H-655 Ecc Piping Materials Quantity Control

7/27/2019 H-655 Ecc Piping Materials Quantity Control

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ABB Lummus Global B.V.

SPECIFICATION

Client Shell Eastern Petroleum (Pte) Ltd. Always refer to this number

Plant Shell ECC Project Singapore 421 04217 H-655

Location Pular Ular, Singapore Dept./Sect. Project Specification

Doc. No. E-00000-PI-7737-0024Rev.

Specification For:

PIPING MATERIALS QUANTITY CONTROL

AND ISOMETRIC PRODUCTION

LGN SSPE xx-xxxx-xx.xxx (2002-04-10) 164395549.doc Page 1 of 7

1.00 2006-12- Updated JPLI CLY ADB0.00 2006-05-22 For information CLY JBRO ADB

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED


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SPECIFICATION

Client Error: Reference source not found Always refer to this number

Plant Error: Reference source not found Error: Error: Error: Reference source

Location Error: Reference source not found Dept./Sect. Project Specification

Doc. No.Error: Reference source Rev. Error:

INDEX

SECTION PAGE

1. INTRODUCTION 3

2. OBJECTIVE 3

3. ABBREVIATIONS 3

4. DEFINITIONS 4

5. MATERIAL CONTROL PRINCIPLES 4

5.1 BEST QUANTITY CONCEPT 4

5.2 PIPING MATERIAL QUANTITY CONTROL PROCESS OVERVIEW 4

6. TOOLS 5

6.1 MTO-EXPLORER 5

6.2 MARIAN 6

6.3 3D CAD (PDMS) 6

6.4 PIAS, ISOMETRIC CONTROL 6

6.5 INTERFACES 7

7. POINTS OF ATTENTION 7

8. ATTACHMENTS 8

LGN SSPE xx-xxxx-xx.xxx (2002-04-10) 164395549.doc Page 2 of 7


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1. INTRODUCTION

The timely availability of piping materials is of great importance for the pre-fabrication/construction of the project. Managing piping material quantities is a complicated task requiringthe best effort of all piping designers and engineers. A Piping Designer is not only responsiblefor piping layouts and/or isometric production, but also material quantity control is part of theresponsibility.

The initial procurement of piping materials is based on estimated quantities (the bulk MTO). Inthe course of the project these bulk quantities must be upgraded when actual required quantitiesbecome known based on design development. Regular top-up requisitions will be required tokeep pace with these design developments. At the same time changes are to be managed,surpluses minimized and sufficient work-front for the subcontractor established.

To achieve all this, ABB Lummus Global has developed a Piping Material Quantity ControlSystem using MARIAN (our material management database system) that will assist the projectin achieving the best result.

This specification describes the piping material quantity control system in general.Attachment-1 will provide further detail on the process of updating piping material quantities(due to revisions or design developments).Attachment-2 will provide further detail on the isometric production process in relation to materialmanagement.

2. OBJECTIVE

The main objectives of the Piping team in the Detailed Design phase of the project are:

Timely release of AFC isometrics for prefabrication/ construction

Timely availability of all related piping materials

Meeting the defined schedules and priorities

Aiming for the lowest cost by efficient design with minimum revisions and minimizing the

number of fittings, welds, surpluses, etc.

The instructions and guidelines of this specification and its attachments are to be strictlyfollowed to ensure that the above objectives are met. Not adhering to these instructions andguidelines will result in material shortages/ surpluses, construction delays, budget overruns, etc.

3. ABBREVIATIONS

The following abbreviations are used in this document and its attachments:

AG Above groundAFC Approved For ConstructionBOM Bill Of Material (piping materials relating to a single isometric)CAD Computer Aided DesignCWP Construction Work PackageDEC Detail Engineering Center (i.e. LGB, LGS or Teil)

EPC Engineering Procurement Construction (Detailed Design)ITAS IT Application SupportLGB ABB Lummus Global Brno officeLGN ABB Lummus Global The Hague officeLGNU ABB Lummus Global The Hague - Underground Piping Department


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LGS ABB Lummus Global Singapore officeLPA Line-number per Area (may consist of multiple isometrics)MOPEX Multi Office Project ExecutionMTO Material Take-Off (Piping Materials)PDMS Plant Design Management System (3D CAD tool from AVEVA)PEFS Process Engineering Flow SchemePIAS Piping Isometric Administration SystemTEIL Toyo Engineering India Mumbai OfficeUG UndergroundWBS Work Breakdown Structure

4. DEFINITIONS

In the Piping Material Quantity Control workflow certain isometric milestones are critical.Attachment 2 lists the applicable isometric milestones for this project. These milestones will bemanaged by PIAS (for LGB and LGS), or in a Status file (TEIL).

For a full definition of a Checked isometric (60% status) see Attachment 2. This is a veryimportant status, and adherence to its definition is crucial in the Material Quantity Controlworkflow.

