1. Pipe Shop Consulting Planning and Execution of an Automated Pipe Shop
with full Software Integration

2. Observation Analysis Solution Execution
Impressions of the pipe shop and work processes, data collection
Identification of problems and requirements, data evaluation
Creation of a customized workshop concept, machines, layout, software
Commissioning of design, software development, machine manufacture and assembly

3. Visit to the pipe shop
Discussion with involved personnel
How are the drawings / geometries created?
How are the workers and the workflow organized?
What materials and diameters are used?
How does the material get from storage to the machines?
What machines and techniques are used?

4. What is the current output and the projected output?
What problems exist in the workshop and on the administrative side?
What capacities exist at the moment and what are required?
What machines / techniques need to be used?
How do current methods need to be adjusted?
What fabrication control system is used?
What budget is available for solutions?

5. Step 1 Step 2 Step 3 Step 4 Step 5
Optimized workshop layout (2D and video)
Machine recommendations
Streamlined and coordinated flow of material
Detailed outline of cost and benefits
Control of workshop and fabrication processes

6. Optimized workshop layout (2D and video)
Optimal usage of available floor space
Automated transport of pipes wherever feasible
Reduction of manual transport to a minimum

7. Machine recommendations
Selection of the most suitable machines
Integration of machines into the transport system automation wherever possible
Customization / adjustment of machines where necessary

8. Streamlined and coordinated flow of material
No idle times at the machines
No double-handling or backtracking
Significant reduction of cycle times

9. Initial investment of 4,800,000 €
Outline of cost and benefits: Example
Initial investment of 4,800,000 €
Year
Itemized list of machine and software costs
Savings calculation (direct and indirect savings)
ROI calculation based on average number of projects per year

10. Control of workshop and fabrication processes
Real-time feedback from all processing stations
Full awareness of each spool’s fabrication status
Detailed documentation for every piece, worker or machine (joint history, performance history)

11. Features and advantages
Full software integration
Streamlined data flow
Data import directly from 3D model
Automatic generation of isometric drawings
Spool splitting according to internal parameters
Consistent and reliable spool generation
Interfaces to connected machines
Automatic generation of CNC data
Interfaces to scheduling and warehouse systems
Balanced work packages making optimal use of capacities
Integration of all work processes into the system
Real-time updates and complete overview of the fabrication status of each spool

12. For optimal pipe shop control
Available reports and documentation
For optimal pipe shop control
Worksheets
Welding documentation
Flushing reports
Part lists
Surface treatment documentation
Spool weight calculations
Bill of Material
Iso drawings for assembly
Dia-Inch: Shop weld
Cutting lists (optimized)
Testing documentation
Dia-Inch: Field weld
Bending lists
Insulation reports
Dia-Inch: Installation weld

13. Commissioning of design and technical drawings
Purchase of machines
Manufacture of storage / transport system components
Assembly of machines and storage / transport system
Installation of an integrated software framework, incl. operator training

14. Processes that used to require manual work now happen automatically
Drawings are automatically split into spools using consistent logic (from the 3D system used in construction or customizable parameters)
Worksheets, Bills of Material and other documentation is created automatically
Work packages are created automatically, based on capacitices, scheduling, material
All CNC data is automatically generated, operators only need to confirm and start the machine
The fabrication status for every spool is automatically updated and accessible

15. Task
Investment
Consultation / Layout / Installation supervision
€ 150,000
Transport / Storage system (incl. automation)
€ 1,500,000
Bending machine (1“ - 6“)
€ 900,000
Plasma cutting machine
€ 475,000
Flange welding machine (TIG) (elbows, reducers, tees, neck-weld flanges, pipe-pipe)
€ 800,000
Flange welding machine (MAG) (slip-on flanges, sleeve-welding)
€ 750,000
High-power bandsaw
€ 75,000
Software suite
Total
€ 4,800,000
Example for investment involved in optimizing a pipe shop projected to fabricate 10 projects p.a.:
The customer wants to build a new carbon steel workshop for the fabrication of spools for offshore workboats.

16. Administrative side (based on 10 projects p.a.)
Tasks can be performed in significantly less time, allowing fewer engineers to perform the job
Constant status updates facilitate change management
All reports can be created automatically
Empirical data from past projects makes the planning and budgeting for future projects faster and easier
Data from warehousing and scheduling is considered for fabrication planning, for improved capacity utilization

17. Workshop side (based on 10 projects p.a.)
It will be possible to reallocate approx. half the current workshop staff to other jobs (assembly, hull welding, ec.)
Due to bending machines / flame-cutting, fewer t-branches, reducers and elbows will be needed
Automatic welding machines for fittings (flanges, reducers, elbows, t-branches)
Consistent fabrication quality facilitates testing and quality control
Increased workplace safety, reducing risk of accidents

18. Example for manual fabrication I
Task
Time
Total Time
Pipe transport
1 x 20 min
20 min
Cutting
3 x 9 min
27 min
Elbow assembly
2 x 22 min
44 min
Elbow grinding
4 x 8 min
32 min
Elbow welding
4 x 22 min
88 min
Cut elbow 57°
2 x 10 min
Flange assembly
2 x 9 min
18 min
Flange welding
2 x 20 min
40 min
Flange grinding
2 x 8 min
16 min
Total
305 min

