- Shell, Channel & Boot Data
Except for Skirt and Nozzle (which will be elaborated on later), data of each crest-like part, to which one of the titles Shell, Channel, or Boot is applied (whether made of plate or pipe), will be entered on Shell page. To enter the data, first select Data Entering-1 from the main menu and then click on Shell icon.
Fig. 28 – (How to access Shell Data Entering Menu)
- General Structures
In PVManage software, a large number of structures are designed similarly. Therefore, processes explained about Shell page manage to be the same for other pages. If there are any special processes regarding any of the pages’ data entering, they will be explained accordingly.
One of these processes is inserting necessary data as minimums. Entering the following data on Shell page is necessary:
- Item No.
- Material Type
- Shell I.D.
- Shell Th’k
- Shell Length
However, it is not necessary to specify Subject and Material until some stages in the project. If we have entered necessary data, the software can figure the weight calculations and required parts, without considering the part’s material and its subject.
These data can be used up to the time you intend to buy materials and provide MTO. Yet, by the time you intend to buy materials, provide MTO or Part List, you will have to enter the data for the two items mentioned above.
- Necessary Fields
In case you have not completed a necessary field all over the software, and click on either “Save” or “New Part”, that field will turn red and the data registration process will stop.
Fig. 29 – (One of the Software’s Reactions to an Incomplete Necessary Field)
- Unreliable Data
The software will also show reactions to entering unreliable data. As an example, if fields which must be completed necessarily with a positive numerical data be completed with negative numbers or text data, the software will launch a reaction.
Fig. 30 – (An Example of the Software’s Reaction to Entering Unreliable Data)
There is another type of unreliable data which is identified and adjusted automatically by the software. To cite an example, if you have considered “Material Type” from Pipe, “I.D. (mm)” will firstly change to “Size (in)”, “Th’k (mm)” to “Schedule” and Material’s contents to pipe material. Secondly, as soon as you select one of “Size (in)” field’s options (for example 24 inches) in Schedule field, only options related to 24 inch in size will be observed. As a result, entering irrelevant data is impossible by all means!
- Material Field’s Intelligent Adjustment
There are two options with regard to material definition in PVManage software.
Fig. 31 – (Material Adjustment Options in the Software)
It is significant to distinguish between the two prior to further discussions.
- Material Library
Material Library is a collection of main materials which completes related fields. For example, there are 50 plate samples as main items in plate group. But, your required and utilized materials in the project might be out of this collection. Each user can add to this collection according to his/her own needs. In this case, added materials are credited in that very username and has no connection with other users (even if they work in one single organization and on one single project). Having said that, contrived materials stay intact in the software library.
Fig. 32 – (Material Library Menu)
Each field in the software, supposed to contain the plate material, will receive its contents from this collection from now on. Thus, any new option’s addition to this collection will spread all over the software.
- Material Index
Material Index is a collection of an item’s constituent materials. If you complete Material Index as you enter the data, material fields will be completed automatically and in proportion to this collection, not requiring to specify the material of a part per its definition. Moreover, you can change every option in its own place. To understand this matter fully, pay attention to an example:
Suppose that plates’ material of an equipment is SA-516 Gr.70 and that of its nozzles SA-106 Gr.B. Besides, take into account that this equipment contains 30 nozzles whose data must be entered into PVManage software. If you complete the Material Index of this equipment prior to entering the nozzles’ data, each nozzle’s material fields and its accessories will be completed automatically as you define the nozzle. Consider the following as accessories of each nozzle:
- Nozzle Material (Pipe / Plate)
- Flange Material
- Blind Material
- Gasket material
- Stud Bolt & Nut Material
- Reinforce Pad
- Vortex Breaker
- Internal / External Pipe
If you have not completed Material Index before, it is required to specify all or some of these items for each nozzle. This case becomes more complicated when your equipment containing 30 nozzles requires you to specify the material for all the parts per identifying each nozzle.
Not only does this task consume a great deal of time and bore the user, it also increases the possibility of committing errors in data entering. Although there are brisk tools included in PVManage software for duplicating and completing data (which will be introduced later on), we must constantly consider to avoid repetitive tasks and devolve them instead to the software. An example of a completed Material Index is presented in the following figure.
Fig. 33 – (Material Index Menu)
This menu is made of three separate pages and an appropriate tool is predicted in order to complete it in no time. If, as you enter data for an equipment, you enter only the “Shell Material” and then click on the option next to it ( ), all the fields containing the plate will be completed with the same material and you will be able to save all or change some of them.
Suppose that you have an equipment whose shell is constituted of SA-15 516 Gr.70 courses and one of its courses is made of SA-20 Gr.316 material. In that case, we choose the body material from SA-516 Gr.70 type in “Material Index” menu. Therefore, whenever we define a course of it, material will be completed automatically with SA-516 Gr.70.
