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Mto Procedure

This document outlines the procedure for material take-off (MTO). It lists required inputs like P&I diagrams, line lists, and piping layouts. The procedure involves estimating quantities of pipes, fittings, valves and other items from the layouts. For critical large bore pipes, exact lengths are calculated by summing fitting and valve lengths. Smaller pipes use estimated coupling lengths. Accuracy improves from preliminary to final MTO as inputs become more defined with layouts and isometrics. The final MTO identifies changes from layout revisions and omitted items.

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Megat Ahmad Afiq Ahmad Shukri
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234 views

Mto Procedure

This document outlines the procedure for material take-off (MTO). It lists required inputs like P&I diagrams, line lists, and piping layouts. The procedure involves estimating quantities of pipes, fittings, valves and other items from the layouts. For critical large bore pipes, exact lengths are calculated by summing fitting and valve lengths. Smaller pipes use estimated coupling lengths. Accuracy improves from preliminary to final MTO as inputs become more defined with layouts and isometrics. The final MTO identifies changes from layout revisions and omitted items.

Uploaded by

Megat Ahmad Afiq Ahmad Shukri
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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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:

1. FIND OUT THE TOTAL LENGTH INCLUDING ALL ITEMS- PIPES, FITTINGS, VALVES, OTHER
SPECIALITIES, ETC.- AS SUCH FROM THE LAYOUT.

2. 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: -

a. ESTIMATE THE NUMBER OF FITTINGS – ELBOWS, TEES, REDUCERS, FLANGES, GASKETS,


BOLTS & NUTS, ETC.

b. 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.

c. 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.
3. 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.

4. 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.

5. 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.

6. 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.

7. 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.

8. 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.

9. 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.

10. 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 CLIENT’S 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.

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