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.