However, we are authorized to select the desired material from “Material” field as we define a course with a different material.
This process applies to other subjects, as well. For example, if all “Fittings” of an equipment, except for one, are made of SA-234 WPB, we select the Fitting material according to SA-234 WPB when defining the “Material Index” of that equipment; and when defining the excepted data, we are authorized to select the desired material from the respected menu.
Fig. 34 – (The Ability to Select Different Materials with Material Index)
- Subject Option
This option is an unnecessary field and you can find it on all pages. However, it is strongly recommended to complete it because its existence will prove highly useful and applicable when organizing Part List or Nesting.
- Organizing Each Courses’ Constituent Plates
We can act in a number of ways to define each shell.
- Defining Each Shell as a Part
In PVManage software, all the three ways are devised and you can choose among them according to your taste. However, as the software designer, I present to you the best way. If you enter each shell as a part, you have chosen the best and the fastest method, provided that you consider each part as a shell when its diameter, thickness, and material are all the same. In other words, if your given shell has the same diameter, thickness, and material – regardless of its length- present it as a part in the software. The software will automatically provide you with its constituent parts!
If you intend to enter data of a shell with an internal diameter of 3,820, a thickness of 32, and a length of 15,200 millimeters – similar to the following figure – and you plan to use plates (courses) as width as 1,500 millimeters in its construction, present it as a part. Further explanations will be provided regarding the arrangement of its plates.
Fig. 35 – (A Shell Presented as a Part According to Its Structure)
As soon as you enter data of a Channel, Shell or Boot into the software (or you edit their former data), you must decide with respect to the status of its constituent plates in case this part is made of plate. Therefore, you will encounter a message dealing with the arrangement of its constituent plates.
Fig. 36 – (Message Dealing with Arrangement of Shell’s Constituent Plates)
If you choose “Yes,” the software employs its logic and based on the dimensions of the standard plate specified by you, manages to calculate the required plates to construct this Shell.
Fig. 37 – (Menu for Providing the List of Your Shell’s Constituent Plates Automatically)
Since you have chosen “Yes,” the software transfers Shell data in a manner unchangeable by you and you can only specify dimensions of the standard plate as well as the minimum distance between the two consecutive weld lines.
Dimensions of plates in use are standardly as follows:
6,000 x 1,250 9,000 x 1,250 12,000 x 1,250
6,000 x 1,500 9,000 x 1,500 12,000 x 1,500
6,000 x 2,000 9,000 x 2,000 12,000 x 2,000
6,000 x 2,500 9,000 x 2,500 12,000 x 2,500
In some circumstances, e.g. for certain materials and thicknesses as well as some factories’ products, there might be produced plates with dimensions other than the aforementioned ones. However, it is quite conclusive that the dimensions mentioned above can be regarded as standard ones in over 90% of cases. After designating the aforementioned data and clicking on “Calculate,” calculations will be conducted and a result similar to what you can see in the following figure will be offered to you.
If you intend to save these data, you are required to click on “Transfer to This Item” and exit the menu above.
Fig. 38 – (Automatic List of a Certain Shell’s Constituent Plates)
If you choose “No” in response to the message in Figure-36, you have personally taken the responsibility of plate arrangement of a certain Shell and you intend to define a Shell’s constituent plates manually. In that case, it is highly essential to point out two main points.
First: This is you who must adhere to the plates’ longitude. The software can neither know your mental plot nor analyze it by any means.
Second: in cases when you use a plate with certain unconventional dimensions (for instance a plate as wide as 3,500 millimeters), you have to introduce it to the software as Stock while preparing two-dimensional Nesting.
An image of the related menu can be seen in the following figure.
It is noteworthy that until the required area is supplied for constructing a certain Shell, the software will not save your defined parts. To put it in other words, your defined parts will be accepted provided that you supply the required area.
Fig. 39 – (Manual List of a Certain Shell’s Constituent Plates)
- Defining Each Course as A Part
If your courses are different – with respect to their diameters, thicknesses, materials or lengths – or if, for any reason, you would like or have to manage arrangement of each course separately, enter each course’s data as a, independent shell and then act according to one of the ways mentioned earlier to set its constituent plates.
- Defining Each Part of Plate of Each Course as a Part
Although this method is not recommended, you will, however, be able to enter each Shell or every constituent part of it as a square on this page using “Extra Part as Plate” option. Suppose that there are a number of plates in your work shop and you plan to use them in constructing a source or a Shell. In that case, it is still recommended to use “Defining Course as a Part” case coupled with manual defining of plate arrangement.
- Observing Each Shell’s Constituent Plates
After registering each shell’s data, you can observe each record’s constituent plates by right clicking on it.
Fig. 40 – (Observing Shell’s Constituent Plates)
If you have not yet set Shell plates, Show Sub Plate(s) option does not exist and you can only set its plates using Sub Plate(s) Define.
