Bulk MTO

Sabir,
You asked a number of questions. This one I have never heard of before "What is MAR for Bulk Materials….?" Where did you hear this and can you furnish any additional information on it?

For the others I offer the following:

MTO & BOM

My answer: (Based on my experience)
MTO means Material Take-Off. This is the counting of the pieces and parts needed to fabricate, purchase and or construct something. There are normally three material take-offs during a process plant project. These are preliminary, secondary and final.
Preliminary MTO:
What is it? – A preliminary MTO is a material take-off very early in the design process when only a limited amount of information is known and very little detail has been developed.
Why is it done? - A preliminary MTO is normally done for two reasons. The first is to assist with the early "order-of-magnitude" (+/- 10%) estimate for the overall project. The second reason is to issue early order of magnitude "RFQ's" (Request for Quote) for piping materials
When is it done? - The preliminary MTO is only possible when there is a Plot Plan that is "Approved" by the Client or has been issued to the client for approval. This is done long before there is any detailed work started on the 3D design model.
Who does it? - A preliminary MTO is best done by very strong well experienced senior piping designers who are familiar with the project.
How is it done? - For the preliminary MTO we used a formatted form on which we could indicate the number or amount of material required for each line. On the form I would identify the line number along with the line class. I would then look at this line on the P&ID and on the Plot Plan and determine the routing of the pipe. Then in the boxes (on the form) I would then mark the amount of pipe required for each size required for that line. Then I would count the number of fittings required, starting with 90 degree elbows. Then continuing through all the other inline fittings and online fittings. After the fittings I would count all the flanges by size. Then I would count all the valves from the P&ID. The high point vents and low point drains would be made last based on an educated guess. Then I would take another form and do another line. As I did each line I would "Yellow" off the line on the P&ID so at the end all the lines are accounted for. As the forms were completed they would be reviewed by the Area Supervisor and then forwarded to the Material Control Group who would process the data to produce the RFQ's
Secondary MTO:
Why is it done? - The primary reason for the Secondary MTO is to update quantities for the issue of the actual Purchase orders for piping material. A second reason is to update the project estimate.
When is it done? - The Secondary MTO can only be done when there is significant progress completed on the 3D design model (or other electronic design method). However it must be done early enough to insure that the procurement (purchase and delivery) of the piping material to the field will fit the overall project schedule.
Who does it? - The Material Control Group.
How is it done? - The Material Control Group would access the electronic data base and down-load all the material available at that time. Some factoring would be done by the Material Control Group and the Piping Design Leads to allow for work not done yet.
Final MTO –
Why is it done? - The final MTO is done first to identify any item added late in the project or anything that was missed on the Preliminary or Secondary MTO's. The second reason for the Final MTO is to get a fix on the final job costs.
When is it done? - The Final MTO is done when the last Isometric has been issued.
Who does it? - The Material Control Group.
How is it done? - The Material Control Group would access the electronic data base and down-load all the material. Any differences between the Final MTO and the Secondary MTO would be identified. Purchase orders would be issued for the updated quantities.

Please remember this is only how it was done where I was. Use it as a guide but please do not be misled that this is the only way an MTO can be done.



Line Numbering
The question:
“Is there a common system for line numbering and if so what is it?”

