Piping Fabrication Services: All You Need to Know

Piping fabrication services involves crafting and assembling piping systems, crucial for industries like oil and gas, petrochemical, and pharmaceuticals. These sectors heavily rely on efficient pipework for fluid and gas transport, essential for operational success. Understanding the intricacies of piping fabrication is vital for ensuring safety, compliance, and operational efficiency in these industries.

This guide by Sheng Jian Engineering and Construction (SJEC) dives into the intricacies of piping fabrication. We discuss the process of piping fabrication, the required expertise, and the importance of good project management.

By sharing our expertise and best practices, we aim to equip you with a strong foundation in piping fabrication and assist you in making the best decisions for your project.

What is Piping Fabrication?

Piping fabrication encompasses a series of meticulously executed procedures including cutting, bevelling, and welding of pipes, all meticulously aligned with design specifications to form intricate piping systems.

This intricate process entails the precise manufacturing of individual pipe components such as elbows, tees, and flanges, which are then meticulously integrated to construct fully functional piping networks.

Primarily utilized for the construction of new piping infrastructure or the restoration of existing systems, these meticulously crafted networks serve as conduits for the transport of liquids, gases, and solids within diverse industrial facilities.

Here are a few common tools used in this process:

common-tools-used-in-piping-fabrication

Here are a few frequently used types of pipes:

types-of-pipes-in-piping-fabrication-infographics

The selection of pipe or piping material depends on several factors including the application, water quality, and budget. Additionally, specific considerations such as potential hazards (e.g., fire), corrosion resistance, and chemical compatibility, must be considered.

Steel pipes are widely favored for heating systems owing to their cost-effectiveness, robustness, and exceptional heat resistance. Conversely, cast iron pipes find prominence in sewer and stormwater systems, prized for their superior corrosion resistance.

Unsure which option suits your requirements best? Seek guidance from SJEC for bespoke solutions perfectly aligned with your needs.

Do you know there is a rising demand for eco-friendly and sustainable building solutions in today’s modern landscape? Get to know more in our article on structural steel fabrication now!

Types of Piping Fabrication

Piping fabrication is divided into two: shop fabrication and field fabrication. Depending on the project’s specific needs and requirements, you may opt for either one or both fabrication methods.

Here is a general comparison between the two types:

Aspect

Shop Fabrication

Field Fabrication

Location of AssemblyAt the in-house facility (fabricator’s facility or pipe fabrication shop).At the construction site/project facility.
Type of pipes/pipe fabricationsBut welded pipes, pipe bending, and modular items.Small bore pipes, threaded and socket welded pipes.
CostLower cost - on-site resources are not required.Higher cost - more expenses are required for labor, transportation, and equipment.
LogisticsLess logistical planning - fabrication is done in a single location.More logistical planning - materials and equipment need to be transported to the site.
Quality ControlBetter quality control - fabricators have control over the environment and conditions of the fabrication process.Less quality control - the fabricators have to adapt to the site environment.
Weather DisruptionNot affected - fabrication is done in an enclosed / indoor environment.Affected - must protect from the elements.

On-Site CustomizationNot available - all fabrications are done in the in-house facility.

However, shop fabrication can use tools such as 3D laser scanning / AutoCAD virtual blueprint to obtain accurate measurements.

Available - lowers the rework risk and associated costs of field verification (before shop fabrication).

SafetyMore safety measures - familiar and controlled environment.More challenges in implementing safety measures - subject to the site environment.

Piping Fabrication and Installation Procedures

Person drafting on a blueprint.

In this section, we’ll be going over the process of transforming piping blueprints into functional installations. There are two main procedures: piping fabrication and piping installation. 

Piping Fabrication Procedure 

Piping fabrication is an extensive and detailed process. There are various steps of preparation, assembly, and inspection to ensure the quality and integrity of the final product:

Step

Title

Details

1

Review and PlanningDuring this stage, pipe fabricators calculate various parameters based on the drawing specifications.
Here are a few aspects that must be considered:

  • Welding and tack welding procedures

  • Potential welding-related distortions

  • Tools needed for pipe and flange fitting (e.g., pipe supports, clamps)

  • Next, the fabricators create a basic model of the pipe spool according to the drawings. Pipe fabricators are also provided with information such as material take-off and the client’s fabrication specifications.

2

MarkingAccording to the drawing requirement, pipe materials are marked and verified.

3

TaggingPipe materials are tagged using paint or a stamp so that pipe heat numbers are displayed before cutting.

