A White Paper February System for piping global management

Transcription

1 A White Paper February 2004 System for piping global management

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3 Table of contents Summary... 4 Modules... 5 Piping Classes... 6 Data Dictionaries 6 Tables 6 Piping Classes 7 Branch Tables 7 Assemblies 8 Components catalogues 9 Process Fluid List 10 Line List 11 Take-off MTO checks 12 Surplus Tables 12 Bill of Materials List 13 Shop fabrication 13 Mechanical Checks Checks for internal/external pressure 14 Checks for intersections 14 Material Requisitions Requisition generation and issue 15 Painting & Insulation Order Main functions 17 Cosmo Simulation of line feasibility 18 Document management 19 Import / Export Integration with CAD modules AP-Link 21 PDS-Link 22 System for piping global management 3

4 Summary Puma5 is an application software system for the piping materials management, specifically developed for the companies working in the industry plant layout, such as: refinery, petrochemical, power generation, iron and steel, water treatment, naval, pharmaceutical, food, construction and erection, etc.. Besides exploiting the normal functions which are typical of management systems, Puma5 is really a working methodology since it is an effective tool for the execution and optimisation of design and management activities, during the whole project lifecycle, from the piping classes creation up to the materials accounting and related MTO s, procurement and construction. Its features, based on major international EPC Main Contractors requirements, permit the execution of piping design and management activities in a fully integrated environment and through easy-to-use modules, giving good quality results. The Puma5 main functionalities are: Elaboration and management of piping classes Definition and optimisation of Fluid Lists and line lists Materials accounting and MTO s issue Requisitions and support to procurement activities Welding quantities calculation Construction and erection weight calculation Surfaces and materials calculation for painting and insulation Automated mechanical verification of pipe thickness and intersections Management of prefabrication and site construction and erection Integration with the world-wide utilised 3D CAD systems Integration with major ERP systems The system runs in Microsoft Windows environment and is fully integrated with MS Office, thus permitting immediate import/export towards Word and Excel. It is available in both Client-Server and Web-enabled version, which provides the centralised project database to be concurrently accessed by Clients, Contractors and Sub-Contractors, Partners, Construction sites, etc 4 System for piping global management

5 Modules Piping Classes Process Dictionaries for the definition of components, materials, design standard with automatic creation of codes Definition and management of conveyed fluids process data, with check of data consistency and alignment of piping classes, Line List and Fluid List Take-off Materials accounting to obtain the MTO s for procurement and construction, both from manual input and directly from 3D CAD systems Mechanical Checks Material Requisitions Checks on component dimensioning in accordance with the design codes, calculation of hydraulic or pneumatic minimum test pressure and definition of test circuits Generation of requisitions, from MTO s and/or simulated accounting, grouped and organised per product class, project or sub-project, destination Painting & Insulation Surfaces and quantities calculation of painting and insulation based on Line List data and component quantities contained in MTO s Order Cosmo Supporting the procurement activities by providing continuously updated situation of materials, from bidding of requisitions to comparison, purchase order, expediting and shipping Management of piping during prefabrication and erection activities, including the feasibility and constructability analysis Import / Export Data import/export from/to different groups performing accounting activities, export in the most common formats, interface with other applications Integration with CAD modules Interface and integration with the most commonly used 3D CAD systems, which permit the quick and easy generation of component database and piping classes, as well as to directly import the models material list System for piping global management 5

6 Piping Classes This is the main module in PUMA5 which provides the definition of dictionaries (including components, materials, design standard, weights, stud and bolts dimensions, component selection rules), as well as piping classes, intersections and assemblies, with automatic creation of codes for each project components. It is composed by several applications here below described. Data Dictionaries they comprise the basic information for the definition of piping components, i.e. materials, standards of design, piping objects, rules for component generation. Tables for component weight calculation, definition of component attributes in accordance with engineering standards, welding generation, bolt size automatic generation, CAD dimensional tables. They include also the ANSI B31.x and ASME VIII for mechanical checks. 6 System for piping global management

7 Piping Classes they define the characteristics of project piping components and are easily and quickly filled in by using the Data Dictionaries. Once ready PUMA5 will automatically create the project piping components that will be used to generate the Material Take-Off. Form for the definition of the piping class header and components Branch Tables which provide the definition of intersections between headers and branches for the specific project. A branch table can be linked to one or more piping classes, this automatically defines the intersection objects foreseen in the linked piping class, avoiding any mistakes in automatic import of take-off. System for piping global management 7

