MTO PROCEDURE

THIS SECTION BRIEFS OUT THE GENERAL PROCEDURE TO BE FOLLOWED FOR MATERIAL TAKE-OFF. THE FOLLOWING IS A LIST OF INPUTS/REFERENCE DOCUMENTS WHICH SHOULD BE KEPT READY PRIOR TO,AND FOR, THE PROCESS OF MATERIAL TAKE-OFF: P&I D LINE LIST PIPING MATERIAL SPECIFICATION, APPROVED BY THE CLIENT MTO DATABASE APPROVED MTO SPARE PHILOSOPHY BRANCH TABLE BOLT TABLE VALVE LIST & SPECIALITIES LIST INSTRUMENT HOOK-UP DETAILS PLOT PLAN (For Preliminary MTO) EQUIPMENT LAYOUTS (For Preliminary MTO) PIPING LAYOUTS (For Intermediate MTO) ISOMETRICS (For Final MTO) KNOWLEDGE OF CRITICALITY OF THE PIPING WHETHER THE PIPE IS TO BE IMPORTED/ EXPENSIVE, LONG DELIVERY AND, WHERE TO DRAW A LINE OF ACCURACY BETWEEN LARGE BORE/CRITCAL PIPE AND SMALL BORE/ LESS EXPENSIVE PIPES.

PROCEDURE: FIND OUT THE TOTAL LENGTH INCLUDING ALL ITEMS- PIPES, FITTINGS, VALVES, OTHER SPECIALITIES, ETC.- AS SUCH FROM THE LAYOUT. IF THE PIPING IS ABOVE 80 NB OR IF THE PIPE MATERIAL IS VERY EXPENSIVE, THEN ACCURACY OF THE ESTIMATE SHOULD BE GIVEN UTMOST IMPORTANCE AND HENCE, THE FOLLOWING STEPS SHOULD BE STRICTLY ADHERED TO: ESTIMATE THE NUMBER OF FITTINGS ELBOWS, TEES, REDUCERS, FLANGES, GASKETS, BOLTS & NUTS, ETC. ESTIMATE THE NUMBER OF VALVES AND OTHER SPECIALITIES IN THE PARTICULAR LINE. CHECK OUT THEIR END CONNECTIONS WHICH WILL STRAIGHT AWAY GIVE THE NUMBER OF FLANGES, GASKETS, BOLTS AND NUTS APART FROM THOSE ESTIMATED FOR EQUIPMENT AND OTHER INSTRUMENT CONNECTIONS. SUM UP THE LENGTH OF THE FITTINGS AND THAT OF THE VALVES AND OTHER SPECIALITIES AND DEDUCTION OF THE SAME FROM THE TOTAL LENGTH WILL GIVE THE EXACT LENGTH OF PIPES.

FOR PIPES 50 NB AND BELOW, THE TIME INVOLVED IN CALCULATING THE EXACT LENGTH OF PIPES IS NOT ALWAYS JUSTIFIED AND HENCE DEDUCTION OF THE LENGTH OF FITTINGS AND OTHER ITEMS IS NOT ADVISABLE. FOR JOINING TWO LENGTHS OF PIPE A FULL-COUPLING IS NORMALLY EMPLOYED AND HENCE ONE FULL-COUPLING FOR EVERY 6m LENGTH OF PIPE, OR AS THE CASE MAY BE, SHOULD BE CONSIDERED. CARE SHOULD BE TAKEN TO ENSURE THAT NO ITEM IS LEFT OUT OR DUPLICATED DURING ESTIMATION AND THIS IS ENSURED BY