4

CuttingPipe cutting methods like gas cutting, grinding, flammable cutting, or plasma cutting are used based on the type of steel pipe:

  • Carbon steel - Gas cutting and grinding

  • Alloy steel - Flammable cutting or grinding

  • Stainless steel - Plasma cutting or grinding

5

End preparationBeveling and fit-up are done after an approved specification and WPS.

6

Pipe Welding Planning & WeldingPipe welding planning ensures that pipes are aligned during the welding piping process.

7

Pipe and Fitting WeldingPiping and fittings are supported and secured for a fit-up inspection. Upon passing the inspection, welders will weld the joints.

8

Marking detailsIdentifying signs of the piping system, such as inspection details and welding date, are marked near joints.

9

Heat treatmentsTreatments such as preheating and post-weld heat treatment are completed if required by the project.

10

InspectionsNon-destructive testing certifies that every fabrication process step is completed and meets the project standards and requirements.

If the piping passes, it is released for painting or construction. If it does not pass, it must be repaired and reinspected. Do note that piping that will be painted must be inspected again before being released for construction.

Piping Installation Procedure

Piping installation usually begins after the erection of civil supports and the installation of major equipment at the construction site. Here are the stages of piping insulation:

Step


Title

Details

1


Pipework ErectionProper planning and adherence to safety guidelines are a vital part of erecting pipework. Here are a few highlights:

  • Inspect tools, equipment, ropes, and pipes for safety and cleanliness.

  • Pre-fabricated spools should be identifiable and tagged.

  • Piping should be erected on designated supports.

  • Undue stress should be avoided on piping.

  • Pipe openings should be sealed.

  • Installation of piping on pipe racks should proceed from lower to higher elevations.

  • Large-bore piping should be installed before small-bore piping.

  • Piping joints should be properly aligned.

  • Pipe clearances from other pipes, equipment, and structures.

2

Installation of Piping Flanges, Valve, and equipment Flange ConnectionPipe flanges should be properly installed and prepared to achieve secure and efficient connections. Here are a few highlights:

  • Align the pipe flanges properly without applying excessive force.

  • Install components such as orifice flanges, spectacle blinds, and strainers correctly.

  • Follow a logical bolt-tightening sequence.

  • Check flange connections for misalignment and excessive gaps.

  • Keep flange covers on until both sides are ready for connection.

  • Take extra care when connecting flanges to equipment like pumps, turbines, and compressors.

  • Use blanks or spades to prevent internal pipe debris from entering equipment.

  • Before installing gaskets, ensure bolts move freely through bolt-holes and maintain a clear gap between flange faces.

3

Installation of pipe supportsHere are a few highlights:

  • Use relevant pipe support detail drawings for guidance.

  • Avoid introducing additional stress to fit the supports.

  • Install the pipe shoe at the center of the beam without any offset.

  • Lock parts where spring supports are required until hydro testing and insulation, following manufacturer guidelines.

  • Prevent sand ingress between stainless steel (SS) and PTFE plates, at parts where PTFE plates are used for friction reduction.

  • Arrange piping to facilitate pipe-supporting and plan for easy removal of equipment for inspection and servicing.

4

Pressure testingHydrostatic and pneumatic testing are performed to assess the integrity of the system. If leakage occurs, the parts are repaired and re-tested.

5

Insulation and PaintingPipes are painted and high-temperature lines are insulated.

6

Marking and IdentificationTo identify lines and their services, all pipes and fabricated fittings are stamped, tagged, or stenciled with letters and numbers.

7

Installation of Expansion JointsCritical piping systems require expansion joints.

8

Vents and DrainsVents and drains should be depicted in the isometric or general arrangement (GA) drawings.

If high-point vents and low-point drains are not included, they should be added based on:

  • Instructions from the engineer in charge.

  • Job standards.

  • Piping specifications.

9

Installation of Underground PipeBefore starting the installation, an assessment must be done to check that trench excavation adheres to the approved drawing.

Before backfilling - final measurements, tests, and surveys are done.

Precision and Skills in Piping Fabrication 

Person welding on metal inside lighted building.

The Role of Precision in Pipework

Piping systems must be precisely fabricated to ensure proper fit, alignment, and functionality, as even minor deviations from specifications can result in costly rework, inefficiencies, or safety hazards.

For instance, precision in pipe cutting helps to prevent leaks, ensure uninterrupted flow, ease future maintenance, and strengthen structural integrity. Overall, this leads to a longer lifespan and optimal performance for the piping system.

Achieving the required level of precision involves meticulous attention to detail, accurate measurements, and adherence to strict guidelines throughout the fabrication process.

