(pp)I had this same question a few months ago. Here is the discussion on that occasion.

(Q)I am trying to establish the piping database per your guideline, but right now I have some
questions as follows:

1. As far as I know, this code must be unique for each type of piping item. But if we do not
include the size as your point 11 above, then the code will not be unique anymore.

For example: if I have 10" x S80 Weld neck flange A182 RF and 8" x S80 Weld neck flange
A182 RF, the code will be the same as PA10S80 (P: piping, A: alloy, 10: weld neck flange
numbering in my database(ex: 11: slip-on flange, 15: equal tee, 16: reducing tee.. and so
forth), S80: schedule 80). How can I distinguish between these two without the size?

2. If I try to include the size, what is your advice with regard to some items with different sizes
at both ends such as: eccentric reducer or reducing tee or reducing cross. Right now I don't
know how to code this without further complicate the database

I find that the pipe with the same size, same material and same schedule but with different
end finish like: bevel end or plain end will complicate things even more.
The more I get into creating this database the more I get disorientated trying to incorporate
all piping info into just a few digits of code. Maybe I should use 10 digits.

(pp)I think that you need to start over again. You have forgotten a few basic issues that are
important to this effort.

(pp)Consider the following:

1. You say that you are trying to establish the piping database. No. you are trying to
establish a material item code structure that will fit piping materials (and others) and will not
be complicated.
2. You need to define ALL the places where an item code number will be used and how it will
be used. To do this you need to collect samples of all the documents where the Item Code
Number (ICN) will be used. These documents include the Piping Material Line Class
Specifications, The Bill of Material for each Isometric, The Purchase Order for piping materials,
etc. Also if you are going to require a pipe Shop Fabricator to use your ICN then you need to
consider the shop documents and systems. For each document type is there already a Field
or column for an ICN and for other things such as Size.
3. Go talk to the people in the IT (Information Technology) department about the added cost
of each additional digit to a field.
4. Your Piping Material Line Class Specification now probably has two metric letter size sheets
for all the material for a single line class. Here you find that it takes a single line entry for
Carbon Steel, Seamless Schedule 40 pipe , API 5L GR B, for sizes 3 (80mm) to 10 (250mm).
Under your premise of a separate code number for each size this would become 5 different
lines with 5 different code numbers. Consider what it will be if every item in the Line class
Specifications had a different item code number for each different item for each different size
and each different end connection.
5. Item code numbers should be designed to get you to the primary item. In the piping
industry for the last 100 years or so there have been items that almost always have the same
description for multiple sizes. This should bring you to the understanding that you can group
multiple sizes under one ICN and then use a Qualifier (size) to define the differences.
6. Another qualifier is the End Prep (Bevel End, Plain End and Thread End) which can be
added to the BOM and Purchase order. If you take all the possible size combinations for the
Concentric and Eccentric Swedges times all the possible end preps you will have a very long
list and it is just not cost effective.
7. Valves are another thing that can be a simple one item code with a size qualifier or a
nightmare of added cost. Example: Class 150 Carbon Steel Gate Valve with F6 Trim can be
one item code with the size (3 to 24) added in the size column of the BOM or PO or you can
have 12 different item code numbers and 12 different line items on your Piping Material Line
Class Specifications for this one valve.

(pp) The following is a list of recommendations for the development of a Piping Material
Commodity Code.
The Item Code
1. Keep the length of the piping material Item Code Number as short as possible. Keep it
simple. In the past (30, 40 years ago) one of the major clients at the time had piping item
code numbers 27 digits long. They claimed that they wanted the item code number to be a
Smart number. By that they meant that each position had a specific meaning. It was a real
mess.
2. The Item Code Numbers should allow for and fit all the other Bulk Material Disciplines
(i.e.: Structural, Civil, Electrical, Instruments, etc.)
3. The Item Code number should not be more than 7 digits long. Example: PC12345
4. The first position is the discipline P=Piping, S=Structural, E=Electrical
5. The first and second position are Alpha only
6. The second position is Alpha only and for Piping might be C for Carbon Steel
7. All other positions would be Alpha-Numeric and different for each discipline depending on
needs.
8. The third and forth position might be a two place designation for object type (Pipe, fitting,
flange, valve, gasket, bolts, etc.) With two places you have 00 to 99 plus AA to ZZ plus 1A to
9Z and that is a lot of different items (1036).
9. Position 5 and 6 could be the rating designator. With two places you have 00 to 99 plus AA
to ZZ plus 1A to 9Z and that is a lot of different ratings (1036).
10. Position seven could be reserved for a special qualifier.
11. Do not make the mistake of trying to include the size in the Item Code Number. That just
complicates things too much.
12. Start out by analyzing all the material you purchased on the last four or five projects.
Select the mainstream items and then leave gaps in the Code number structure. Using the
guidelines above apply the preliminary Code Number to the full purchase description for the
Items that you repeat purchase. Then run a test on the Catalog.

(pp) If seven positions do not give the flexibility needed for your company then the position 8
&/or 9 can be added. Just remember for each digit you add you must check for all the places it
will be used on printed documents. This includes the Bill of Material (BOM) on the Isometric,
Purchase Orders, etc. Is there space available for a larger number? A word of advice here,
dont try to make the Item Code number too smart.

(pp) The Item Description

For a "Smart" Item Description you would need to provide the following (Example Gate Valve):
Company material item code number for primary identification ( example: 5051771)
Name (example: Gate Valve)
Rating and Facing (example: 300# RF)
Reference Manufacturer: Voit (Model Number) or Equal
Operator- Handwheel (could be gear operator or Motor operator)
Body Material (example: Carbon Steel)
Disk Material (example: Disk Carbon Steel)
Seat Material (example: Seat F6)
Stem Material (example: Stem Carbon Steel)
Stem Packing Material (example: Teflon)
Body Taps None (or define which Body tap you want drilled and threaded)
Testing - (define Manufacturer standard or other)
Painting- (None, Manufacturer Standard, Prime only, special as you define)
Shipping Preparation- Rust preventative on Flange faces, Stem and all other unpainted
surfaces.
Packaging Standard (non-Ocean going shipping), Special (for Ocean or export shipping)
(pp) This is trying to be way too smart!
Some of this can be included in the special notes section of the P.O.

prognosis: Lead or Lag

BigInch (Petroleum)21 Dec 12 16:23

Here's what I've done.
Just give them mark numbers that do not relate to size or component. Write the mark
numbers on the drawings showing the part, but only on one drawing. In the case of pipe
extending across several drawings, or more, write the mark number on the drawings each
time you add the length of pipe shown on that drawing to the material take off. That
drawing(s) becomes the reference drawing(s) for that mark number and component.

"People will work for you with blood and sweat and tears if they work for what they believe in......" -
Simon Sinek

StevenHPerry (Mechanical)26 Dec 12 13:12

SRUTGU,

If you use a 3D design software (e.g. SmartPlant, AutoPlant, etc) the software developer most
likely had some commodity code schema delivered with the software. Look into adopting that
before you venture too far down the path of making your own.

There are commercial software solutions that are dedicated to this task, but they make things
painfully complicated. I am working on HDPE pipe today and here is my pipe commodity code
from one of those material management software packages: NTPIPAX2AWAX10XBAZZZ. Good
luck decoding that! It's almost shorter for me to spell out exactly what I want than use a
commodity code for some components.

If you do make your own system, begin with the end in mind and keep it simple. Allow for
flexiblity in your codes but strictly enforce the rules set. Divergent, overlapping, or competing
commodity codes undermine your whole effort. Invest a little money in a simple Excel or
Access application that manages your commodity codes and enforces the rules.

Devil's advocate against your first example: there's more than one type of carbon steel. Even
the commonplace ASTM A53 carbon steel pipe offers 3 grades and 3 types. You can
additionally specify a few more "flavors" on top of those 9 vanilla combinations. Plus, if you
buy A53-B Type S, it may be delivered as dual or triple graded pipe with the equivalent A106
and API grades. Will your warehouse be able to cope with that or are they looking for a
verbatim match?