19. Example for automated fabrication I
Task
Time
Total Time
Pipe transport
1 x 3 min
3 min
Cutting
1 x 4 min
4 min
Bending
2 x 5 min
10 min
Flange welding
1 x 7 min
7 min
Flange grinding
2 x 8 min
16 min
Total
40 min
Estimated savings: 265 minutes (approx. 86 %)

20. Example for manual fabrication II
Task
Time
Total Time
Pipe transport
1 x 20 min
20 min
Cutting 6“
4 x 15 min
60 min
Cutting 4“
1 x 9 min
9 min
Elbow assembly
3 x 28 min
84 min
Elbow grinding
6 x 14 min
Elbow welding
6 x 40 min
240 min
Cut elbow 31° / 59°
2 x 15 min
30 min
Flange assembly
12 / 9 min
21 min
Flange welding
30 / 20 min
50 min
Flange grinding
14 / 8 min
22 min
Assembly & welding reducer
117 min
Total
737 min

21. Example for automated fabrication II
Task
Time
Total Time
Pipe transport
1 x 3 min
3 min
Cutting 6“
1 x 5 min
5 min
Cutting 4“
1 x 4 min
4 min
Bending
5 / 3 / 2 min
10 min
Flange welding 6“
1 x 18 min
18 min
Flange welding 4“
1 x 7 min
7 min
Flange grinding
14 / 8 min
22 min
Assembly & welding reducer
95 min
Total
164 min
Estimated savings: 537 minutes (approx. 73 %)

22. Example for manual fabrication III
Task
Time
Total Time
Pipe transport
1 x 20 min
20 min
Cutting
1 x 31 min
31 min
Flange assembly
2 x 20 min
40 min
Flange welding (semi-auto)
2 x 40 min
80 min
Total
171 min

23. Example for automated fabrication II
Task
Time
Total Time
Pipe transport
1 x 3 min
3 min
Cutting
1 x 12 min
12 min
Flange welding
1 x 43 min
43 min
Total
59 min
Estimated savings: 112 minutes (approx. 66 %)

24. Manual vs. automatic work preparation / fabrication
Average 5 spools / drawing
Average 2000 drawings / project
10 projects per year
Drawings are split into logical spools, spool data is documented, balanced work packages are created based on capacities and schedule
Task
1 Drawing manual
1 Drawing auto
Difference
2000 Drawings
Man-Hour Cost
Savings per Project
10 Projects
Splitting
5 min
0.5 min
4.5 min
150 h
25 €
3,750 €
37,500 €
Balancing
20 min
19.5 min
650 h
16,250 €
162,500 €
Documentation (incl. printing)
30 min
3 min
27 min
900 h
22,500 €
225,000 €
Total
55 min
4 min
51 min
1700 h
42,500 €
425,000 €
Actual savings may differ, based on project details

25. Administrative advantages
Spool splitting is consistent and logical
All bills of material and order forms are created automatically
All reports are generated automatically
All CNC data is generated and transferred to the machines automatically
All work packages are created automatically, making the best use of machine capacities, and reducing scrap and retooling times

26. Calculation of savings due to bending machines
Example: Bending (based on 10 projects per year)
Calculation of savings due to bending machines
Elbows
60,000
Bends at 60 % bending
36,000
Average cost / elbow
10 €
Savings (parts)
360,000 €
Saved welds
72,000
Welding cost (avg. 2 h / elbow)
15 € / h
Savings (welding)
1,080,000 €
Total savings
1,440,000 €

27. Example: Welding / Plasma cutting (based on 10 projects per year)
Calculation of cutting and welding costs without welding and plasma cutting machines
Reducers
3,125
Tees
3,500
Total number of welds (per reducer: 2 / per tee: 3)
16,750
Total welding time (avg. 2h) (incl. cutting, grinding, fitting)
33,500 h
Total cost (without automation)
502,500 €

28. Calculation of savings due to welding and plasma cutting machines
Example: Welding / Plasma cutting (based on 10 projects per year)
Calculation of savings due to welding and plasma cutting machines
50 % less tees required (due to plasma cutting)
-7,000 h (-3,500 welds)
40 % less welding time per reducer
-5,000 h
30 % less welding time per tee
-3,150 h
Total reduction in welding time
15,150 h
Total savings (with automation)
227,250 €

29. Total savings Task Savings per project Savings 10 projects
Data preparation
42,500 €
425,000 €
Bending
144,000 €
1,440,000 €
Welding (reducers, tees)
22,725 €
227,250 €
Traceability during all worksteps
Indirect savings
Optimized use of machine capacities
Constant output quality
Automatic welding seam tracking
Automatic batch tracking
Total savings
2,092,250 €

30. Initial investment of 4,800,000 €
Based on 10 projects per year: Example
Initial investment of 4,800,000 €
Year

31. Initial investment of 4,800,000 €
Based on 15 projects per year: Example
Initial investment of 4,800,000 €
Year

32. Initial investment of 4,800,000 €
Based on 20 projects per year: Example
Initial investment of 4,800,000 €
Year

33. Contact Details 3R solutions Kleistrasse 39 59073 Hamm Germany
Phone:
Fax:
Web: