In industrial construction, the phrase “one size fits all” rarely applies, especially when it comes to pipe fabrication. Different industries bring different standards, tolerances, and performance requirements. A power generation facility may need high-pressure steam piping built for thermal expansion, while a pharmaceutical plant demands high-purity systems with sterile welds. Understanding the distinctions between these sectors is key for any facility manager, EPC contractor, or project engineer evaluating potential pipe fabricators.
This article explores how industry-specific pipe fabrication varies between the power, pharmaceutical, and chemical industries. It highlights critical differences in materials, welding procedures, quality control, and compliance expectations.
Power Facilities: Built for Pressure and Performance
Material Selection and Strength
Power plants, particularly those involved in steam generation, demand pipe materials capable of withstanding extreme temperatures and pressures. Chrome-moly alloys like P91 or P22 are commonly used for high-pressure service. These materials offer creep resistance and are subject to precise preheat, interpass, and post-weld heat treatment requirements.
Fabricators serving this industry must be familiar with ASME B31.1 Power Piping Code, which governs design and construction. Piping must maintain integrity under thermal cycling, which creates significant stresses that must be accounted for during fit-up and weld planning.
Welding and Heat Treatment
In the power industry, multi-pass welding techniques such as GTAW (TIG) followed by SMAW (stick welding) are often used to guarantee penetration and durability. Post-weld heat treatment (PWHT) is frequently required to reduce residual stresses and meet metallurgical properties specified in material standards.
Quality Control and Testing
Power industry pipe fabrication relies heavily on nondestructive examination (NDE). Radiographic Testing (RT), Ultrasonic Testing (UT), and Hardness Testing are used to detect flaws and confirm mechanical performance.
Compliance and Certifications
Fabricators must be ASME Section I and B31.1 compliant and often carry the ASME “S” or “U” stamp. These credentials show that a fabricator has passed rigorous inspections and operates with traceable procedures.
Pharmaceutical Facilities: Precision and Cleanliness
Materials for Sanitation and Corrosion Resistance
Stainless steel (typically 316L) is the material of choice in pharmaceutical pipe fabrication due to its corrosion resistance and ease of sterilization. These systems must handle clean steam, purified water, and chemical solutions without contamination. Orbital welding is preferred because it produces uniform, repeatable welds with minimal human contact.
Welding Requirements
Pharmaceutical piping systems require welds that are smooth, clean, and free of crevices. Purge gas systems and enclosed orbital welding tools are commonly used. Weld mapping and detailed inspection records are kept for every joint.
Welds are often polished or electropolished to promote cleanability and minimize microbial growth, which is critical for validation and inspection under Current Good Manufacturing Practices (cGMP).
Documentation and Validation
Every weld, material certificate, and weld procedure must be documented. Pharmaceutical facilities must follow FDA guidelines for validation, which often includes video boroscope inspection, dye penetrant testing, and surface roughness measurements.
Fabricators must understand and meet standards from ASME BPE (BioProcessing Equipment) and USP <797> for cleanroom fabrication.
Regulatory Requirements
Fabricators working in the pharmaceutical space must demonstrate cleanroom welding capabilities, training for orbital systems, and the ability to comply with strict FDA audit protocols.
Chemical Plants: Durability and Chemical Compatibility
Material Selection for Harsh Environments
Chemical plants require materials compatible with a wide range of aggressive fluids, acids, solvents, and caustics. Depending on the process, materials may include Hastelloy, Inconel, PTFE-lined carbon steel, or alloy 20.
Material handling and traceability are vital, as incorrect materials can lead to catastrophic failures, contamination, or OSHA-reportable events. Each project typically begins with a detailed Process and Instrumentation Diagram (P&ID) that outlines flow characteristics and material compatibility requirements.
Fabrication Considerations
Welders must be qualified under procedures that address corrosive resistance and chemical compatibility. These often include controlled heat input and minimal weld spatter to prevent corrosion initiation points.
Chemical piping systems may be jacketed for temperature control or dual-contained to protect personnel and equipment in the event of leaks.
Testing and QA
Testing for chemical piping typically includes pressure testing, visual inspection, and in corrosive service, Positive Material Identification (PMI) to confirm alloy content. RT and UT may also be used in high-risk lines.
Safety and Environmental Compliance
Fabricators must meet OSHA’s Process Safety Management (PSM) standards, which focus on hazard analysis, emergency planning, and mechanical integrity for equipment and piping systems.
Why It Matters to Choose a Fabricator with Industry-Specific Pipe Fabrication
Selecting a pipe fabricator who understands the nuances of your specific industry is more than a preference, it’s a necessity. A fabricator with proven experience in power systems might not meet the documentation or hygienic requirements of pharmaceutical applications. Similarly, a shop focused on high-purity systems may not be equipped for the heavy-wall chrome work in a combined cycle power plant.
Scott Process provides fabrication services across all three of these industries. Backed by ASME certifications and industry-trained personnel, Scott Process tailors its approach to the material, pressure class, and regulatory requirements of each project. From welders with orbital welding certifications to project managers fluent in PSM, the team adapts to the unique demands of every sector.
Final Thoughts
Industry-specific pipe fabrication is not just about cutting and welding, it’s about understanding each industry’s language, regulations, and performance goals. Whether working in the cleanrooms of pharmaceutical facilities, the high-heat environments of power plants, or the corrosion-prone systems of chemical operations, experienced fabricators like Scott Process bridge the gap between engineering specs and real-world execution.
By aligning capabilities with the specialized needs of each industry, Scott Process helps clients stay on budget, meet compliance, and avoid costly rework, because in these environments, quality is non-negotiable.