Process Skids, Modular Equipment & Packaged Plants worked example

Pipe Spool Count at 65% weld station uptime: a worked example

Suppose weld station uptime falls to 65%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Pipe Spool Count capacity tells a skid fabrication shop how many good, weld-out pipe spools it can realistically deliver from a run, after downtime and rework are stripped out.

The inputs for this scenario

  • Spools fabricated per weld station cycle: 4 units / cycle (held at the documented default)
  • Available weld station cycles: 480 cycles (held at the documented default)
  • Weld station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass spool yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross pipe spool count capacity = units per cycle × available cycles.
  • Good output capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 1,920 units at these inputs.
  • Uptime loss works out to 672 units at these inputs.
  • Yield loss works out to 37.44 units at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where weld station uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 27.78% below the baseline at 1,211 units.
  • It multiplies spools per cycle by available cycles for gross capacity, then applies weld uptime and first-pass yield to give net good spools. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Good output capacity: 1,211 units (headline result)
  • Gross capacity: 1,920 units
  • Uptime loss: 672 units
  • Yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Pipe Spool Count calculator, set weld station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.