and planning field weld locations may take more time during detailed design. However, this upfront effort is crucial for smoother project execution, reducing delays and rework, and building confidence in project delivery.

The industry has recognized the value of modularization and skid-mounted equipment. Moving pipe welding to the shop can save you 2-5 times the fabrication costs, especially with larger pipe diameters, thicker walls, or exotic materials, empowering project managers to optimize project budgets and efficiency.

Don't let off-site errors disrupt your installation workflow and prolong your outage. Turnaround EPC provides Source Inspections, which are crucial to delivering Shutdowns, Turnarounds, and Outages on time and within budget.