8 Assemblies together with the related piping classes the assembly defines the typical components of a standard arrangement, typically they are: vents, drains, instrument connections, steam traps. In Puma5 the assemblies are easily standardized and this provides the automatic calculation of the assembly piping components. Form for assembly definition 8 System for piping global management

9 Components catalogues These are automatically obtained by the piping classes, the objects of which produce a number of components related to the selected sizes range. Each component is automatically associated to its description, weight, surface and to two different codes: one used in the database (Corporate Code) and the other used in the Project (Mark). The system allows for the utilisation of User coding in case of Companies having their own coding. Generation of component catalogue System for piping global management 9

10 Process This module allows the management of process data in the Fluid list and Line List, thus permitting a constant control of the revisions and an automatic adjustment of the data and documents created in the different engineering phases (Piping Classes, Material Take-Off). Fluid List The conveyed fluids are defined by indicating the maximum pressure and temperature conditions, the components main characteristics, i.e. basic material, rating and flange facing, heat treatment and valve type. The application creates links between Fluid List, Piping Classes and Line List, in order to assure the alignment and simulate the consequences of modifications on the Project Line List and on the Take- Off. Form for the definition of the fluid list 10 System for piping global management

11 Line List Puma5 allows to create links among Line List, Fluid List and Piping Classes in order to assure the alignment and simulate the consequences of modifications on the Project Line List and on the Take- Off. Form for the definition of the line list Warnings list System for piping global management 11

12 Take-off This module permits the execution of materials accounting to obtain the MTO s for procurement and construction. The Take-Off may be performed by line or by isometric drawing. The input is easy and fast and can be manually performed through a friendly interface that allows to select components directly from the Piping Classes, or to record the material lists automatically from CAD systems through import/export interfaces. Form for the material accounting MTO checks The material quantity variations due to Piping Classes revisions are automatically recorded and upgraded, also while the work is in progress, thus granting always the consistency among Material Take-off, Piping Classes and Material Requisitions. Surplus Tables Possibility for the user to create and apply his own surplus tables, which will automatically increase the quantities of the calculated materials, in order to balance the construction and erection scraps. 12 System for piping global management

13 Bill of Materials List From the Bill of Material List the user can directly obtain the lists normally needed for planning and management control as well as for prefabrication and erection, including welding quantities, construction, component traceability. The user can set his own filters and printing forms. Form to filter and print Take-Off Shop fabrication According to the project requirements the user can define the divisions between prefabrication and erection and obtain the related list accordingly. Definition of prefabrication System for piping global management 13

14 Mechanical Checks This module performs the mechanical checks of the piping components according to the standard piping design codes, which are: ASME B31.1, B31.3, B31.4, B31.8, ASME VIII. Also the check of rating curves and their automatic association to piping classes is performed, together with the calculation of minimum test pressure (hydraulic or pneumatic) and the definition of test circuits. Menu to access the mechanical checks Checks for internal/external pressure The check for internal and external pressure (vacuum) may be performed either on Piping Classes and on Line List. Checks for intersections The necessity of reinforcing pad in pipe-to-pipe intersection may be checked at the piping class maximum conditions or at the effective design conditions indicated in the Line list. 14 System for piping global management

15 Material Requisitions From the MTO the Material Requisitions are automatically obtained, grouped per: project, subproject, destination. The materials components are organised according to aggregations (product class) that meet the selected market suppliers. The MTO quantities may be manually and/or automatically increased or decreased (by means of the surplus tables), before the requisitions issue. It is also possible to issue material requisitions for materials not yet included in the Take-Off. Possibility to export data to ERP systems, such as SAP and J.D.Edward. Requisition generation and issue Usually the Material Take-Offs are performed in several phases, at the end of which requisitions are issued or updated. The application automatically monitors the difference between actual and previous needs, by comparing the quantities already issued for purchase and the updated quantities from Take-Off. System for piping global management 15

16 Painting & Insulation This module performs the calculation of surfaces and material quantity necessary for painting and insulation. The calculation is based on the Project Line list data (i.e. temperatures and coating types) and the Material Take-Off data (i.e. material quantities and types). The module is provided with a complete set of dictionaries for: painting materials, insulation materials, piping components surfaces and the most used standard coatings. An easy-to-use interface allows the selection of reports according to the user needs. 16 System for piping global management

