techview Joe Ryan
Weld Monitoring Solutions Help Pipe Shops Improve
P
ipe fabrication shops are always looking for ways to boost productivity and effi ciency to differentiate them- selves—without negatively impacting the rigorous weld
quality requirements the shops must meet. In addition to these challenges, many pipe shops face
increasing pressure from clients to track and document weld quality and other factors based on customer specifi cations. As data monitoring becomes a growing customer expec- tation, there are technologies available that can help pipe shops track and measure productivity, quality and other data. Weld data monitoring systems that are designed specifi cally for pipe fabrication can help shops ensure they are meeting the codes and standards necessary for pipe welding applica- tions—as well as client expectations. Weld data monitoring solutions new to the market ad-
dress the unique needs of pipe fabricators and make track- ing key metrics easy and effi cient. These solutions allow individual joints to be documented by recording welding parameters and attaching those parameters to a contract, spool and joint being fabricated as it fl ows through a shop. This helps drive continuous improvement efforts without requiring the welding operator to spend nonproductive time inputting data.
Gathering welding parameter information for each individ- ual joint allows pipe shops to effi ciently track productivity and quality metrics that are crucial in pipe welding applications. Shops can easily see information on any out-of-parameter welds to help prevent defects or correct specifi c issues. This streamlined data collection and documentation
improves the quality control process for pipe shops—for total traceability of welding parameters and reportability to clients. One of the biggest benefi ts of these systems is the ability for pipe fabricators to monitor progress and production in real time, since the systems collect welding information as welds are completed. Previously, manual data collection meant a piece of paper had to travel with the spool joint through the shop and on through the process of weld testing. Information was recorded by hand on the paper along the way.
Marketing Segment Manager
Oil & Gas Processing Miller Electric Mfg. Co.
Now that the tracking process is electronic pipe shops can get instant visibility to factors such as arc-on time and in- stances when a weld fails to meet established thresholds for amps and volts. This improved, real-time insight is especially useful when change orders happen, since it makes knowing whether or not a specifi c part has been welded much easier and more effi cient to track.
The ability to track individual joints through the welding
process is also helpful when a customer wants a progress report, since a check of the system will show if a spool has been welded or not.
Some of these systems also can import and export jobs in a generic fi le format, which allows easy integration with the business software programs a shop may have. This gives us- ers fl exibility and more options for gathering additional data. Other benefi ts of using an electronic process is it reduces the chance for errors or problems and it reduces the time it takes to gather the information. When data is tracked and entered by hand it’s a time-con-
suming process that has the potential for errors due to typos or poor handwriting. When a paper system is used, the paper traveling with or following each joint on the production fl oor must be sent to the offi ce and entered into a computer data- base, which introduces the element of human error. Problems can also arise if the handwriting on the paper for each weld joint becomes smeared or damaged on the production fl oor. Using a system that collects data electronically directly
from the weld cell eliminates these issues. Technology advancements and the options now available in weld data monitoring are providing simple solutions that help pipe shops drive improvement.
Knowing what aspects within the welding operation actu- ally need to change to drive improvement is an important part of helping pipe shops reach their productivity, effi ciency and quality goals. Better information going into the system helps drive better business decisions—and better outcomes. Weld data monitoring solutions provide the ability to easily track performance and quality metrics so shops can imple- ment changes that result in improvements.
21 — Energy Manufacturing 2016
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