Broadly speaking quality for a pipeline project can be split into two sections: (i) the quality plan and (ii) traceability. Whilst the development of a quality plan, including all the subsidiary plans, procedures and specifications, is relatively easy to implement and maintain, traceability is often more difficult. Traceability work is predominantly field-based and reliant on input from many individuals who are usually remote from any central office database. For the NQGP Project there was an added dimension to the traceability issue in that the Project decided to construct the bulk of the spooling for all the facilities in-house - quite a large task given the size of the compressor facilities at Moranbah.

Traceability on the NQGP Project has been achieved through the use of the Epic Energy developed FMS (facility management system) and CMS (construction management system) software. The NQGP is the first project to use the FMS software which was originally developed by Epic Energy’s John Girle (deceased) and John Quigley aided by Mike Hennessey who is the NQGP Construction Quality Manager. The system was developed to ensure traceability of all material and components welded into the facilities. The system allows tracking of all elements against drawings and purchase orders providing a fully integrated materials tracking system.

The process commenced with the ISO drawings and associated material take offs (MTO) being loaded into the FMS. The FMS was then able to identify all components associated with a spool that was manufactured in accordance with its ISO.

The MTO was also forwarded to the procurement department which input the required items into a purchase order that was subsequently placed with a supplier. Prior to dispatching the materials the supplier placed a uniquely numbered bar code sticker provided by NQGP to each item. Upon affixing the bar code sticker to each item or piece of equipment the supplier entered the bar code number into the MTO spreadsheet which was then returned to NQGP for electronic transfer into the FMS. As goods were delivered to the fabrication shop they were scanned using a hand held Symbol bar code reader which was then downloaded into the FMS. At this point the FMS generated a goods received listing which was automatically forwarded to the procurement and accounts groups to enable payment of the invoices.

In the fabrication shop the production co-ordinator used the FMS to determine which ISOs had all the required materials to enable fabrication to be completed. This was done by the FMS doing a comparison of the ISOs against the inventory of materials on hand. The production co-ordinator was able to request the FMS to provide listings of ISOs for production based on many variables such as spool diameter, individual skid or station. Once a particular ISO was selected for fabrication the necessary components were drawn from stores and tacked together ready for the quality verification and final welding.

It was at this stage that the quality officer, whilst performing the dimensional check, scanned all the components of the tacked spool for completeness. The data was downloaded into the FMS and the system checked that all the relevant items and materials were as per the ISO. Once validated the spool underwent final welding. Upon completion of the welding the spool then underwent non-destructive testing (x-ray or MPI) and the results were electronically transferred back into the FMS. The spool was then cleared for grit blasting and coating. As with the previous steps the results of all coating tests were entered into the FMS providing a complete record of the works carried out. Once the spool was finally cleared it was then ready for either installation onto a skid or for shipment to site for installation.

Any welding of spools on-site followed the same rigorous quality and traceability checks with the data being scanned into the FMS. On completion of construction the section was ready for hydrostatic testing and once again the test reports were entered into the FMS on completion.

The FMS data base containing all the traceability records is held by the Pipeline Operator and is linked and accessed via the geographical information system (GIS). This allows the operator to readily access all traceability for any component on the pipeline and facility via the click of a mouse.

The CMS was also developed by Epic Energy and has been in use in the pipeline construction industry since 1995 with the construction of the South West Queensland pipeline from Wallumbilla to Ballera. The system was developed to ensure traceability of all pipe and components welded onto the pipeline.

The traceability commenced at the pipe mill where a unique number was applied to each pipe. The pipe number identified the heat and coil number from the steel mill. This number was carried through the coating plant and following successful coating bar code stickers were applied to each end of the pipe. The bar code number and mill number were entered into the CMS automatically from a CMS formatted database at the pipe supplier. From this point all necessary pipe movements were tracked via hand held bar code scanners as the pipe was loaded out of the coating yard onto transport, received at the stockpile and upon dispatch from the stockpile to the right of way (ROW).

When each pipe was welded together the field quality officer scanned the upstream and downstream pipe bar code and recorded all the associated information such as the welder identification and electrode batch numbers. The welds were then X-rayed, grit blasted and coated and the data electronically transferred into CMS at each step. Upon clearance of the welding, blasting and coating, the pipe was laid into the trench where each weld was then surveyed with reference to the weld number prior to backfilling.

The records were checked to ensure completeness against the survey and alignment sheets prior to being cleared for hydrotest. Again hydrotest data was entered into the CMS for use by Pipeline Operations. As with the FMS this data can be accessed via the GIS enabling the Pipeline Operator at the click of a mouse to trace all information from the metallurgical analysis of the steel to the coating, field welding, field coating, survey and hydrotest.

By utilising the FMS and CMS for traceability the Pipeline Operator has an electronic record that is readily accessible via GIS for everyday use. Whether responding to a third party query on pipe location, an engineering query in relation to a new off-take or pipeline pressure assessment, or as a Risk Management System to provide evidence of protection at various locations along the pipeline, Operations has a fully automated system linked to physical ground information via the GIS.

“The bar coding system associated with this Project provided some challenges for suppliers” said the Technical Manager Chris Gorham “however, it paid huge dividends in the field and, combined with the FMS and CMS systems, Operations will have a fully documented history of every part of their facility and pipeline.”