The document discusses the history and current regulations regarding material traceability for natural gas pipelines. It proposes that operators must acquire and retain manufacturing records for steel pipe, pipeline components, and welder qualifications for the life of the pipeline. The document then outlines a typical workflow for tracking material on new construction projects using radio frequency tags, barcode scanning, and a database integrated with survey mapping. It discusses lessons learned and requirements for ensuring an effective material tracking system that provides value through transparency, communication, and reducing completion time.
2. MERCER TECHNICAL SERVICES
Historical Perspective
• 1935, The "American Tentative Standard Code for Pressure Piping”,
ASA B31.1 was issued
• 1955, Section 8, designated B31.1.8, represented a significant
technical advancement in requirements for natural gas transmission
and distribution piping systems
• 1970, DOT issues original versions of 49 CFR Parts 191 & 192
• 2011, PHMSA issues Advisory Bulletin requiring material to be
“Traceable, Verifiable and Complete”
• 2016, PHMSA NPRM: Safety of Gas Transmission & Gathering Pipelines
3. MERCER TECHNICAL SERVICES
Steel Pipe (proposed rule)
§ 192.67 Records: Materials.
Each operator of transmission pipelines must acquire
and retain for the life of the pipeline the original
steel pipe manufacturing records that document
tests, inspections, and attributes required by the
manufacturing specification in effect at the time the
pipe was manufactured, including, but not limited to,
yield strength, ultimate tensile strength, and
chemical composition of materials for pipe in
accordance with § 192.55.
4. MERCER TECHNICAL SERVICES
Pipeline Components (proposed rule)
§ 192.205 Records: Pipeline components.
Each operator of transmission pipelines must acquire and
retain records documenting the manufacturing standard
and pressure rating to which each valve was
manufactured and tested in accordance with this
subpart. Flanges, fittings, branch connections, extruded
outlets, anchor forgings, and other components with
material yield strength grades of 42,000 psi or greater
must have records documenting the manufacturing
specification in effect at the time of manufacture,
including, but not limited to, yield strength, ultimate
tensile strength, and chemical composition of materials.
5. MERCER TECHNICAL SERVICES
Welders (proposed rule)
§ 192.227 Qualification of welders.
* * * * *
(c) Records for transmission pipelines demonstrating
each individual welder qualification in accordance
with this section must be retained for the life of the
pipeline.
7. MERCER TECHNICAL SERVICES
Typical Work Flow
Receive
Material at Pipe
Yard and Create
a Pipe Tally with
HN and JN
MTR’s
Pipe Mill
String Pipe
and Document
Check HN and
JN to Pipe Tally
Load Out Pipe
At Pipe Yard and
Track Inventory
Check HN and
JN to Pipe Tally
As-Build Survey
Collects GPS
Shots in Ditch
and Check HN
and JN to Pipe
Tally
As-Build Survey
Off Line
Features
As-Build
Drawings, Check
HN and JN to
Pipe Tally
Data to Client
X-Check to Pipe Tally
MTR’s to Client
12. MERCER TECHNICAL SERVICES
Mitigate Risk
Ensure material is RTVC when consequence is low
Receive
Material at Pipe
Yard and Scan
Material
Pipe Mill
Receive MTR’s
and Enter into
Database
String Pipe
and Scan to
Track Material
Load Out Pipe
At Pipe Yard and
Scan to Track
Inventory
As-Build Survey
Collects GPS
Shots in Ditch
and Scan
As-Build Survey
Off Line
Features
As-Build
Drawings, Use
Information
From Database
Data to Client
Interactive Database
13. MERCER TECHNICAL SERVICES
Material Tracking Systems
• Tagging system have been in the pipeline industry
since 19XX
• Various types of tags can be used
• RFD
• Bar Codes
• Wide range of quality
• One tag does not fit all needs
• Material Database
• What is tracked in the database
• Is the database real time
14. MERCER TECHNICAL SERVICES
Lessons Learned - Tags
• Tags places on the inside of pipe
• Comes off the pipe and flows with the product
• Tags prevents pipe coating from being jeeped
• Tags destroyed during handling
• Pipe is cut at the firing line and pup moved ahead
• Tags deteriorated on pipe being stored due to UV
The type and style of the tags you use on your
project is a critical desicion point
15. MERCER TECHNICAL SERVICES
Material Database Requirements
• What data will be stored and the method of storage
• Remote access to the database
• Office
• Field
• Operator
• Database security
• Levels of access to database
• Cyber security
• Storage requirements
• Data transfer to operator at end of project
16. MERCER TECHNICAL SERVICES
Database
Material database can evolve into a project database
• Tracking of X-Rays
• Welder Qualifications
• Hydrostatic test
• Maintenance tickets for defective material
• Tracking location of material
• Inventory control
17. MERCER TECHNICAL SERVICES
Mapping
• You must be able to tie your material information
to the physical location of the material
• Fencing will not be excepted
• Survey must be integrated with the database
• Survey accuracy will be key
• Mapping material on a liner pipeline is no problem
• Mapping material for fabrication is challenging
18. MERCER TECHNICAL SERVICES
Planning
• As with any project, planning is key in
implementing a material tracking system
• Review the process with all stake holders
• The material tracking starts with the ordering of the
material to the final as-built into the operators
records system
• Work with the affected service providers
• Combined traditional tasks with new tasks needed
for material tracking
19. MERCER TECHNICAL SERVICES
Value Added
• Transparency for the project team
• Streamline communications through real time
reporting (dashboards)
• Reduce the time from physical completion of
project to completion of the project
20. MERCER TECHNICAL SERVICES
Contact Information
Mark E. Anderson
Vice President
Mercer Technical Services
8826 Santa Fe Drive, Suite 150
Overland Park, KS 66212
mark.anderson@mertechserv.com
P: 913.433.4099
