BM AUTOMATIC CALCULATION METHOD FOR PLANT STATIONARY EQUIPMENT

Abstract

The present disclosure relates to a bill of material (BM) automatic calculation method for plant stationary equipment, and more particularly, to a BM automatic calculation method for plant stationary equipment capable of automatically calculating BM data for purchasing a plate required quantity required for manufacturing stationary equipment through cutting plan and optimization deployment in order to manufacture stationary equipment using data extracted from a strength calculation program of the plant stationary equipment prepared in a plant engineering step. The present disclosure has an advantage of greatly reducing the labor force by automatically calculating the cutting plan drawing, the nesting plan drawing, and required BM of the plate of the stationary machine which has been manually performed in the related art.

Claims

1. ABM automatic calculation method of plant stationary equipment implemented by a computer comprising the steps of: (a) performing strength calculation for each item of a stationary machine having each unique number based on process data required in a plant using a strength calculation program and extracting input data in a first format from a strength calculation result for each item in which the strength calculation is performed; (b) extracting all object data for each item for preparing drawings from the extracted input data in the first format and converting all of the extracted object data into a second format; (c) extracting only information on a part where an item-specific plate is used from all of the object data for each item converted into the second format and generating total part list data interlocking with an MPS number sheet in information data for the extracted part where the item-specific plate is used; (d) loading the total part list data as input data in a BM calculation program; (e) setting the standard of a purchasing plate built with a library within the BM calculation program; (f) setting cutting and fabrication margins for each part for preparing cutting plan drawings built with the library within the BM calculation program; and (g) calculating BM related data by executing the BM calculation program.

2. The BM automatic calculation method of plant stationary equipment of claim 1, wherein in step (a), the first format is formatted in an XML file form.

3. The BM automatic calculation method of plant stationary equipment of claim 1, wherein in step (b), the second format is formatted in a data sheet file form.

4. The BM automatic calculation method of plant stationary equipment of claim 1, wherein in step (b), all of the object data for each item of the stationary machine include nozzle data, design data, material specification data, and detail drawing data.

5. The BM automatic calculation method of plant stationary equipment of claim 1, wherein in step (c), the part where the item-specific plate is used includes a shell, a head, a cone, a nozzle neck, a reinforced pad, a wear plate, and a stiffener ring, which are parts included in the item-specific object data converted into the second format.

6. The BM automatic calculation method of plant stationary equipment of claim 5, wherein information about the parts of the shell, the head, the cone, the nozzle neck, the reinforced pad, the wear plate and the stiffener ring is name information of each part, type information of each part, size information of each part, and material information of each part.

7. The BM automatic calculation method of plant stationary equipment of claim 1, wherein the material purchaser specification (MPS) number sheet of step (c) is mutually mapped based on an item number of the stationary machine and interlocks with the information data for the part where the plate is used.

8. The BM automatic calculation method of plant stationary equipment of claim 7, wherein items to be added to the total part list by the interlocking of the MPS number sheet are a project number, a requisition number, and an MPS number.

9. The BM automatic calculation method of plant stationary equipment of claim 1, wherein the total part list of step (c) includes data for size information, material information, shape information, MPS number information, and dimension information on the item-specific plate application part.

10. The BM automatic calculation method of plant stationary equipment of claim 1, wherein the setting of the standard of the purchasing plate in step (e) is to set minimum and maximum sizes of a width and a length of a purchasable plate as defaults in the library and set the standard of the purchasing plate within the set default range.

11. The BM automatic calculation method of plant stationary equipment of claim 1, wherein the setting of the cutting and fabrication margins for each part in step (f) is to set the cutting and fabrication margins in consideration of a consumed amount during cutting and a consumed amount during fabrication.

12. The BM automatic calculation method of plant stationary equipment of claim 1, wherein step (g) includes (g-1) preparing a cutting plan drawing according to the set cutting and fabrication margins for each part; (g-2) preparing a nesting plan drawing optimized by disposing the cutting plan drawing in the standard of the set purchasing plate; and (g-3) generating BOM list and cutting plan part list data based on the nesting plan drawing.