I could be wrong but I think it is safe to say there is no “common pipe line numbering system” in use in the process plant engineering and design world. There are just too many companies and people and clients and project types to be able to achieve such commonality. I don’t remember seeing anything in ASME B31.3 (or any other Code), but then again it is not the purpose of the B31 Code to dictate a line numbering system.
To properly discuss this subject we need to understand the purpose of the “Line Number.” We also need to acknowledge that some companies use the term “Line Designation.” Whether your company uses the term “Line number” or the term “Line designation” the purpose is the same. It is for line identification. This identification is necessary through out the project and is used for many purposes by different people or groups. The line numbering should be controlled by the piping group for the project and done by the piping material engineer for that project.
As with any of the other “gray hair” pipers, I too have seen many different line numbering systems in my working past. Of all of them I have determined that there are some similarities but no totally common system.
Here are some details that I have been able to determine for myself. There are two basic areas that tend to govern line numbering. These are the line number method and the line number elements.
• Methods - There are two basic line numbering “methods.” The first method is based on the Purpose or Function of the line. The second method is based on the line “Size.”
• Elements - There are many potential line identification elements that may be included in a line numbering system. The elements that are most commonly included in a line numbering scheme are: Plant Location, Line Identity, Line Class (or Line Specification), Size, Insulation Type (when required) and Heat Tracing Type (when required).
The “purpose or functional” method of line numbering is where the line is best defined as a single line having an origin and a terminus consistent with a purpose or function. An example of this might be a pump suction line. It might come from a Storage Tank, a Tower Bottom or an Accumulator. It travels some distance and then splits and connects to the two pumps designated for that one service or function. This is one line, it serves one purpose or function therefore it has only one line number. Another example would be the pump discharge that leaves both of these pumps and join to form the single pipe line that runs to the next piece of equipment. This line also has one purpose or function therefore it has only one number.
The “line size” method is where the line number changes whenever and wherever the line size changes. When compared to the first (purpose or function) method, the pump suction line might have five line numbers instead of one. The pump discharge might also have five or more depending on what happens at the destination end of the line.
One or the other of these two methods becomes the “Rule” for a company, client or project. As we all know, for every rule you will always be able to find an exception. One exception that is common to both of these “Rules” is the rule of the change of line class (or line specification). The change in line class is most often caused by a change in pressure or material. A line might be the same size from one point to another but includes a pressure control valve that lets the pressure down to a level that allows a lower flange rating and or another material therefore a different line class. There are other line class change initiators but I think you get the idea. Any change in a lines conditions or material causes a mandatory change in the line number no mater which line numbering method is being used.

The elements of a line number might be arranged and look something like this:

10-1021-CA1A-12”- IH -ST
Where:
10 = the plant Unit or Area (mandatory)
1021 = the numeric line number (mandatory)
CA1A = the line class (mandatory)
12” = the line size (mandatory)
IH = Hot Insulation (only when required) (1)
ST = Steam Tracing (only when required) (2)

(1) Other types of insulation include IC = Cold Insulation, IS = Safety Insulation, IA = Acoustic (or Sound) Insulation, etc.
(2) Other types of tracing include: ET = Electric Tracing, CWT = Chill Water Tracing, TT = Thermon (Hot Oil) Tracing, etc.

I have no doubt that there are other items of information that could be or are added in some form or another based on the preference of a specific company of client. My credo is “Keep It Simple.” The manner of arranging the Elements to form a line number is something that is also dictated by the Company and or in some cases the Client. The sequence that is shown above is in the order of information priority that I am used to.

The line numbering activity should only be done when the P&ID’s are well along in the development process. The more complete the P&ID’s are the less hours will be wasted and the better the results of the line numbering effort. The degree of P&ID completeness prevents recycle when new equipment or systems are added or when equipment or systems are deleted.

Line List

As the Piping Material Engineer (or designate) performs the line numbering of the P&ID he or she also initiates the first draft of the Line List (or Line Designation Table) data base. The resultant document from this data base will be extensive for a whole project but will be broken down by plant area.

In addition to the line identification elements (indicated above), the Line List (data base and document) will or should also include important information for the design process and construction process such as the following:
• The line commodity
• The phase (liquid or gas)
• The origin of the line
• The destination of the line
• The line pressure, both the normal operating pressure and the maximum operation (or Design) pressure
• The line temperature, both the normal operating temperature and the maximum operation (or Design) temperature
• An indicator code for Stress Analysis requirements
• PWHT requirements
• The insulation thickness (optional)
• The line schedule (optional)

The line list once initiated will have many additions, deletions and be used by lots of people throughout the project both in the design office and in the field.

One of the first and most important activities where the line list is used is when the definitive labor hour estimate in generated. The number of lines on a project has a direct bearing on the labor hours required. This is true for the piping design activities in the home office, the pipe fabrication shop and for the installation contractor in the field. So it is very important to get it right.

Bulk material is all the items that are purchased in "Bulk" as opposed to a pump which is purchased as a descrete "Tag" item of equipment.

For Piping it is: Valves, Pipe, Fittings, Flanges, Nuts & bolts, Gaskets etc.

For Electrical it is: Conduit, Cable, Wire, Switches, Junction boxes, etc.

For Structural it is: Concrete, Reinforcing bar, Anchor bolts, etc.