High Volume Pipe Spooling Project Control Systems
Spooling Manager
RCR Stelform has spent
several years developing and improving its own software for the management of spooling projects. The software, Spooling Manager, performs an
important role in the company's spooling operations including work flow control,
progress reporting, material control, material and consumable traceability, NDT
control, costing, dispatch and reports for Manufacturer's Data Folders.
Work Flow Control
Spooling Manager is a valuable tool for controlling the progress of each spool and
therefore the project. Each spool progresses through several stages of production
including the following:
- Receipt of approved client documentation
- Processing and approval of RCR Stelform's documents
- Fabrication Ability assessment (often referred to as a "Fabricability Run")
- Issue for fabrication
- Fabrication
- Non-destructive examination
- Surface Treatment
- Final examination
- Dispatch
In addition to these stages, the system also allows us to revise and/or hold spools
during these stages.
Progress Reporting
The Progress Report for a project is typically reported against the stages discussed
above. Progress statistics may include the number of spools, welds, diameter inches
or tonnes for each stage and the totals for the project.
Material Control
Materials for the project may also be controlled by Spooling Manager. Receipt of
goods are recorded in Spooling Manager. Material batch numbers or Heats may be recorded
for traceability purposes. The materials received into stock are regularly compared
against the material's required by each spool. This comparison assesses the spools
in order of priority to determine which spools have sufficient materials available
for fabrication to commence.
Material shortages may be reported for all spools with completed documentation.
These reports are often beneficial to our clients when they are supplying materials,
particularly when shortages exist for priority spools.
Non-destructive Examination
It is essential that non-destructive examination is performed at the correct time
during the fabrication process. A production line facilitates the correct timing
of inspections. However, a workshop environment rarely allows a production line
to be employed. In the workshop environment, the task of ensuring that all required
inspections are performed can be complicated. Ensuring they are done at the correct
time increases this complexity. Spooling Manager provides the ability to ensure
that the inspections are not only requested, performed and recorded, but ensures
that this is done at the correct time during production. Once the inspections are
completed, all results are recorded in Spooling Manager for future reference in
the Traceability Reports included in our Manufacturer's Data folders. If an inspection
fails to comply, the spool will proceed to a re-work stage where it is repaired
before being tested again. The spools will not proceed to the next fabrication stage
until a complying result is recorded.
Traceability
Traceability for welds, welders, procedures and processes is maintained in Spooling
Manager. These records form the basis of the Welder Statistic Report and form a
regular part of the inspection process, ensuring that inspection levels for each
welder and process are satisfied.
Welder Approvals and Weld Registers are also maintained in Spooling Manager. As
well as providing data for the Manufacturer's Data folder, this information allows
the software to safeguard against the use of incorrect procedures and to ensure
that all welders have been approved to perform the procedures used.
Traceability for both Material and Consumable batches is provided in Spooling Manager
and included in the Traceability Report included in the Manufacturer's Data folder.
Material Heat Numbers may be recorded during fabrication and are checked against
the data recorded during the receipt of materials. Similarly, Consumable batches
are recorded during the welding process.
Costing
Spooling Manager may also be used to calculate the costs for each spool. These costs
may include amounts for materials, fabrication or surface treatment. Individual
cost sheets for each spool can be provided to the client for their information.
All costs are then invoiced through our accounting software.
Dispatch
Dispatched spools are recorded in Spooling Manager and a Dispatch Advice is generated
showing each spools weight, as-built revision level and any loose items associated
with it. Prior to dispatch, spools may be labelled with a printed label including
the spool's identification, line, area, etc. Spools may also be identified with
a Bar-Coded label if necessary.
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