13. The BM automatic calculation method of plant stationary equipment of claim 12, wherein in step (g-2), a part-specific cutting plan drawing having the same MPS number, the same thickness, and the same material is disposed in the optimized nesting plan drawing.

14. The BM automatic calculation method of plant stationary equipment of claim 1, wherein the BM calculation program in steps (d) to (g) is executed on an AUTOCAD as a universal drawing preparation program.

15. The BM automatic calculation method of plant stationary equipment of claim 1, wherein the BM related data includes a cutting plan drawing, a nesting plan drawing where the cutting plan drawing is optimized and disposed, BOM list data, and cutting plan part list data.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The above and other aspects, features and other advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0030] FIG. 1 is a flowchart of a BM automatic calculation method for plant stationary equipment according to the present disclosure;

[0031] FIGS. 2 and 3 are exemplary diagrams for a second format form in the BM automatic calculation method for plant stationary equipment according to the present disclosure;

[0032] FIG. 4 is a diagram for a program screen for generating a total part list in the BM automatic calculation method for plant stationary equipment according to the present disclosure;

[0033] FIG. 5 is an exemplary diagram of an MPS number sheet interlocking with a program for the total part list in the BM automatic calculation method for plant stationary equipment according to the present disclosure;

[0034] FIG. 6 is an exemplary diagram of the total part list expressed by execution of the program of FIG. 5;

[0035] FIG. 7 is an exemplary diagram for a start screen of a BM calculation program in the BM automatic calculation method for plant stationary equipment according to the present disclosure;

[0036] FIG. 8 is an exemplary diagram for a screen for setting cutting and fabrication margins for each part in the BM calculation program of FIG. 7;

[0037] FIG. 9 is an exemplary diagram for a screen for setting a standard of a purchasing plate in the BM calculation program of FIG. 7;

[0038] FIG. 10 is a program screen for a step of preparing a cutting plan drawing in the BM calculation program of FIG. 7;

[0039] FIG. 11 is an exemplary diagram of the cutting plan drawing prepared through the BM calculation program of FIG. 10;

[0040] FIG. 12 is a program screen for a step of preparing a nesting plan drawing in the BM calculation program of FIG. 7;

[0041] FIG. 13 is an exemplary diagram of the nesting plan drawing prepared through the BM calculation program of FIG. 12;

[0042] FIG. 14 is a program screen for a step of generating BM-related data in the BM calculation program of FIG. 7;

[0043] FIG. 15 is an exemplary diagram of a BOM data sheet generated by FIG. 14; and

[0044] FIG. 16 is an exemplary diagram of a cutting plan part list data sheet generated by FIG. 14.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0045] Hereinafter, exemplary embodiments of the present disclosure in which the above objects can be specifically realized will be described in detail with reference to the accompanying drawings. In describing the embodiment, the same name and the same reference numeral are used with respect to the same component and the resulting additional description will be omitted.

[0046] FIG. 1 is a flowchart of a BM automatic calculation method for plant stationary equipment according to the present disclosure, FIGS. 2 and 3 are exemplary diagrams for a second format form in the BM automatic calculation method for plant stationary equipment according to the present disclosure, FIG. 4 is a diagram for a program screen for generating an total part list in the BM automatic calculation method for plant stationary equipment according to the present disclosure, FIG. 5 is an exemplary diagram of an MPS number sheet interlocking with a program for the total part list in the BM automatic calculation method for plant stationary equipment according to the present disclosure, FIG. 6 is an exemplary diagram of the total part list expressed by execution of the program of FIG. 5, FIG. 7 is an exemplary diagram for a start screen of a BM calculation program in the BM automatic calculation method for plant stationary equipment according to the present disclosure, FIG. 8 is an exemplary diagram for a screen for setting cutting and fabrication margins for each part in the BM calculation program of FIG. 7, FIG. 9 is an exemplary diagram for a screen for setting a standard of a purchasing plate in the BM calculation program of FIG. 7, FIG. 10 is a program screen for a step of preparing a cutting plan drawing in the BM calculation program of FIG. 7, FIG. 11 is an exemplary diagram of the cutting plan drawing prepared through the BM calculation program of FIG. 10, FIG. 12 is a program screen for a step of preparing a nesting plan drawing in the BM calculation program of FIG. 7, FIG. 13 is an exemplary diagram of the nesting plan drawing prepared through the BM calculation program of FIG. 12, FIG. 14 is a program screen for a step of generating BM-related data in the BM calculation program of FIG. 7, FIG. 15 is an exemplary diagram of a BOM data sheet generated by FIG. 14, and FIG. 16 is an exemplary diagram of a cutting plan part list data sheet generated by FIG. 14.

