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ystem for piping

global management

A White PaperFebruary 2004

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System for piping global management 3

Table of contents Summary..................................................... 4

Modules....................................................... 5

Piping Classes ............................................. 6

Data Dictionaries 6

Tables 6Piping Classes 7Branch Tables 7

Assemblies 8Components catalogues 9

Process........................................................ 10

Fluid List 10Line List 11

Take-off....................................................... 12

MTO checks 12Surplus Tables 12Bill of Materials List 13Shop fabrication 13

Mechanical Checks ...................................... 14

Checks for internal/external pressure 14Checks for intersections 14

Material Requisitions................................... 15

Requisition generation and issue 15

Painting & Insulation .................................. 16

Order........................................................... 17

Main functions 17

Cosmo ......................................................... 18

Simulation of line feasibility 18Document management 19

Import / Export........................................... 20

Integration with CAD modules .................... 21

AP-Link 21PDS-Link 22

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4 System for piping global management

Summary Puma5 is an application software system for the piping materialsmanagement, specifically developed for the companies working inthe industry plant layout, such as: refinery, petrochemical, powergeneration, iron and steel, water treatment, naval,pharmaceutical, food, construction and erection, etc..Besides exploiting the normal functions which are typical ofmanagement systems, Puma5 is really a working methodology

since it is an effective tool for the execution and optimisation ofdesign and management activities, during the whole project life-cycle, from the piping classes creation up to the materialsaccounting and related MTOs, procurement and construction.Its features, based on major international EPC Main Contractorsrequirements, permit the execution of piping design andmanagement activities in a fully integrated environment andthrough 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 MTOs 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 andintersections

Management of prefabrication and site construction anderection

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 immediateimport/export towards Word and Excel. It is available in bothClient-Server and Web-enabled version, which provides thecentralised project database to be concurrently accessed byClients, Contractors and Sub-Contractors, Partners, Constructionsites, etc

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Piping Classes Dictionaries for the definition of components,materials, design standard with automatic creation of

codes

Process Definition and management of conveyed fluids processdata, with check of data consistency and alignment of

piping classes, Line List and Fluid List

Take-off Materials accounting to obtain the MTOs forprocurement and construction, both from manualinput and directly from 3D CAD systems

MechanicalChecks

Checks on component dimensioning in accordancewith the design codes, calculation of hydraulic orpneumatic minimum test pressure and definition oftest circuits

Material

Requisitions

Generation of requisitions, from MTOs and/or

simulated accounting, grouped and organised perproduct class, project or sub-project, destination

Painting &

Insulation

Surfaces and quantities calculation of painting andinsulation based on Line List data and componentquantities contained in MTOs

Order Supporting the procurement activities by providingcontinuously updated situation of materials, frombidding of requisitions to comparison, purchase order,expediting and shipping

Cosmo Management of piping during prefabrication anderection activities, including the feasibility andconstructability analysis

Import / Export

Data import/export from/to different groupsperforming accounting activities, export in the mostcommon formats, interface with other applications

Modules

Integration

with CAD

modules

Interface and integration with the most commonlyused 3D CAD systems, which permit the quick andeasy generation of component database and pipingclasses, as well as to directly import the models

material list

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Piping Classes This is the main module in PUMA5 which providesthe definition of dictionaries (including components,materials, design standard, weights, stud and boltsdimensions, component selection rules), as well aspiping classes, intersections and assemblies, withautomatic creation of codes for each project

components. It is composed by several applicationshere below described.

Data Dictionaries

they comprise the basic information for thedefinition of piping components, i.e. materials,standards of design, piping objects, rules forcomponent generation.

Tablesfor component weight calculation, definition ofcomponent attributes in accordance withengineering standards, welding generation, bolt sizeautomatic generation, CAD dimensional tables. Theyinclude also the ANSI B31.x and ASME VIII formechanical checks.

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Piping Classes

they define the characteristics of project pipingcomponents and are easily and quickly filled in byusing the Data Dictionaries. Once ready PUMA5 willautomatically 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 betweenheaders and branches for the specific project.A branch table can be linked to one or more pipingclasses, this automatically defines the intersectionobjects foreseen in the linked piping class, avoidingany mistakes in automatic import of take-off.