At every stage, the pipework will be inspected and tested. Parts which do not pass will undergo repairs before proceeding to the next phase. This reduces the risk of defects and guarantees the pipework meets industry standards.

Building a Skilled and Experienced Team 

The success of piping fabrication projects hinges on the expertise and proficiency of the certified pipefitters and welders tasked with executing them.

These professionals are at the forefront of pipe fabrication, responsible for transforming raw materials into functional piping systems.

They possess a diverse range of capabilities and qualifications essential for the fabrication process, including:

Skill

Details

Blueprint ReadingPipefitters and welders must be proficient in reading and interpreting technical drawings, blueprints, schematics, and specifications to understand the layout and requirements of the piping system they are fabricating.
AutoCADPipefitters and welders must have a firm grasp of this software. AutoCAD assists in designing piping systems with accuracy, while ensuring compliance to requirements and offering valuable visualization prior to installation.
Pipe Cutting and ShapingSkillful manipulation of various cutting tools, such as saws, torches, and cutting machines, is necessary to accurately cut and shape pipes according to design specifications.
Pressure TestingPipefitters must be well-versed in pressure testing, allowing them to verify the integrity and safety of the piping systems through the detection of leaks and weaknesses.
Welding TechniquesProficiency in various welding techniques, including gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), and shielded metal arc welding (SMAW) enables welders to join pipes and fittings securely and efficiently while maintaining structural integrity.
Assembly and FittingPrecise assembly of piping components, including fittings, valves, and connectors, requires attention to detail and the ability to ensure proper alignment, tightness, and integrity of connections.
Quality ControlAdherence to quality control standards are important for identifying defects, ensuring dimensional accuracy, and verifying compliance with requirements throughout the fabrication process.
Safety ProtocolsComprehensive knowledge of safety protocols and practices (e.g., wearing personal protective equipment (PPE), following hot work procedures) is critical to maintaining a safe working environment and preventing accidents during fabrication activities.

At SJEC, our welders undergo rigorous qualification processes to ensure top-notch quality and safety standards. Equipped with advanced skills, they are adept at handling even the most complex challenges.

Watch this video highlighting our dedication to welding quality:

Importance of Proper Planning and Execution

1. Assurance of Quality

By meticulously planning every aspect of the project, including material selection, fabrication techniques, and installation procedures, potential quality issues can be identified and addressed early in the process.

For instance, the selection of either shop fabrication, field fabrication, or both methods, will determine the additional steps project teams need to perform to ensure standard pipework.

This proactive approach minimizes the risk of defects, errors, and rework, leading to a streamlined process and quality outcomes.

Additionally, thorough planning allows for the implementation of quality control measures at each stage of fabrication and installation, ensuring that the final product meets industry standards and client expectations.

2. Cost Efficiency

Effective planning and execution play a crucial role in achieving cost efficiency throughout the piping fabrication and installation process.

By carefully planning resource allocation, optimizing workflow, and identifying potential cost-saving opportunities, project managers can minimize unnecessary expenditures and maximize every investment.

This strategic approach to cost management ensures that projects are completed within budgetary constraints without compromising quality or safety.

For example, advancements in fabrication tools could increase productivity and reduce labor costs, where AI-based systems are bringing us one step closer to autonomous pipe welding.

However, do note that these AI systems cannot completely replace skilled welders, who are capable of working on and overseeing more complex projects.

3. Timely Delivery of Projects

Proper planning and execution enable project managers to develop realistic timelines, allocate resources efficiently, and identify potential bottlenecks before they occur.

For example, the project may face issues such as material shortages, equipment failures, or adverse weather conditions.

By anticipating and addressing these potential challenges proactively, project teams can mitigate delays and keep the project on track.

Additionally, effective communication and coordination among all stakeholders ensure that work progresses according to schedule, ultimately resulting in the timely completion of projects.

4. Compliance with Safety Standards

Compliance with safety standards is non-negotiable in piping fabrication and installation to protect the well-being of workers, the integrity of the infrastructure, and the surrounding environment.

Proper planning and execution involve thorough risk assessments, hazard identification, and implementation of safety protocols to prevent accidents, injuries, and environmental incidents.

For instance, safety is the number one priority during the installation process, with protocols such as:

  • Identifying piping-services-associated hazards.
  • Understanding pipe color codes.
  • Using safety guidelines when working in certain conditions (e.g., at heights, confined spaces).
  • Carrying personal safety equipment at all times.

Failure to comply with these standards could also lead to legal and financial repercussions such as fines, penalties, lawsuits, and shutdowns of the facility.

By integrating safety considerations into every phase of the project, from design and fabrication to installation and commissioning, project teams can guarantee compliance with relevant regulations and industry best practices.

