Fit Up

Client Requirements

The welding of pipelines is a precise art. Pipes normally have geometrical defects or fit together poorly, which often leads to costly rework and delays to tight production schedules. Counterboring the pipes can solve pipe fit-up issues, but this may not be viable due to cost or pipe wall thickness limitations. So how can fabrication specialists ensure that pipes delivered into the bead stall will fit together within the requirements for welding?

OMS’ Smart-Fit software uses pipe measurement data to predict and control fit-up, before the pipes are brought into the bead stall for welding. This prevents production hiccups due to poor fit-up and manages the assembly of problem pipes to maximise welding productivity.

Measure, Mark and Fit-Up

Pipes are pre-measured and data is made available to a Smart-Fit station.  This comprises a laptop located prior to the firing line. Each pipe in turn is identified and logged into the software, which analyses the fit-up, enabling the user to mark the best rotational position on each pipe end. In the bead stall, these marks are aligned to immediately achieve the best rotational position so that misalignment is minimised. Any problem pipes that won’t fit at a specified HiLo are also indicated and can be re-sequenced or removed. Production delays due to mismatched pipes are therefore avoided.

Experience shows that with typical flowline HiLo limits and using typical seamless line pipe that has not been counterbored, fit-up issues can occur every 10 to 20 pipes, though this will vary depending on the project. With Smart-Fit, a much higher proportion of pipes will fit when offered up at the optimal rotation. Smart-Fit enables this to be achieved in the bead stall without trial and error.

Proven Solutions for Any Pipeline Project

OMS provides a suite of measurement and Smart-Fit technologies to solve fit-up issues on any pipeline project, onshore or offshore. For cost-conscious land-based projects or for large UOE pipes, OMS offers the most cost-effective measurement solution using its Manual PipeChecker tool.

For the highest productivity, ‘gold standard’ measurement accuracy, OMS offers its Automatic PipeChecker service. Options for Smart-Fit stations include ‘Visualisation’, which gives the user an on-screen view of the simulated fit-up, or the ‘Sequencer’ software, which gives the user a model of the ready rack and allows re-sequencing at a click, while presenting a table of fit-up data with any problems highlighted. Marking the rotation can be laser- or tape-based.

Tailor-made Solutions

Elements of the Smart-Fit solution can be deployed in different ways to suit the practicalities of different production processes, both onshore and offshore. OMS can advise clients on the most efficient procedures for their production scenario.

Deploying the System

When you need to deliver a pipeline welding project against challenging logistics, Smart-Fit can minimise fit-up risk. OMS can measure a sample of pipes and quantify likely problems. Issues can be considered upfront and OMS can tailor a solution using proven technology.