17 Order This tool supports the procurement activities and maintains continuously updated the material tracking situation. It provides for time and cost reduction as well as for bottleneck and errors reduction for the whole procurement activity (requisitions, bidding and comparison, P.Orders, shipping). The integration with engineering permits to mitigate materials surplus and to globally shorten the material management Main functions The application permits the continuous control of all materials during all the typical procurement phases, starting from the requisitions of bids to Vendors to the comparison activities, to purchase orders issue, to expediting and shipping activities. The main functions available at present are: Bids requisitions in MS Excel format Automated and configurable commercial comparisons Automated data updating through standard format import Configurable access by third parties, such as Vendors System for piping global management 17

18 Cosmo It allows the management of field warehouse and of prefabrication and erection works. By using the data import functions, this module gets from PUMA5 the information related to the component characteristics and their layout on the lines. These data, together with the data from procurement (requisitions, purchase order, packing list) and the warehouse materials availability allows the analysis of lines feasibility. Simulation of line feasibility The application analyses the store situation and provides, for the interested lines, the percentages of feasibility with the list of components necessary to complete the line, based on actual material availability. It is possible to select the lines to be analysed by assigning them the construction priority. The selection of the lines may be carried out on the basis of defined criteria (such as plant, fluid, etc.). The application allows also to carry out the feasibility study with a theoretical materials supply, based on the incoming orders and the present availability. Once selected the lines to be prefabricated or erected the application unload automatically the store and print the delivery vouchers for the storekeeper. By using the load/unload functions the storehouse situation is continuously maintained updated and the relevant materials situation can be printed when needed. Form for feasibility simulation 18 System for piping global management

19 Document management COSMO allows the management of documents related to piping materials life-cycle, thus permitting the check of procurement situation. This provides the traceability and procurement status for each component during its life-cycle phases (Take- Off quantity, requested quantity, purchased quantity, shipped quantity, forecast incoming quantity, delivered quantity, etc.). System for piping global management 19

20 Import / Export To make the use of Puma5 more flexible, particular attention has been given to the exchange of data among different working groups. External companies: to make easier the transfer of data to/from external companies in case of subcontracted works, appropriate functions have been implemented to import/export data from Piping Classes, Take-Off and Line List. This is obtained by installing Puma5 in the computers of the external companies, then the piping classes are transferred there to permit the accounting activities. When finished the Material Take-Offs can be collected in the main computer to obtain the project MTO. Drie: this tool handles the operations of importing/exporting data from other applications. Its main characteristic is the possibility of configuration directly by the end-user, including the definition of the record layout of files to be imported or exported. The main purpose of this module is to allow an easy transfer of data from/to Puma5 without creating specific interfaces, saving time and maintenance operations. 20 System for piping global management

21 Integration with CAD modules These are interface and integration modules with the most commonly used 3D CAD systems, which permit the quick and easy generation of component database and piping classes, as well as to directly import the models material list. The modules at present available are: AP-Link, for AutoPLANT (Bentley) system PDS-Link, for PDS (Intergraph) system UG-Link, for Unigraphics system PDMS-Link, for PDMS (Aveva) system AP-Link Size Catalog: customisation of size attributes, automatic codification of components from Puma5 component catalogue, revision management. Piping class generation: generation of component database and piping classes for the modules AutoPLANT Piping 3D and Isometrics. Material take-off import: the material lists are automatically imported from 3D model and isometrics to proceed with the following MTO and procurement steps. Form for the generation of the piping classes System for piping global management 21

22 PDS-Link Piping Class generation: PDS-Link allows to automatically generate the piping classes and their supporting tables for PDS: Material Class Data, Commodity Spec.s Data, Branch Insertion Tables, Nominal Piping Diameters, Gaskets Separation tables, implied components, Option code, Bolt tables, Component description library, Size depending material data, Weight tables. Material take-off import: from Model 3D or from Isogen (Alias) the material lists are automatically imported to proceed with the following MTO and procurement steps. Form for the generation of the piping classes 22 System for piping global management

23 Prepared by COMPUTER LINE ASSOCIATES S.r.l. Via della Viggioletta, Piacenza, Italy tel.: +39 (0523) fax: + 39 (0523) web site: Computer Line Associates believes the information in this publication is accurate as of its publication date. Such information is subject to change without notice and is subject to applicable technical product descriptions. Computer Line Associates assumes no responsibility for any errors in this document. Reproduction, distribution, and transmission of this document by any means photo static or electronic is restricted without authorization. Microsoft and Windows are registered trademarks of Microsoft Corporation. Other brands and product names are trademarks of their respective owners. CLAP5WP Printed in Italy. System for piping global management 23

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