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Assemblies

together with the related piping classes the assemblydefines the typical components of a standardarrangement, typically they are: vents, drains,instrument connections, steam traps.

In Puma5 the assemblies are easily standardized andthis provides the automatic calculation of theassembly piping components.

Form for assembly definition

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Components catalogues

These are automatically obtained by the pipingclasses, the objects of which produce a number ofcomponents related to the selected sizes range. Eachcomponent is automatically associated to its

description, weight, surface and to two differentcodes: one used in the database (Corporate Code) andthe other used in the Project (Mark). The systemallows for the utilisation of User coding in case ofCompanies having their own coding.

Generation of component catalogue

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Process This module allows the management of process datain the Fluid list and Line List, thus permitting aconstant control of the revisions and an automaticadjustment of the data and documents created inthe different engineering phases (Piping Classes,Material Take-Off).

Fluid List

The conveyed fluids are defined by indicating themaximum pressure and temperature conditions, thecomponents main characteristics, i.e. basic material,rating and flange facing, heat treatment and valvetype. The application creates links between Fluid List,Piping Classes and Line List, in order to assure thealignment and simulate the consequences of

modifications on the Project Line List and on the Take-Off.

Form for the definition of the fluid list

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Line List

Puma5 allows to create links among Line List, FluidList and Piping Classes in order to assure thealignment and simulate the consequences ofmodifications on the Project Line List and on the Take-

Off.

Form for the definition of the line list

Warnings list

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Take-off This module permits the execution of materialsaccounting to obtain the MTOs for procurement andconstruction. The Take-Off may be performed by lineor by isometric drawing. The input is easy and fastand can be manually performed through a friendlyinterface that allows to select components directly

from the Piping Classes, or to record the materiallists automatically from CAD systems throughimport/export interfaces.

Form for the material accounting

MTO checks

The material quantity variations due to PipingClasses revisions are automatically recorded and

upgraded, also while the work is in progress, thusgranting always the consistency among MaterialTake-off, Piping Classes and Material Requisitions.

Surplus Tables

Possibility for the user to create and apply his ownsurplus tables, which will automatically increase thequantities of the calculated materials, in order tobalance the construction and erection scraps.

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Bill of Materials List

From the Bill of Material List the user can directlyobtain the lists normally needed for planning andmanagement control as well as for prefabrication anderection, 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 candefine the divisions between prefabrication anderection and obtain the related list accordingly.

Definition of prefabrication

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MechanicalChecks

This module performs the mechanical checks of thepiping components according to the standard pipingdesign codes, which are: ASME B31.1, B31.3, B31.4,B31.8, ASME VIII. Also the check of rating curvesand their automatic association to piping classes isperformed, together with the calculation of minimum

test pressure (hydraulic or pneumatic) and thedefinition 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-pipeintersection may be checked at the piping classmaximum conditions or at the effective designconditions indicated in the Line list.

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MaterialRequisitions

From the MTO the Material Requisitions areautomatically obtained, grouped per: project, sub-project, destination. The materials components areorganised according to aggregations (product class)that meet the selected market suppliers. The MTOquantities may be manually and/or automatically

increased or decreased (by means of the surplustables), before the requisitions issue. It is alsopossible to issue material requisitions for materialsnot yet included in the Take-Off. Possibility to exportdata 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 areissued or updated. The application automaticallymonitors the difference between actual and previousneeds, by comparing the quantities already issued forpurchase and the updated quantities from Take-Off.

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Painting &Insulation

This module performs the calculation of surfaces andmaterial quantity necessary for painting andinsulation. The calculation is based on the ProjectLine list data (i.e. temperatures and coating types)and the Material Take-Off data (i.e. materialquantities and types).

The module is provided with a complete set ofdictionaries for: painting materials, insulationmaterials, piping components surfaces and the mostused standard coatings.An easy-to-use interface allows the selection ofreports according to the user needs.

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Order This tool supports the procurement activities andmaintains continuously updated the material trackingsituation. It provides for time and cost reduction aswell as for bottleneck and errors reduction for thewhole procurement activity (requisitions, bidding andcomparison, P.Orders, shipping).

