CASE STUDY: 8000" of 8" Pipe R.I.K Line Replacement

Comparison of Welding Methods: SWR vs. Conventional (Hand Welding)

This case study examines the efficiency and cost-effectiveness of using spool welding robots (SWR) versus hand welders for a project involving 8,000 inches of 8-inch pipe standard schedule. The study evaluates productivity, safety, schedule, cost savings, and return on investment (ROI). Additionally, a comparison is made between the number of hand welders required to match the productivity of SWR.

Trades are the backbone of our infrastructure and will continue to play a crucial role in our industry.

Firstly, the demand for skilled trade professionals is expected to rise steadily. As our society evolves and new technologies emerge, there will be an increasing need for skilled workers. The decline in the number of tradespeople in the industry can be attributed to several factors.

? Perception and societal pressure.

? Lack of promotion and awareness.

? Skills gap and the aging workforce.

? Technological advancements.

? Physical demands and work conditions.

These trades are the backbone of our infrastructure and will continue to play a crucial role in our daily lives.

Moreover, with the ongoing shift towards sustainability and green technologies, there will be a growing demand for tradespeople specializing in renewable energy installations, energy-efficient construction, and eco-friendly practices. Another significant trend in the trade industry is the integration of technology. Advancements in automation, robotics, and artificial intelligence are reshaping various trades, increasing efficiency and productivity. The trade industry holds immense potential for growth and innovation. Skilled trade professionals will continue to be in demand.

Introduction.

In the construction industry, welding is crucial in joining pipes for various applications. Choosing between spool welding robots or manual hand welding can significantly impact project timelines, safety, and cost. This case study analyzes these factors in a scenario involving 8,000 inches of 8-inch pipe standard schedule.

Methods.

The project used two different welding methods: SWR (spool welding robots) and hand welding. The productivity of each process was measured in terms of factored diameter inches (FDI) completed per day. For hand welding, the average productivity was 85 FDI per day, while SWR achieved an average of 400 FDI per day. The study considered an 8-hour workday for both methods.

RESULTS 7 Analysis:

Productivity:

Considering the project's total length of 8,000 inches, the number of days required to complete the welding is calculated for each method:

- Hand Welding:

Total FDI required = 8,000 inches

FDI completed per day = 85 inches (per welder)

Number of welders needed = 8,000 / 85 = 94.12 (round up to 95)

Number of days required = 95 / (number of welders)

- SWR:

Total FDI required = 8,000 inches

FDI completed per day = 400 inches

Number of days required = 8,000 / 400 = 20

Comparison:

4.75 by hand welders needed to produce the same as 1 SWR

Cost savings:

Considering the wage rate for hand welders and the operational cost of SWR, the cost savings can be calculated:

- Hand Welding:

Total labor cost = (Number of welders) x (wage rate per day) x (number of days required)

- SWR:

Total operational cost = (SWR cost per day) x (number of days required)

The cost savings can be calculated as the difference between the total labor and operational costs.

Safety:

Welding operations involve inherent risks, such as exposure to hazardous fumes and potential accidents. SWR reduces workers' exposure to these hazards as it is an automated process. Hand welding, on the other hand, requires welders to work close to the welding area and its associated dangers.

Condensed Schedule:

SWR offers a significant advantage in terms of a condensed schedule. We are completing the project in 20 days using SWR results in a shorter overall construction timeline than hand welding, which may require more time.

Continuous Improvement of Processes

The project highlighted the importance of continuous process improvement. Leveraging the experience gained from this project, ONSITE3D will review and refine its procedures and workflows. This includes enhancing scanning techniques, optimizing fabrication processes, and further streamlining installation procedures. By embracing a culture of continuous improvement, future projects can benefit from increased efficiency, productivity, and overall project success. Spool Welding Robot Advantages

• 3-5x improvement?in carbon steel pipe welding productivity and up to?12x?on stainless steel pipes
• Less than 1%?repair rates
• Accountability and Traceability?for your QA/AC through our Welding Vision System
• Smallest footprint?in the industry

Client Satisfaction and Stakeholder Engagement

The positive feedback and recognition received during the project emphasized the importance of client satisfaction and stakeholder engagement. ONSITE3D will continue to prioritize open and transparent communication with clients, regularly seeking feedback and engaging stakeholders at various project stages. By fostering strong relationships and ensuring client satisfaction, future projects will benefit from enhanced collaboration and a shared sense of success.

**By incorporating these lessons learned into future projects, ONSITE3D aims to enhance project execution further, mitigate risks, and deliver even greater value. The continuous pursuit of improvement and applying these lessons will contribute to the ongoing success of projects**

CONCLUSION

The completion of the project has marked a significant milestone for comparison. The project demonstrated the successful application of advanced workflows and technologies. Based on the comparison between SWR and hand welding methods for welding 8,000 inches of 8-inch pipe standard schedule, it is evident that SWR offers significant advantages in terms of productivity, safety, condensed schedule, and potential cost savings. Implementing SWR in this scenario resulted in a shorter completion timeline, reduced safety risks, and potential cost savings through decreased labour requirements. Calculating the ROI will provide a comprehensive understanding of the long-term financial benefits of adopting SWR technology.

The project also validated ONSITE3D's industry-leading approach to leveraging modern technology and skilled labor to execute projects with enhanced precision, safety, and efficiency. The project featured no re-work (shop or field), and no area welds were required.

ONSITE3D remains committed to delivering innovative solutions, embracing new technologies, and continuously improving its processes to meet the evolving needs of our partners.

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About ONSITE3D:

ONSITE3D is an Indigenous-owned VDC (virtual design and construction) company that offers a comprehensive range of services to the industrial and construction sectors. Our innovative front-end planning and design process leverages advanced technology and highly skilled labour to optimize project efficiency, minimize waste, and reduce the risk of cost and schedule overruns.

Our state-of-the-art manufacturing facility uses automated welding to prefabricate components, ensuring precise and consistent quality. And our experienced construction and maintenance crews provide expert support every step of the way, from the field to final commissioning.

?From start to finish, ONSITE3D is your trusted partner for turn-key VDC solutions that deliver exceptional results. https://www.onsite3d.ca