This project (and also MARIAN) is organized in areas in line with the WBS. The Piping bulk-

MTO is also prepared perLine-numberPerArea (LPA). In a way MARIAN does not contain onelarge bulk MTO for all piping materials, but many small bulk MTO's, one for each line-numberwithin an area (i.e. one for each LPA). The material quantities of these small bulks are to bemanaged from the bulk take-off phase all the way up to final material release.

A Closed LPA means: All isometrics of a LPA have reached the 60% status* or higher.An Open LPA means: At least one isometric of a LPA has not yet reached the 60% status*.

* Checked isometric in distribution, with its BOM uploaded from PDMS to Marian. See Attachment 2.

5. MATERIAL CONTROL PRINCIPLES

5.1 BEST QUANTITY CONCEPT

Material quantities are managed according the Best Quantity Concept. Hereby the material

quantities are evaluated and managed based on the best available data in MARIAN, i.e.

P partly bulk MTO quantities (based on the initial or updated manual bulk MTO),

P partly upgraded quantities from PDMS (based on checked and distributed isometrics)

and

P partly final quantities from PDMS (based on issued isometrics).

Such an evaluation can result in material cancellation (when still possible) or in additional

purchasing (via a top-up or supplement requisition). To make this possible the bulk MTO is

continuously managed on a LPA level, with each LPA its own status.

5.2 PIPING MATERIAL QUANTITY CONTROL PROCESS OVERVIEW


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The following list is an overview of activities, and illustrates the concept of material quantity

control as applicable for the ECC project:

A piping bulk MTO has been prepared by LGN in MTO Explorerfor each Line-number per

Area (LPA). The area division is the same as the WBS and is shown on the PEFS.

It must be noted that one LPA may consist of multiple isometrics when the piping system is

build in PDMS. No automatic isometric-split (by PDMS) is allowed. One Pipe in PDMS

shall fit on one isometric sheet. If a Pipe requires more isometric-sheets, a forced-split will

be required (i.e. more pipes/isometrics of the same LPA). See the Piping Design instructions

(H-005) for more details on isometric breaks.

As long as a system is not yet build in PDMS, e.g. during the piping study phase, or as longas an LPA is still open (see par. 4), all important changes to the bulk MTO are to be

handled via MTO Explorer (see par. 6.1) by each DEC. At project start each DEC will

receive MTO Explorer with the basis piping bulk MTO. Important changes to be incorporated

are:

o Changes in LPA breaks

o Changes in line-numbers or area allocations

o Deletion or addition of line-numbers (and related materials)

o Major PEFS changes or design developments

These updated MTO Explorer files are to be sent to LGN (timing to be agreedsee DEC

Instructions, E-00000-PI-7737-0026) for review and upload into MARIAN.

Once an isometric in PDMS has reached the status 60% (checked isometric in distribution),

material quantities will be transferred from PDMS to MARIAN. For LGB and LGS this will be

automatically initiated via PIAS. For TEIL this must be manually initiated by the designer via

PDMS.

Once all isometrics of an LPA are distributed (and all its material quantities uploaded from

PDMS to MARIAN = closed LPA) the original bulk MTO quantities for that LPA shall beare

replaced by the actual quantities from PDMS. From that moment any future changes to the

MTO for this LPA are to be handled via the PDMS CAD model and subsequent isometric

revision distributions (and not via MTO Explorer).

All piping (supplement) requisitions are generated from MARIAN based on its MTO data as

uploaded from PDMS (for closed LPAs) or MTO Explorer (for open LPAs), or original bulk

MTO data. In other words, the Best Quantity.

See Attachment-1 for a full overview of the procedure for maintaining piping material quantities,and Attachment-2 for isometric milestones and modeling instructions in relation to materialmanagement.

6. TOOLS

The following IT tools play an important role in the material quantity control process:

6.1 MTO-EXPLORER

MTO-EXPLORER is an application to produce the initial Piping Bulk MTO. Its content has beenuploaded to MARIAN by LGN for further handling (e.g. requisitioning).


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MTO-EXPLORER will also be used by each DEC to maintain majorchanges to the bulk MTO forall open LPAs (see Attachment 1 par. 2)

6.2 MARIAN

MARIAN is our Material Management System, a huge database where the bulk MTO is storedand maintained e.g. via uploads from 3D CAD (PDMS). MARIAN is also the source for allrequisitioning and material control activities (applicable for all departments that is).All MARIAN input will be executed by LGN. Each DEC will be provided with read-only access toMARIAN, in order to generate Bulk versus Final reports, for analyzing the differences in the bulk

MTO and the final MTO (see Attachment 1 par. 6).

6.3 3D CAD (PDMS)

PDMS is the 3D CAD system used for this project. Here the final plant model is built, isometricsgenerated and final material quantities extracted for further processing in MARIAN.

Important: Proper use of PDMS macros, forms and menus are important for properly setting ofvarious attributes necessary for the material management process!

