ABB Lummus Global B.V.

SPECIFICATION
Client Plant Location Shell Eastern Petroleum (Pte) Ltd. Shell ECC Project Singapore Pular Ular, Singapore 421 Dept./Sect. Doc. No. Always refer to this number 04217 Project H-655 Specification Rev. 0.001.00

E-00000-PI-7737-0024

THIS DOCUMENT/DRAWING IS THE PROPERTY OF ABB LUMMUS GLOBAL B.V. INCLUDING ALL PATENTED AND PATENTABLE FEATURES AND/OR CONFIDENTIAL INFORMATION AND ITS USE IS CONDITIONED UPON THE USERS AGREEMENT NOT TO REPRODUCE THE DOCUMENT/DRAWING, IN WHOLE OR IN PART, NOR THE MATERIAL DESCRIBED THEREON, NOR TO USE THE DOCUMENT/DRAWING FOR ANY PURPOSE OTHER THAN AS SPECIFICALLY PERMITTED IN WRITING BY ABB LUMMUS GLOBAL B.V.

Specification For:
PIPING MATERIALS QUANTITY CONTROL AND ISOMETRIC PRODUCTION

1.00 0.00
REV.

2006-1212 2006-05-22
DATE

Updated For information

DESCRIPTION

JPLI CLY
PREPARED

CLY JBRO
CHECKED

ADB ADB
APPROVED

LGN SSPE xx-xxxx-xx.xxx (2002-04-10)

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INDEX SECTION PAGE

1. INTRODUCTION 2. OBJECTIVE 3 3. ABBREVIATIONS 4. DEFINITIONS 5. MATERIAL CONTROL PRINCIPLES 5.1 BEST QUANTITY CONCEPT 5.2 PIPING MATERIAL QUANTITY CONTROL PROCESS OVERVIEW 6. TOOLS 5

3 4 4 4 4

6.1 MTO-EXPLORER 6.2 MARIAN 6

6.3 3D CAD (PDMS) 6.4 PIAS, ISOMETRIC CONTROL 6.5 INTERFACES 7. POINTS OF ATTENTION 8. ATTACHMENTS

6 6 7 7 8

LGN SSPE xx-xxxx-xx.xxx (2002-04-10)

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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 requiring the best effort of all piping designers and engineers. A Piping Designer is not only responsible for piping layouts and/or isometric production, but also material quantity control is part of the responsibility. The initial procurement of piping materials is based on estimated quantities (the bulk MTO). In the course of the project these bulk quantities must be upgraded when actual required quantities become known based on design development. Regular top-up requisitions will be required to keep 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 Control System using MARIAN (our material management database system) that will assist the project in 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 material management.

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 strictly followed to ensure that the above objectives are met. Not adhering to these instructions and guidelines 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 AFC BOM CAD CWP DEC EPC ITAS LGB LGN LGNU Above ground Approved For Construction Bill Of Material (piping materials relating to a single isometric) Computer Aided Design Construction Work Package Detail Engineering Center (i.e. LGB, LGS or Teil) Engineering Procurement Construction (Detailed Design) IT Application Support ABB Lummus Global Brno office ABB Lummus Global The Hague office ABB Lummus Global The Hague - Underground Piping Department

ABB Lummus Global B.V. SPECIFICATION

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LGS LPA MOPEX MTO PDMS PEFS PIAS TEIL UG WBS

ABB Lummus Global Singapore office Line-number per Area (may consist of multiple isometrics) Multi Office Project Execution Material Take-Off (Piping Materials) Plant Design Management System (3D CAD tool from AVEVA) Process Engineering Flow Scheme Piping Isometric Administration System Toyo Engineering India Mumbai Office Underground 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 be managed 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 very important status, and adherence to its definition is crucial in the Material Quantity Control workflow. This project (and also MARIAN) is organized in areas in line with the WBS. The Piping bulkMTO is also prepared per Line-number Per Area (LPA). In a way MARIAN does not contain one large bulk MTO for all piping materials, but many small bulk MTO's, one for each line-number within an area (i.e. one for each LPA). The material quantities of these small bulks are to be managed 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. 5.1

MATERIAL CONTROL PRINCIPLES 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. Ppartly bulk MTO quantities (based on the initial or updated manual bulk MTO), Ppartly upgraded quantities from PDMS (based on checked and distributed isometrics) and Ppartly 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 Explorer for 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 long as 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 o o o Changes in LPA breaks Changes in line-numbers or area allocations Deletion or addition of line-numbers (and related materials) 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 material management.

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 been uploaded 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 major changes to the bulk MTO for all open LPAs (see Attachment 1 par. 2) 6.2 MARIAN MARIAN is our Material Management System, a huge database where the bulk MTO is stored and maintained e.g. via uploads from 3D CAD (PDMS). MARIAN is also the source for all requisitioning 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 to MARIAN, 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, isometrics generated and final material quantities extracted for further processing in MARIAN. Important: Proper use of PDMS macros, forms and menus are important for properly setting of various 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 between MARIAN and PDMS. PIAS will initiate the upload of material quantities from PDMS to MARIAN for isometrics with the appropriate status. PIAS will also flag Closed LPAs when the last isometric of an LPA is distributed (closing the LPA). Proper isometric planning and revision control in PIAS is very important for the material management concept (and also for progress control). Distributing the last isometric of an LPA will set the LPA status from open to close. One must make certain that it really is the last isometric of the LPA. Examples: When inadvertently all isometrics (as listed in PIAS) of an LPA are distributed B1, but not all isometrics of that LPA are yet registered in PIAS (i.e. PIAS is incomplete), the MARIAN bulk will be replaced by insufficient material quantities of the incomplete LPAisometrics. The opposite is dangerous too: When all isometrics of an LPA are distributed B1 (and the whole LPA is covered), but PIAS still contains a superfluous isometric-number of that LPA, the MARIAN bulk will not 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 fast trending of material quantities. Also the priority definition as set for the project need to be followed. TEIL will not use PIAS but use a Status file for its revision control. TEIL will initiate the upload of material 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 to open).

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PIAS will also provide input to iWorks, a software application used by the Material Management Department (LGN) to produce isometric production curves, to analyze the subcontractors workfront, for planning, etc. As TEIL is not using PIAS, TEIL will have to produce a weekly interface file, in accordance to specification E-00000-KA-7880-0005 Isometric Data for iWorks. 6.5 INTERFACES The listed tools have a direct relation with each other. The following picture is a simple schematic 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 understand the concept as described in this specification, and adhere to the instructions and guidelines provided in this specification and its attachments, as well as in all other project instructions and specifications. 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 (and subsequent 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 to maintain the piping bulk MTO (and subsequent material requisitions) for closed LPA isometrics. 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).

ABB Lummus Global B.V. SPECIFICATION

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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 when materials are uploaded to MARIAN. If you need a piping component not available in the PDMS 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 such changes affect the MTO and you must take appropriate action to correctly implement the related 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 PDMS command prompt. Many forms and macros not only execute commands properly, but also set various attributes in the background of PDMS that are essential for correct handling of the materials. Only use the command prompt to quickly move or rotate components, or for queries. 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 piping material quantities. ATTACHMENT 2: Piping Isometric Production: This attachment covers the requirements for the isometric production in relation to correct material management such as status and revision control.