Pipe spools are the pre-build parts of a piping system. Pipes, flanges, and fittings are called pipe spools and they are produced before they are used in the piping system. Pipe spools are pre-shaped to make easier assemble using hoists, gauges and other tools for joining the parts. Pipe spools unite long pipes with flanges from the end of the long pipes so they can be bolted with each other with matching flanges. These connections are embedded inside concrete walls before the pouring of concrete. This system must be aligned properly before concrete pouring because it needs to withstand the weight and force of the structure.
Figure 1: Pipeline spools
They generally easily corrode because of the elements they exposure; water and natural electrolytes. Acceptable protective monitoring must be done when applying pipe spool systems. Pipe spool fabrication is very important because the construction of the ship and other marine industries require intensive piping. Pipe spools create great advantages because they reduce the limitations of space on site. With this advantage, all of the pipeline using industries has a great opportunity to increase their pipeline system efficiency and decrease their need for workforce and time.
Pipe spool systems are mostly used in power plants and petroleum refineries which requiring intensive piping. These systems include carriage and transport of fluid and gas and these transportation systems need lots of connection parts. In these systems, there is no place for mistakes. Assembly and fabrication of pipelines must be done correctly. This piping application has two main stages;
1.Pipe Spool Production
Pipe spools are produced by the usage of raw pipes and pipe fittings. The cutting process of the raw pipes is done with prespecified sizes that are suitable for the pipe fittings and other components.
There are two main parts of pipe spooling process:
1.Roll correction and welding
2. Durable position fitting and welding
Pre-Fabrication of Pipe Spools
Roll correction and welding process are fitting of the main pipe by rolling machine and the welder does not need to change his situation, and also the position of fitting and welding occur when more than one branch of the long pipe overcome the clearance limit. To create a more efficient piping system and save time, pipe spool pre-fabrication is used. Because if the system did not produce preliminary, the welding of the system will take much more time and the welder has to move over the main pipe to accomplish fitting or welding.
Why pipe spools are pre-fabricated?
Pipe spools are pre-fabricated to reduce field installation costs and provide higher quality in the products. They are generally flanged to obtain the connection to other spools. The spool fabrication is normally performed by special companies having the required infrastructure. These specialist fabricators produce the system under the specified set of quality and accuracy to obtain proper fit at the site and to maintain the necessary technical properties defined by the client.
Mainly used pipeline systems are generally;
For the supply of water and flammable gases, steel pipes are the most useful pipes. They are used in many homes and businesses to transfer natural gas or propane fuel. They also used for fire sprinkler systems due to their high heat resistance. The durability of steel is one of the best advantages of the pipeline systems. It is strong and it can withstand the pressures, temperatures, heavy shocks, and vibrations. It also has unique flexibility which provides an easy extension.
Copper pipes are mostly used for the transportation of hot and cold water. There are mainly two types of copper pipes, soft and rigid copper. Copper pipes joined using flare connection, compression connection, or solder. It is expensive but offers a high level of corrosion resistance.
It is used due to its low cost, resistance to corrosion and its ductility. They are more desirable than steel for the conveyance of flammable solvents because of none spark formation. Aluminum pipes can be connected by the flare of compression fittings.
Tempered glass pipes are used for specialized applications, such as corrosive liquids, medical or laboratory wastes, or pharmaceutical manufacturing. Connections are generally made using a specialized gasket or O-ring fittings.
PRE-FABRICATION ADVANTAGES (REDUCING COST IN PRE-FABRICATION, INSPECTION, AND TESTING)
- In controlled environments, the quality of the work is easier to manage and maintain.
- Specified tolerances avoid rework at the site because of high accuracy.
- Fabrication is weather independent, so it minimizes the production delays.
- The pre-fabrication process is the best advantage because it provides less workforce for the fabrication of spools on site.
- Mass production manufacturing results in lower manufacturing costs in comparison with site fabrication.
- Lesser fabrication and assembly time needed for pre-fabricated spools, with this way, extra time and cost wastage is avoided.
- Pre-fabricated spools want little investments in production and testing equipment by the users. For better and efficient performances, Radiography, PMI, MPI, Ultrasonic tests, Hydro tests, etc. can be used.
- To obtain a lesser probability of rework at the site, better control of welding parameters must be done in the controlled environments.
- Power availability is not necessary.
- Unnecessary time delays are avoided.
THE MAIN DISADVANTAGE OF MAKING PIPE SPOOLS
Making pipe spools has wonderful benefits but the main disadvantage is the not fitting on site. This problem causes terrible results. One small mistake in the pre-production of pipe spools causes a non-fitting system in the working environment and creates a huge problem. When this problem occurs, pressure tests and x-rays of the welds must be checked again and re-welding should be needed.
High-Quality Engineering & Procurement
With our over 15 years of experience in the piping industry; YENA Engineering offers Piping systems solutions from design, engineering, prefabrication to transport to site as per ASME and EN. We supply pipe spools as carbon steel, alloy steel and stainless steel for Power, Oil&Gas and Chemical Industries.
For more information, please check out https://yenaengineering.nl/pipe-spools-and-skid-units/
or feel free to contact us https://yenaengineering.nl/contact/