If you have already set Shell plates (whether manually or automatically) the number of its constituent plates are visible on Sub Plate(s) QTY column. Show Sub Plate(s) is active, too. Clicking on this option makes Shell constituent plates visible and reportable. If constituent plates are defined automatically, “Auto Course” is marked; and vice versa.
Fig. 41 – (Observing Each Shell’s Constituent Plates)
- Optimizing Plate Arrangement
If standard plates as long as 6,000 and as wide as 1,500 millimeters are used to construct the vessel in figure-35, development drawing and required materials are as in the following figure.
Fig. 42 – (Development drawing and Table of Vessel Materials with 6000 x 1500 Standard Plates)
If the minimum distance allowed between the weld lines is considered 400 millimeters, development drawing and table of required materials for the vessel above will be as the figure below. In this case, also, 6,000 × 1,500 millimeter plates are used.
Fig. 43 – (Development drawing and Table of Vessel Materials, adhering to the minimum distance)
Fig. 44 – (Cutting Plan with Regard to Fig. 43)
If the Vessel’s plate arrangement is performed based on 2,000 × 9,000 millimeters, development drawing and table of materials will be as the following figure.
Fig. 45 – (Development drawing and Table of Vessel’s Materials with 2000 x 9000 Standard Plates)
Fig. 46 – (Cutting Plan with Regard to Fig. 45)
If plate arrangement of the vessel above is performed based on 2,000 × 12,000 millimeters, and distance limits of the adjacent welds are still met, development drawing and table of materials will be as follows:
Fig. 47 – (Development drawing and Table of Vessel’s Materials with 2000 x 12000 Standard Plates)
Fig. 48 – (Cutting Plan with Regard to Fig. 47)
It is deduced from the previous figure that we can use 8 plates as long as 12,000 millimeters and 1 plate as long as 6,000 millimeters so as to reduce the amount of waste (although it is still usable and is introduced as Offcut).
If we have only one vessel or the project content is limited, it will be quite easy to prepare a cutting plan, as indicated above. However, in case the number of equipment items is large and we are subject to lack of time, the need to be furnished with an intelligent tool which can prepare the cutting plan as soon as possible is inevitable. Additional to this issue are market limits; the fact that dimensions of required plates are not always in accordance with our wishes and that market status designates the measurements of the plates in use!
Fig. 49 – (Comparative Table of Various Cases)
Comparing data in the table, we understand that case “A” is not an appropriate option, due to the long cut as well as the weld length (one and a half times more than other cases). Although case “B” has a shorter cut than other cases, it is not an appropriate option either because of greater amount of waste. It should be noted, too, that weld length is the same in all cases except for case “A”. Thus, “E” proves to be the best option because, compared with other cases, it has smaller amount of waste. We should also keep in mind that in case we are bound to choose between cases “B” and “C”, “B” will be the best option since it has a shorter cut. If plate’s waste is the basis for our decision, our most favorable option is still “E”. If, however, we regard the issue from a larger viewpoint, we can never neglect expenses caused by cutting, edge preparing, welding, and testing.
Frankly speaking, which pattern should we follow if we want to achieve all together the best plate arrangement mode for a number of vessels with respect to the aforementioned limits?
In a case when plate dimensions are changing constantly and especially according to the market status, how can we reach a favorable and appropriate result in no time using a brisk tool?
I will promise users of PVManage software that there are designed appropriate tools in the software to meet this requirement, which render the arrangement of your project’s entire required plate up-to-date in no time together with cutting plans of all the plates, offering them to you as an AutoCad file!
Selecting “Optimize” when setting each Shell’s constituent parts will calculate the best arrangement which is optimized in every respect. Keep in mind that you must consider the optimized mode of all issues (primary materials, the minimum weld line, the minimum waste).
- Adjusting Roll Margin
When you choose a Shell’s “Material Type” from the “Plate” type, you are allowed to consider a certain amount of every course as Roll Margin.
Fig. 50 – (How to Adjust Roll Margin)
This amount depends on the equipment which rolls plates. Typically, we consider the amount zero if the equipment consists of four rollers. Otherwise, a different number between 100 and 250 millimeters is considered as roll margin. This number will be present in plate supply calculations, but since it is removed after the rolling process, it will not be included in part weight calculations. Because this amount is different for each diameter, thickness, as well as factory, it can be adjusted for each course separately. Keep the fact in mind that this number must be taken into account for “Nozzle” and “Skirt”, as well.
- Observing and Adjusting Each Course’s Constituent Plates
Once you have decided about each course’s plates, you will be able to observe the list of constituent plates or adjust them anew. To do this task, right click on your desired record and choose the option in mind. If a record lacks these options, it signifies that you have not yet decided about its constituent plates, or that the course will be made of pipe and thus lacks constituent parts.
Fig. 51 – (How to Get Access to Each Course’s Constituent Plates)