This proactive approach to safety not only protects personnel and assets but also shields the reputation and credibility of the organization.

Did you know meticulous planning is also a best practice in industrial construction? Learn more in our comprehensive article on industrial construction services.

SJEC’s Excellence in Piping Fabrication and Installation

Over the past decade, Sheng Jian Engineering & Construction (SJEC) has established itself as a renowned leader in piping fabrication and installation across diverse industries.

Leveraging our extensive experience and unwavering commitment to excellence, SJEC consistently surpasses client expectations, setting the benchmark for quality and innovation in the field.

Our portfolio boasts a myriad of successful projects, ranging from large-scale industrial plants to intricate commercial developments. For instance, we spearheaded the fabrication and installation of complex piping systems for a state-of-the-art petrochemical facility, ensuring seamless operations and unparalleled reliability.

Additionally, our expertise was instrumental in the completion of a groundbreaking pharmaceutical manufacturing plant, where precision and adherence to strict regulatory standards were paramount.

These projects exemplify SJEC’s unparalleled proficiency in delivering top-notch piping solutions tailored to the unique requirements of each client, solidifying our reputation as a trusted partner in the industry.

Distillation Plant by SJEC.

Hot Gas Piping and Insulation by SJEC

Coal Ducts by SJEC.

Gas Station Piping by SJEC.

Norsechem Piping Works by SJEC.

Closing Thoughts

In summary, piping fabrication is a process which demands high levels of precision from start to finish. With skilled pipefitters and welders and comprehensive planning, your project is set for success.

To achieve the full potential of your project, you need a partner who understands your needs and possesses in-depth industry expertise.

This is where SJEC comes in. With our experience, track record, and commitment to excellence, we form the cornerstone of your project’s success.

Looking for Piping Fabrication Services?

If you’re searching for quality and durable pipework, let’s talk. Visit SJEC to learn more about our capabilities and see why clients trust us with their most ambitious piping projects.

Contact us today for a personalized consultation and see how our expertise can bring your projects to new heights.

Partner with SJEC for industry-standard piping installations.

Sheng Jian Engineering & Construction (SJEC) – Industry Experts

With over a decade of experience, SJEC is a certified expert in piping fabrication and installation. We guarantee first-rate results for every project, leveraging our versatile piping solutions, team of skilled professionals, reliable project delivery, and safety-centric approach.
Here are the type of piping fabrication and installation services we offer:

  • Stainless Steel Pipe Fabrication
  • Carbon Steel Pipe Fabrication
  • Pipe Insulation

We have served a wide array of industries, including:

  • Architecture
  • Automotive
  • Chemical
  • HVAC and Electric Industry
  • Industrial Construction
  • Oil and Gas Industrial
  • Oleochem Industrial
  • Petrochem Industrial
  • Renewable Energy

FAQ

What type of pipes are the best?

The best type of pipe depends on the specific application and requirements of the project. Common types include steel pipes, copper pipes, PVC pipes, and PEX pipes.

Need an expert’s opinion? Consult SJEC for tailored solutions.

What is piping prefabrication?

Piping prefabrication involves the manufacturing of piping components off-site, typically in a controlled environment, before they are transported to the construction site for installation.

What is the difference between shop and field fabrication of piping?

Shop fabrication is the fabrication of piping components in a pipe fabrication shop, while field fabrication is the fabrication of pipes directly at the construction site. Learn more in this section.

What is SJEC’s experience in piping fabrication?

SJEC has over a decade of experience as a reputable steel pipe manufacturer in Malaysia. We have managed a variety of pipework projects across various industries.

What type of piping fabrication services does SJEC offer?

SJEC offers stainless steel pipe fabrication, carbon steel pipe fabrication, and pipe insulation services. 

Can SJEC accommodate pipework in remote locations?

Yes, SJEC’s purpose-built fabrication facility and well-equipped workshop ensure efficient and reliable solutions, allowing us to operate even in distant or isolated locations. 

What is the process for requesting a quote or initiating a piping project with SJEC?

To request a quote or start a piping project with SJEC, simply contact us via our website, email, or phone. Visit our website at https://www.sjec.com.my/ or call us at +6012-596 6228. After initial contact, we’ll schedule a consultation to discuss project needs, feasibility, and provide a detailed proposal covering scope, timeline, and costs. Upon acceptance of the proposal, we’ll proceed with contract signing and project kickoff.

Discover more projects on SJEC’s official website. Connect with us via LinkedIn, Youtube, Facebook, Instagram, X, and Tik Tok.
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