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Robotic spool welding is a process that is revolutionizing the energy industry by providing a more efficient, cost-effective, and consistent method of welding pipes and other structures. This technology involves the use of specialized robotic arms and welding equipment to accurately and consistently prefabricate sections of pipes and fittings. ONSITE3D has chosen to lead the trend of innovation, and for the past several years has been operating two robotic spool welders in our Advanced Fabrication Facility in Grande Prairie, Alberta. These machines work on pipes with diameters between 2 and 60 inches. They also work with an array of materials including carbon steel and stainless steel, as well as Monel and Inconel Nickel alloys, meaning that they can be used for a wide variety of jobs.
One of the key advantages of robotic spool welding is the improved quality of the finished product. Even when performed by the most experienced and skilled welding professional, the manual welding process can be prone to human error and inconsistency. This leads to weld defects and the need for costly rework. On the other hand, robotic spool welding allows for consistent and repeatable high-quality welds. Quality control is of incredible importance for ONSITE3D, and so onboard video automatically records and analyses each weld made to ensure that our top-tier quality standards are met. These analyses depict the exact parameters of each weld, from root penetration to heat treatment. Instead of requiring a third-party inspection for each weld to ensure outstanding quality, it can be done during fabrication.
Another benefit of robotic spool welding is the increased speed of production. By automating the welding process, manufacturers can significantly increase the speed at which spools are welded, allowing for faster turnaround times and higher overall productivity. Depending on the project and material, robotic welding can result in between 3X to 12X faster production. This is especially useful for projects operating under quick turnaround times as is often the case in the energy industry.
In addition to its benefits in quality, consistency, and speed, robotic spool welding also offers several cost-saving advantages. One of the primary ways in which it can lower production costs is through its ability to reduce reliance on skilled labour. In the current labour shortage, highly trained welders often come at a premium cost. With robotic spool welding, the process is automated and requires less skilled labour, making it more cost-effective in the long run. As previously mentioned, the precision of machine welding also greatly lowers the need for rework. This can significantly reduce the overall cost and sustainability impact of a project on its own. Rework increases the cost of a project both in materials and labour, but also in lost profits from time delays.
The importance of leading technology implementation is not lost on company president Wade Eno. In an interview shortly after implementing the welders he stated that it is “…inevitable that in 10 years all welding can be done with robotics and we wanted to be an early adopter”. The benefits in terms of quality, consistency, speed, lower production costs, and lower reliance on skilled labour make it an attractive option for energy companies looking to improve the efficiency and effectiveness of their turnaround projects. With its ability to operate 24/7 and its high level of precision and consistency, robotic spool welding is set to play an increasingly key role in the future of the energy industry.
To learn more about the prefabricated projects using robotics, reach out to us at hello@onsited3d or visit our website www.onsite3d.ca/fabrication
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