Comprehensive Piping Production System: Total Control from Design to Dispatch

In high-stakes industrial environments like oil & gas, power plants, and heavy fabrication yards, piping systems serve as critical arteries—connecting processes, equipment, and utilities across the plant. Yet, managing the lifecycle of each pipe spool, weld joint, and inspection record often remains fragmented across spreadsheets, manual logs, and disconnected systems.

The result? Lost traceability, costly rework, audit failures, and constant firefighting during commissioning.

Our Comprehensive Piping Production System changes this. It’s a purpose-built, end-to-end solution that manages design, fabrication, welding, QA/NDE, logistics, and auxiliary operations—giving you a single source of truth from the first cut to final bolt-up.

⚙️ Key Use Cases & Capabilities

1. Design Module – Blueprint to BOM

• Material Codification System – Standardizes and assigns unique codes to all materials for uniform identification.
• Plant Level Master – Manages core master data relevant to the entire plant setup.
• Project Level Master – Maintains project-specific master data for efficient tracking and execution.
• Maintain CRS BOM – Stores and manages the Bill of Materials from the Client Requirement Specification.
• Maintain Line List – Tracks all piping line numbers with specifications and service details.
• Maintain Spool BOQ – Keeps Bill of Quantity for each spool prepared for fabrication.
• Joint Management – Records and manages all weld joints with traceability and specifications.
• Drawing Document Management – Centralizes all project drawings and revision control.

Benefits: ✔ Eliminates inconsistent BOMs
✔ Speeds up fabrication planning
✔ Ensures early material traceability

2. Welding Module – Plan, Execute, Trace

• Welding Procedure Specification (WPS) – Defines standard procedures for each welding type and material.
• Weld Plan – Schedules and assigns joints to be welded per procedure and priority.
• NDE Plan – Prepares a plan for Non-Destructive Examination post welding.
• PWHT Plan – Manages Post Weld Heat Treatment requirements and scheduling.
• Execute Weld/NDE/PWHT Plan – Executes planned welding, NDE, and PWHT activities.
• Update Joint Weld/NDE Plan – Tracks progress and updates weld/NDE completion status for joints.
• Welder Master List (WML) – Maintains qualification and availability records of all welders.
• Token Generation – Issues weld tokens to welders for traceable assignment and tracking.

Benefits: ✔ Ensures qualified welders per spec
✔ Reduces weld rework with better assignment
✔ Meets ISO and ASME traceability

3. Production Module – Fab Floor Visibility

• Offer Part – Marks individual parts ready for quality inspection.
• Offer Joint – Flags welded joints for inspection and approval.
• Offer Spool – Declares completed spools for inspection and clearance.
• Inspection Joint – Conducts quality check and documentation of each joint.

Benefits: ✔ Real-time view of fab completion
✔ Syncs production with QA and NDE
✔ Improves throughput with better handshakes

4. QC/NDE Module – Certified Every Step

• Plant Level Masters – Maintains quality standards and benchmarks at plant level.
• Project Level Masters – Holds QC/NDE parameters for specific project requirements.
• Create & Execute Plans – Builds detailed inspection and examination plans, then executes them.
• Inspection Part – Examines and approves individual parts as per plan.
• Inspection & Examination of Joint – Carries out NDE and visual checks for each weld joint.
• Inspection Spool Hydro – Performs hydrostatic pressure testing of spools.
• Inspection Spool FD – Final dimensional inspection of spools before painting.
• ICS Preparation – Prepares Inspection Clearance Sheet for spool release.
• Inspection Spool Painting – Verifies painting and coating quality on spools.
• Request for Spool End Caps Fixing – Raises request for end cap installation prior to shipping.
• Create SCN – Generates Shipping Clearance Note for dispatch-ready spools.
• TPI Clearance – Records Third Party Inspection approvals and clearance.
• Grouping – Groups inspected spools for efficient logistics and dispatch.

Benefits: ✔ Streamlined audit preparation
✔ Live inspection status tracking
✔ Unified NDE and production data

5. Auxiliary Module – Beyond Welding

• Offer for Hydro – Submits spools for hydro testing stage clearance.
• Offer for Painting/Pickling & Passivation/Galvanizing – Offers completed spools for surface treatment processes.

Benefits: ✔ Avoids overlooked compliance activities
✔ Structured handling of post-fab steps
✔ Full material lifecycle logging

Role-Based Access & Interfaces

Before vs After – Problem Solving Matrix

Analytics & Dashboards

• Spool readiness and queue status
• Welder productivity and defect rate tracking
• Joint-wise NDE pass/fail ratio
• Painting, pickling, galvanizing performance
• Spool delivery status and logistics KPIs

Use Case Impact – Real Industry Examples

Pipe Fabricator for Oil Refineries
Reduced NDE turnaround time by 35% with digital test planning and execution modules.

EPC Contractor on a Power Project
Achieved 100% traceability of welds, spools, and materials during a critical ISO audit.

Heavy Engineering Yard
Streamlined 5,000+ spool dispatches with no QA leakage using SCN + weld completion checks.

Why Choose This Solution?

• Designed for the full lifecycle of piping—from design to dispatch
• Integrates with your project’s ERP, QA systems, and document control
• Adheres to industry codes: ASME, AWS, ISO, DIN
• Enables faster audit readiness with digital traceability
• Supports multi-project, multi-location rollouts

Get Started

Looking to eliminate chaos in your piping fabrication workflows and gain end-to-end visibility?

Let’s show you how our system can ensure better compliance, productivity, and cost control.