HIGHLIGHTING THE LINES IN THE P&I D. HOWEVER, THE SCOPE DEMARCATION BETWEEN PIPING & INSTRUMENTATION AND THE PIPING FROM THE UNIT AREA TO RACK AREA & VICE VERSA SHOULD BE DEFINED CLEARLY. IN THE PRELIMINARY STAGES OF MTO, MOST OF THE QUANTITIES MAY HAVE TO BE ESTIMATED WITH THE HELP OF STUDY SKETCHES AND ASSUMPTIONS. THE BASIS OF MTO, THE ASSUMPTIONS MADE, REFERENCE AND INPUT DOCUMENTS , LINES/ITEMS NOT INCLUDED ETC., SHALL BE RECORDED AS NOTES AND SHALL FORM PART OF MTO. THIS WOULD HELP IN IDENTIFYING THE LEFT OUT ITEMS, REASONS FOR VARIATIONS ETC.. HELP/ADVICE FROM THE LEAD ENGINEER/ DESIGNER SHOULD ALWAYS BE SOUGHT BY THE MTO ENGINEER WHENEVER THE LATTER FACES SOME PROBLEMS IN THE PROCESS OF ESTIMATION. ONCE THE MTO INPUT SHEETS ARE READY, THE SAME SHALL BE GIVEN TO THE PROGRAMMER FOR DATA ENTRY. THE INPUT THUS ENTERED SHALL BE VALIDATED WORD BY WORD WITH THE ORIGINAL MTO INPUT SHEETS. THE PROGRAMMER THEN TRANSFORMS THE ERROR-FREE MTO INPUT INTO MTO OUTPUT BY MAKING USE OF THE MTO DATABASE, MTO SPARE PHILOSOPHY, BRANCH TABLE AND BOLT TABLE. THE OUTPUT THUS OBTAINED WILL HAVE THE BULK QUANTITIES SORTED OUT EITHER LINEWISE OR SIZEWISE AND MATERIALWISE. THE ACCURACY OF THE OUTPUT THUS GENERATED WILL SOLELY DEPEND ON THE ACCURACY OF THE PROGRAM WHICH LINKS THE MTO DATABASE, SPARE PHILOSOPHY, BRANCH TABLE, BOLT TABLE FOR BULKING AND HENCE, THE PROGRAM SHOULD BE A VALIDATED AND TESTED ONE. OF COURSE, THE MTO DATABASE, SPARE PHILOSOPHY, BRANCH TABLE AND BOLT TABLE SHOULD ALSO BE THIROUGHLY VALIDATED BEFORE USING THE SAME FOR BULKING. THE FINAL OUTPUT IS THEN TRANSFORMED TO THE FORMAT APPROVED BY THE CLIENT.

THE ABOVE PROCEDURE HOLDS GOOD FOR ALL THE THREE STAGES OF MTO VIZ. PRELIMINARY, INTERMEDIATE AND FINAL. THE DIFFERENCE BEING THE INPUT AVAILABLE FOR ESTIMATING THE BOQ AND THE ACCURACY LEVEL OF THE BOQ ESTIMATED, WHICH IN TURN DEPENDS ON THE ACCURACY LEVEL OF THE INPUTS AVAILABLE (SUCH AS P&I D, LINE LIST, EQUIPMENT DATA SHEET AND PIPING LAYOUTS ETC.)

GENERALLY, THE ACCURACY LEVEL EXPECTED OF THE PRELIMINARY MTO WILL BE ABOUT 60%-70% AND THIS MTO IS PRIMARILY INTENDED FOR ARRIVING AT A ROUGH ESTIMATE OF PIPING COST AND VENDOR IDENTIFICATION. VALVE LIST CAN BE DEVELOPED WITH REASONABLE ACCURACY AT THIS STAGE IF THE P&I Ds AND LINE LIST FURNISHED ARE FAIRLY ACCURATE ( SAY 80% ACCURATE ) THE ACCURACY LEVEL OF INTERMEDIATE MTO WILL BE ABOUT 85% - 90% AS AT THIS STAGE THE EXPECTED LEVELS OF ACCURACY FOR P&I Ds AND LINE LIST WILL BE 90% AND THE PRELIMINARY PIPING LAYOUTS WOULD HAVE BEEN RELEASED FOR CLIENTS APPROVAL ( ALL MAJOT LINES WOULD HAVE BEEN ROUTED )

THE FINAL MTO WILL BE PREPARED WITH ISOMETRICS AND APPROVED PIPING LAYOUTS. THIS MTO WILL HELP IDENTIFYING THE ADDITIONAL QUANTITIES DUE TO LAYOUT CHANGES, THE VENTS AND DRAINS AND MISCELLANEOUS LINES/ITEMS LEFTOUT IN THE PREVIOUS MTO STAGES.