6.4 PIAS, ISOMETRIC CONTROL

PIAS is the isometric administration system used by LGB and LGS. It provides a link betweenMARIAN and PDMS. PIAS will initiate the upload of material quantities from PDMS to MARIANfor isometrics with the appropriate status. PIAS will also flag Closed LPAs when the lastisometric of an LPA is distributed (closing the LPA).

Proper isometric planning and revision control in PIAS is very important for the materialmanagement concept (and also for progress control). Distributing the last isometric of an LPAwill set the LPA status from open to close. One must make certain that it really is the lastisometric of the LPA. Examples:

When inadvertently all isometrics (as listed in PIAS) of an LPA are distributed B1, butnot all isometrics of that LPA are yet registered in PIAS (i.e. PIAS is incomplete), theMARIAN bulk will be replaced by insufficient material quantities of the incomplete LPA-

isometrics.The opposite is dangerous too:When all isometrics of an LPA are distributed B1 (and the whole LPA is covered), butPIAS still contains a superfluous isometric-number of that LPA, the MARIAN bulk willnot be replaced and MARIAN will maintain the (out-of date) original bulk MTO data.

It is preferred to complete and release all isometrics of an LPA simultaneously to allow fasttrending of material quantities. Also the priority definition as set for the project need to befollowed.

TEIL will not use PIAS but use a Status file for its revision control. TEIL will initiate the upload ofmaterial quantities from PDMS to MARIAN via a special interface in PDMS (provided by LGN).Also the LPA flag open or close will be set via PDMS, and is to be logged in the Status file.Note that a closed LPA should remain closed (i.e. never reset the LPA status from closed toopen).


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PIAS will also provide input to iWorks, a software application used by the Material ManagementDepartment (LGN) to produce isometric production curves, to analyze the subcontractors work-front, for planning, etc.As TEIL is not using PIAS, TEIL will have to produce a weekly interface file, in accordance tospecification E-00000-KA-7880-0005 Isometric Data for iWorks.

6.5 INTERFACESThe listed tools have a direct relation with each other. The following picture is a simpleschematic of these interfaces between the tools:

Note that TEIL will use a Status File in stead of PIAS.

7. POINTS OF ATTENTION

To benefit from this material management concept, each piping designer must fully understandthe concept as described in this specification, and adhere to the instructions and guidelinesprovided in this specification and its attachments, as well as in all other project instructions andspecifications.

See par. 6.8 of Attachment 2 for a number attentionpoints for the piping design to follow.

REMINDER: once all isometrics of an LPA have been (checked and) distributed, the LPA is

closed and new material updates to MARIAN can only be handled via PDMS (andsubsequent isometric distributions and material uploads).

A closed LPA should remain closed. Never reset the LPA status from closed to open, as

this may affect the requisition quantities.

Keep the PDMS model up-to-date with changes to isometrics of closed LPAs, and

immediately initiate the isometric distribution (and material upload). This is the only way tomaintain the piping bulk MTO (and subsequent material requisitions) for closed LPAisometrics.

Never release unfinished isometrics, as the missing piping components may be removed

from the bulk MTO when the MTO in MARIAN is overwritten (for a closed LPA).


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Beware of selecting piping components in the PDMS component choose-form. An

accidental wrong choice may result in unintentionally purchasing of the wrong component(and likely cancellation of the right component).

Do not use dummy components when a certain piping commodity is (still) unavailable in

the pipeclass. These temporary components may unintentionally be purchased whenmaterials are uploaded to MARIAN. If you need a piping component not available in thePDMS pipeclass, follow the Piping Component Request procedure < hold for number >

Do not model unapproved changes, as the related materials may unintentionally be

uploaded to MARIAN and purchased.

Ensure Tagnumbers in PDMS are correct and in the right format (e.g. for instrumentation,

special piping items). An input error can result in incorrect purchasing.

Ensure the line-number- and area breaks of your isometrics matches the breaks on the

PEFS. Remember an LPA break is also an MTO break

Be extremely careful when: changing line-numbers, deleting isometrics, copying lines,

changing area locations (e.g. due to equipment relocation to another area). All suchchanges affect the MTO and you must take appropriate action to correctly implement therelated material changes (see Attachment 2 for details). Never re-use a deleted line-number.

Use the PDMS forms, menus, macros etc. as instructed, and avoid the use of the PDMScommand prompt. Many forms and macros not only execute commands properly, but alsoset various attributes in the background of PDMS that are essential for correct handling ofthe materials. Only use the command prompt to quickly move or rotate components, or forqueries.

Check with your supervisor when things are not fully clear to you!

8. ATTACHMENTS

The following attachments to this specification provides further details to the piping team in

relation to the subject topic. Ensure these instructions are fully understood and followed.

ATTACHMENT 1: Piping Material Quantity Processing:

This attachment covers the activities and procedures related to updating and managing pipingmaterial quantities.

ATTACHMENT 2: Piping Isometric Production:

This attachment covers the requirements for the isometric production in relation to correctmaterial management such as status and revision control.

Documents

H-655 Ecc Piping Materials Quantity Control