- Steve Perry
This post is designed to provide accurate and authoritative information in regard to the subject
matter covered. It is offered with the understanding that the author is not engaged in rendering
engineering or other professional service. If you need help, get help, and PAY FOR IT.

SRUTGU (Chemical)
(OP)
27 Dec 12 08:57
Thanks everyone for all of the good suggestions. Even though I thought someone would have
developed a part numbering system that had some relationship to the actual piping
components, apparently not. I had remembered a piping model system that was being
developed that had such of a system, but could not find it either.

In the engineering and design of our typical facilities, I think I have developed a system that
will work for 98% of our material requirements.

Thanks again for your help. I hope all of you had a good Holiday and wish you a Happy New
Year!
Piping Questions - Norms & Assumptions For Piping &
Structural Work
1. Write the estimation for welding consumables for piping work (Groove & Fillet welding)?
2. What are the consumption norms for grinding/cut-off wheel?
Answer:-
For piping work:-
A. Grinding wheel for fabrication : 0.035 Numbers/ inch dia.
B. Grinding Wheel for joint grinding for UT : 0.012 Numbers/ inch dia.
For structural work:-
A. Grinding Wheel AG 7 (7"*7MM) : 0.75 Numbers/ MT.
B. Grinding Wheel AG 5 (5"*5MM) : 0.25 Numbers/ MT.
For support fabrication at shop:-
A. Grinding Wheel : 2 Numbers/ MT.
3. What are the consumption norms for Dissolved Acetylene and Oxygen?
Answer:-
For piping work:-
A. Dissolved Acetylene (D.A.) : 0.0140 Cu-M/ inch dia.
B. Oxygen (O 2 ) : 0.0510 Cu-M/ inch dia.
For structural work:-
A. Dissolved Acetylene (D.A.) : 2.2 Cu-M/ inch dia.
B. Oxygen (O 2 ) : 8.0 Cu-M/ inch dia.
For support fabrication at shop:-
A. Dissolved Acetylene (D.A.) : 3.5 Cu-M/ inch dia.
B. Oxygen (O 2 ) : 12 Cu-M/ inch dia.
4. What are the manpower deployment norms for structural steel work?
Answer:-
For fabrication of 1 MT of structural steel per day, the manpower required is as:-
A. Welder : 02
B. Fitter : 02
C. Gas cutter : 01
D. Grinders : 01
E. Riggers : 02
F. Helpers & others : 02
For erection of 1 MT of structural steel perday, the manpower required is as:-
A. Welder : 0.75
B. Fitter : 01
C. Gas cutter : 01
D. Grinders : 0.5
E. Riggers : 03
F. Helpers & others : 02
5. What are the manpower deployment norms for piping erection work?
Answer:-
Normally, 90 to 120 IM is erected per day per gang. One gang comprises the following:
A. Welder : 01
B. Fitter : 01
C. Gas cutter : 0.5
D. Grinders : 0.5
E. Riggers : 04
F. Helpers & others : 02
6. What is the productivity of the welder for plant piping and for off-site piping?
Answer:-
PIPE SIZE FOR PLANT PIPING FOR OFF-SITE PIPING
Upto Dia. 1 10 ID/welder/day 12 ID/welder/day
Dia. 2 to 12 16 ID/welder/day 18 ID/welder/day.
Dia. 8 to 12 18 ID/welder/day 20 ID/welder/day
Dia.14 & above 20 ID/welder/day 22 ID/welder/day
7. How many pipe joints for plant piping & for offsite piping are assumed?
Answer:-
PIPE SIZE FOR PLANT PIPING FOR OFF-SITE PIPING
Upto Dia. 1 1JT/MTR. 1JT/2MTRS.
Dia. 2 to 6 1JT/1.5MTR 1JT/4MTRS
Dia. 8 to 12 1JT/2MTR 1JT/4MTRS
Dia.14 & above 1JT/2.5MTR 1JT/4MTRS
8. What are the consumption norms for Electrodes & Filler wire?