Quality Control and Assurance - for Gas Pipeline Construction Carly Voigt - Quality Manager
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Quality Control and Assurance
for Gas Pipeline Construction
Carly Voigt – Quality Manager
Discussion Topics
• Why is it important to focus on Quality now?
• What exactly is Quality Control and
Assurance?
• How can I implement it?
2
Why is it important to focus on Quality
now?
3
Why Focus on Quality Now? 4
Why Focus on Quality Now? 5
Why Focus on Quality Now?
• When: September, 2010
• What: A pipeline explosion killed 8 people, injured
dozens more, and destroyed 38 homes. The blast left a
crater in the ground measuring 167’ long, 26’ wide,
and 40’ deep.
• Why: Long seam failure of a 30” transmission pipeline
• Probable Cause: “…inadequate QA/QC in 1956, which
allowed the installation of a substandard and poorly
welded pipe section with a visible seam weld flaw
that, over time grew to a critical size, causing the pipe
to rupture…”
6
Why Focus on Quality Now? 7
Why Focus on Quality Now?
U.S. Natural Gas Pipeline System
Interstate Lines
Intrastate Lines
8
Why Focus on Quality Now?
Other Causes
Other Outside
Force Damage
Material/Weld/
8% Equipment
Natural Force 8% Failure
Damage
4% 35%
Incorrect
Operation
1%
18%
Excavation
Damage 26%
Corrosion
2013 Gas Transmission Significant Incidents (By Cause )
9
Why Focus on Quality Now?
Topic Frequency
Coating 117
Welding 87
Excavation 20
Nondestructive Testing 20
Pipe material 12
Bending 9
Lowering In 7
Hydrotesting 4
Design 3
Other 8
10Why Focus on Quality Now?
• Reduce re-work
• Minimize delays
• Increase productivity
• Increase customer satisfaction
Quality Work --> Increased Profit
12What exactly is Quality Control and
Assurance?
13What is QC/QA?
• Not this….
– “We have a great Quality Control program. We have Craft
Inspectors onsite every day during construction.”
– “Wow, I heard about all those construction Quality issues
discovered by PHMSA inspectors, but luckily that kind of
stuff never happens on our jobs…Our guys know better
than that.”
– “We’ve been doing it this way for generations, so it must
be right.”
14What is Quality Control?
A set of processes designed to confirm that a product
meets all requirements
Define the acceptance criteria to meet/exceed those
requirements
Measure to determine whether it meets/exceeds the
requirements
15What is Quality Assurance?
A review and modification of QC processes to ensure
their effectiveness
Confirming QC results on a sampling basis
Performing Root Cause Analysis
Best Practice identification & sharing (copy exact)
Implementing process changes if needed
16Case Study – Field Applied Epoxy Coatings
17How can I implement QC/QA?
18How Can I Implement QC/QA?
Step 1: Determine your most critical work activities
19List of Key Quality Issues
3
1. Material Defects 6
High
2. Lowering-In
3. Welding
5 7
4. Surface Prep 11
10
FREQUENCY
5. Pipeline coating
6. Strength Testing 2 9
7. Underground
separation 4
8. Compaction 12
9. As-built
Documentation
Low
13
10. Non
Non-Destructive 1
Testing (NDT) 8
11. Excavation
12. Shipping Damage
13. Pipe Drying Low CONSEQUENCE High
20How Can I Implement QC/QA?
Step 2: Define and document the process to determine
acceptance for each of those activities
21Step 2: Quality Control Plan
1.1.2: Quality Control Process for Welding
References: PG&E construction drawings; PG&E Gas Standards: D-22, "Arc Welding Procedure Requirements for All Stress Levels"; D-30.2, "Arc
Welder Qualification for Working on Pipelines that Operate at Over 20% of SMYS"; D-30, "Welder Qualification for Under 20% of SMYS"; and D-40,
"Weld Inspection"; and the approved Weld Procedures
Item Documentation Acceptance
No: Quality Control Activity: Frequency: (As Required): Qualifications: Criteria: Tools Required:
D.) Visual Inspection of Welds: All transmission Complete 1.2.1 Completed Weld meets Flashlight,
Perform a visual inspection of welds pipeline welds (100%) "Quality Control - Daily visual inspection requirements GAL V-Wac
as defined by PG&E Gas Standard D-40. are to be visually Field Weld Summary training (OQ 10- in API 1104 for undercut gage,
inspected by qualified Report" for each weld. 02). cap height, GAL Cambridge
individuals. misalignment, gage,
root gap, and GAL Fillet weld
undercut. gages,
Flexible rule
E.) Radiographic Inspection of Welds: Per PG&E Standard D-40 All Radiographic ACCP Level II Contract NDT Per PG&E
Confirm Radiographic Inspection of or construction Inspection Reports and Certification or Inspector Specification
welds is being performed in drawings, whichever is the original films are to better 4793
accordance with PG&E Gas standard D- more stringent. be provided to the
40, or per construction drawings, Foreman or Weld
whichever is more stringent. Inspector.
F.) Magnetic Particle Inspection of Welds: Per PG&E Standard D-40 All Magnetic Particle ACCP Level II Contract NDT Per PG&E
Confirm Magnetic Particle Inspection or construction Inspection Reports to Certification or Inspector Specification
of welds is being performed in drawings, whichever is be provided to the better 4793
accordance with PG&E Gas Standard D- more stringent. Also as Foreman or Weld
40, or per construction drawings, requested by the Inspector.
whichever is more stringent. Pipeline Engineer.
22How Can I Implement QC/QA?
Step 3: Measure and provide feedback to correct non-
conformances (Perform QC)
23Step 3: Perform QC
24How Can I Implement QC/QA?
Step 4: Sample the results from step 3 (Perform QA)
25Step 4: Perform QA
26How Can I Implement QC/QA?
Step 5: Determine root causes of quality issues,
implement corrective actions, and share solutions
across the organization
27Step 5: Root Cause Analysis
Methods Manpower Environment
Welding Long Shifts/
Procedure worker fatigue Wind/Rain
Heat Inputs Unqualified Personnel Ambient Temps
High Travel Speed Adequate Lighting
frequency of Lack of QC
rejected girth
weld x-rays Wall thickness Lincoln vs. Miller Xray Technique
Rod ovens Source Selection
Improper bevel
Interpretation of
Out-of-roundness Use of Clamps Code Req’mts
Materials Machines Measurement
28How Can I Implement QC/QA?
Key Elements of a Quality Management System (QMS)
High Quality Assurance
Process Maturity
Quality Control
Craft Inspection
Leadership Communication & Support
Qualification & Training
Low Policies & Standards
Low Confidence of Quality High
29Summary
• The pipeline industry needs to continue to improve
construction quality - we can’t keep doing the same thing
and expect different results
• With more pipelines being constructed than ever before,
implementing a comprehensive quality program can
mitigate risks, increase profits, and help ensure the
integrity of our nation’s pipelines for many years to come
“I know it’s a hell of a challenge, but ask yourselves, if not
us, who, if not now, when?”
-- President Ronald Reagan (1981)
30Thank You
Any Questions?
Contact Info:
Carly Voigt
carlyvoigt@gtsinc.us
(925) 478-8530 ext. 115
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