The integration with engineering permits to mitigatematerials surplus and to globally shorten the materialmanagement

Main functions

The application permits the continuous control of allmaterials during all the typical procurement phases,starting from the requisitions of bids to Vendors to thecomparison 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 commercialcomparisons

Automated data updating through standard formatimport

Configurable access by third parties, such as

Vendors

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Cosmo It allows the management of field warehouse and ofprefabrication and erection works. By using the dataimport functions, this module gets from PUMA5 theinformation related to the component characteristicsand their layout on the lines. These data, togetherwith the data from procurement (requisitions,

purchase order, packing list) and the warehousematerials availability allows the analysis of linesfeasibility.

Simulation of l ine feasibility

The application analyses the store situation andprovides, for the interested lines, the percentages offeasibility with the list of components necessary tocomplete the line, based on actual material

availability. It is possible to select the lines to beanalysed by assigning them the construction priority.The selection of the lines may be carried out on thebasis of defined criteria (such as plant, fluid, etc.).The application allows also to carry out the feasibilitystudy with a theoretical materials supply, based on theincoming orders and the present availability.Once selected the lines to be prefabricated or erectedthe application unload automatically the store andprint the delivery vouchers for the storekeeper.

By using the load/unload functions the storehousesituation is continuously maintained updated and therelevant materials situation can be printed whenneeded.

Form for feasibility simulation

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Document management

COSMO allows the management of documents relatedto piping materials life-cycle, thus permitting thecheck of procurement situation.This provides the traceability and procurement statusfor each component during its life-cycle phases (Take-

Off quantity, requested quantity, purchased quantity,shipped quantity, forecast incoming quantity,delivered quantity, etc.).

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Import / Export To make the use of Puma5 more flexible, particularattention has been given to the exchange of dataamong different working groups.

Ex t e r n a l co m p a n ie s :to make easier the

transfer of data to/from external companies in case

of subcontracted works, appropriate functions havebeen implemented to import/export data from PipingClasses, Take-Off and Line List.

This is obtained by installing Puma5 in thecomputers of the external companies, then thepiping classes are transferred there to permit theaccounting activities. When finished the MaterialTake-Offs can be collected in the main computer toobtain the project MTO.

D r ie :this tool handles the operations of

importing/exporting data from other applications. Itsmain characteristic is the possibility of configurationdirectly by the end-user, including the definition ofthe record layout of files to be imported or exported.

The main purpose of this module is to allow an easytransfer of data from/to Puma5 without creatingspecific interfaces, saving time and maintenanceoperations.

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Integration withCAD modules

These are interface and integration modules with themost commonly used 3D CAD systems, which permitthe quick and easy generation of componentdatabase and piping classes, as well as to directlyimport the models material list. The modules atpresent 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 Puma5component catalogue, revision management.

Piping class generation: generation of componentdatabase and piping classes for the modulesAutoPLANT Piping 3D and Isometrics.

Material take-off import: the material lists areautomatically imported from 3D model and isometricsto proceed with the following MTO and procurementsteps.

Form for the generation of the piping classes

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PDS-Link

Piping Class generation: PDS-Link allows toautomatically generate the piping classes and theirsupporting 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 dependingmaterial data, Weight tables.

Material take-off import: from Model 3D or fromIsogen (Alias) the material lists are automaticallyimported to proceed with the following MTO andprocurement steps.

Form for the generation of the piping classes

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Prepared by

COMPUTER LINE ASSOCIATES S.r.l.

Via della Viggioletta, 8 - 29100 Piacenza, Italy

tel.: +39 (0523) 497066 fax: + 39 (0523) 497713

web site: www.cla-it.com

Computer Line Associates believes the information in this publication is accurate as of itspublication 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 errorsin this document. Reproduction, distribution, and transmission of this document by any means

photo static or electronic is restricted without authorization. Microsoft and Windows are registeredtrademarks of Microsoft Corporation. Other brands and product names are trademarks oftheir respective owners.

CLAP5WP022004

Printed in Italy.

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