Quality Control – Lone Star (PTS) is a comprehensive application for the control and management of all items utilized in the fabrication of a pipeline. It provides the quality control links between design, materials, welding, examination and coating. Quality assurance functions are also an integral part of the system by recording all welds, repairs and re-weld details as well as radiography, ultrasonic and magnetic particle examinations.
Full Status information is maintained on all material-detailing the stages and its current location within the fabrication process. This also enables the system to record and display the pipeline length and volume at any given time, and helps to ensure that a full material reconciliation can be performed as soon as the project is completed.
Lone Star (PTS) offers users a real competitive advantage. Key features, such as, the comprehensive report, search and status functions, combine functionality and practicality to deliver improved pipeline management.
Lone Star (PTS) is fully scaleable system, available as a stand-alone or client server application, with the operating platform being SQL or Oracle dependent on client requirements. It delivers all the benefits you would expect from an automated pipeline control and monitoring system- including reduced cost, improved efficiency, and the global availability of information. Most importunately, however, it offers effective material traceability and quality assurance for the entire process of pipeline fabrication from the chemical analysis of the casts of the steel through to as-laid records of the completed pipeline.
Lone Star (PTS) is backed up by a comprehensive range of off-site support services. All clients are offered assistance with installation and start-up. Although the system’s intrinsic ease of use means that such help is often not required. In addition, specialist on-site training can be tailored to suite the needs of individual users.
Once Lone Star (PTS) is installed and operational, support is provided through a Helpdesk facility at PTI – Business Solution- and a remote dial-in support option is also available if required.
The superior solution
Lone Star is the pipeline control and monitoring software solution you are looking for. It is easy to use, functional and efficient. It brings a new dimension of quality to all aspects of pipeline fabrication. In short, by choosing to invest in Lone Star (PTS), you are bringing the management of pipeline fabrication into the 21st century.
Overview – The system had a comprehensive range of reports covering every aspect of the pipeline process, examples of the available reports are:
A Pipeline Sequential report will print information for any specified segment in the pipeline, and in either direction.
A Mainline Welding report identifies the pipe numbers, weld numbers and welders involved in the initial fabrication prior to repairs and re-welds.
General Welding reports cover all off-line welds, such as repairs, re-welds, tie-ins and special assemblies.
The Examination Records displays the results of the various examinations carried out on each weld for example Radiography, UT, and MPI.
An as-built and as-laid displays the sequence of pipes and welds that form the final fabrication. This ensures that the final reconciliation can be performed as soon as the project is completed.
A material summary report indicates the quantity of material for each pipe size and location. This is updated throughout the fabrication process, identifying the exact status of individual pipes, if they are used. If so, where they are in the line, the weld number, and the examination results.
The progress report details the totals for a specified period of welds started, completed, examined, accepted and coated, as well as totals for repairs and cutouts.
Overview – Lone Star (PTS) provides pipe-tracking capability which provides the means to locate all material on site. From the moment that material arrives on site, the system records the location and status of each material item, where it was welded, when it was welded, or why it could not be used. The system gives a unique serial number to identify each pipe, using the heat number and length as a cross-check whenever possible. By this means the system minimizes the problems of clerical error and the difficulties that occur with so many pipes that all look much the same!
Electronic pipe import – Information from the pipe supplier can be imported directly into the system, reducing, the time involved in manual entry and the risk of clerical error, while providing a link to information from the pipe manufacture and coating stages.
Classify all sizes
The system classifies all pipes and fittings according to outside diameter, wall thickness and grade, and will indicate any attempt to weld together dissimilar items (as either a transition weld or a mistake).
Always know where your material is
The system keeps track of the receipt of material and where it is located, reducing the physical effort involved in locating material items.
Avoid use of bad material – Every item is classified with a status, and every suspect item can be classified with a status reason. The system will highlight any attempt to weld suspect material into the pipeline, reducing the need to cut out welds.
Overview – Lone Star (PTS) recognizes the speed of a typical production line and the vast quantity of data that this will generate. The system implements fast-key drop-down lists and uses valid assumptions to ensure that data can be entered as rapidly as possible. It recognizes that the best people for entering the data are the inspectors first and system operators second, and keep the screen as simple and straightforward as possible
Identify what examination reports are missing
Each weld is classified by type, which will determine the NDT requirements.
Verification of correct pipe numbers
The system identifies the two items welded, using the stated length and heat number to verify pipe identification. This ensures early detection of incorrect numbers, and highlights use of suspect material or duplicate pipe numbers.
Incorporating all the hurdles
The system monitors the results of the various examinations, combing all of these to ensure that only welds that have passed all essential examinations are accepted.
No problems with positives + negatives
The system makes no distinction on the order that welds are recorded (i.e. they might not be welded in order). It also makes no distinction between a weld joining A to B and a weld joining B to A. Enter the welds in any order and enter the items either way round, and the system will cope. Naturally the reports can be from start to finish or from finish to start or for any portion in between. The system caters for any portion of the line being welded in reverse direction.
Full weld history
The system maintains a full weld history for every weld, assisting in the process of identifying the cause of defective welds. Every repair can be recorded and every cut-out too. The system can cope with any number of repairs and re-welds to a weld, even if the fabricators cannot.
Overview – Lone Star (PTS) provides the link between welding and NDT, ensuring that the status of each weld is updated automatically by NDT personnel and that they are always aware of the welds requiring examination.
Quick and easy data recording
The exam type, exam procedure and technique types are all selected from pre-defined drop down lists.
Tracking the problems
The system can record up to three defects per weld, providing the means to track trends and identifying fatal and marginal defects.
Monitoring the trends
Defects are selected from a list of typical defects, increasing the speed of data entry, as well as enforcing data consistency.
Passing or failing welds
The combined result of all the examinations determines the overall status of the weld.
Exam completion process – The system identifies the NDT requirement for each weld, helping to identify the examinations still required before the weld can be accepted.
Lone Star (PTS) is designed to take into account the high production rates that can be achieved on pipeline projects, resulting in large amounts of data being recorded and verified on a continuous basis throughout the shifts. To assistant in this process, the system records design information that can be specified before fabrication begins and can be used to confirm the fabrication information entered.
Define the design – Each pipeline can be split into segments (termed “stalk” or “section”). The system records the drawing numbers and design length for each stalk. It can also record the designated weld numbers to be used, where applicable.
Identification at transition points
A list of pipe sizes and grades is maintained on the system, and similarly, a list of factory coatings. The system will alert the user when dissimilar items are welded together (can happen but never unknowingly).
Correct specification down the line – For each position in the pipeline, it is possible to specify the item type (such as flange, tee or pipe), the pipe size and grade, the factory coating type and thickness, and whether an anode pipe is required or not.