[0047] FIG. 1 is a flowchart of a BM automatic calculation method for plant stationary equipment according to the present disclosure. The BM automatic calculation method for plant stationary equipment according to the present disclosure is implemented by a computer, and the implemented computer is not limited to a specific computer and is enough to have a memory capable of driving the program. As illustrated in FIG. 1, the BM automatic calculation method for plant stationary equipment according to the present disclosure includes (a) performing strength calculation for each item of a stationary machine having each unique number based on process data required in a plant using a strength calculation program and extracting input data in a first format from a strength calculation result for each item in which the strength calculation is performed (S1), (b) extracting all object data for each item for preparing drawings from the extracted input data in the first format and converting all of the extracted object data into a second format (S2), (c) extracting only information on a part where an item-specific plate is used from all of the object data for each item converted into the second format and generating total part list data interlocking with an MPS number sheet in information data for the extracted part where the item-specific plate is used (S3), (d) loading the total part list data as input data in a BM calculation program (S4), (e) setting the standard of a purchasing plate built with a library within the BM calculation program (S5), (f) setting cutting and fabrication margins for each part for preparing cutting plan drawings built with the library within the BM calculation program (S6), and (g) calculating BM related data by executing the BM calculation program (S7). Hereinafter, a process for each step will be described in detail.

[0048] The stationary equipment to which the present disclosure is applied includes a pressure vessel or drum in which a process fluid is temporarily stored, a column or tower in which the process fluid is separated for each component, a heat exchanger for heat-exchanging the process fluid, a reactor in which the process fluids chemically react with each other, and the like.

[0049] First, the method is subjected to the step (S1) of performing strength calculation for each item of a stationary machine having each unique number based on process data required in a plant using a strength calculation program and extracting input data of a first format from a strength calculation result for each item in which the strength calculation is performed. Generally, the stationary machine is given with a unique number for the stationary machine every project, which is defined as an item number of the stationary machine. The strength calculation program generally uses a compress program. The process data required for the process of the plant is input using the strength calculation program, the compress program performs the strength calculation according to the input data, and a compress file is generated as the performing result of the strength calculation. The compress file includes various data according to the strength calculation, and the input data in a first format form required in the present disclosure is extracted from the compress file of the strength calculation. The extracted first format data is extracted in a general extensible markup language (XML) file form.

[0050] Next, the method is subjected to the step (S2) of extracting all object data for each item for preparing drawings from the extracted input data in the first format and converting all of the extracted object data into a second format. All the object data for each item for preparing the drawings is extracted from the XML file in the first format form. All of the object data for each item include nozzle data, design data, material specification data, and detail drawing data. The nozzle data is data that describes information about a nozzle mounted on each item, the design data is data in which data such as pressure and the like for design for each item is described, the data specification data is data that describes an applicable material used for each item, and the detailed drawing data is drawing data for dimensions and the like of each item. Examples of data for each drawing are omitted. When the object data is extracted, the extracted object data is converted into a second format form, and the second format form is a sheet type comma-separated values (CSV) file form. The CSV file has a format in the form of a data sheet, such as an Excel file, which is a data sheet program. Therefore, the conversion into Excel from the CSV file may be easily performed. Since the CSV file is a data sheet file type, if the second format data may be formatted to a data sheet type file from the first format data instead of the CSV file, the present disclosure may be applied. Therefore, the second format form described in the present disclosure is described in the form of the CSV file, but is not limited thereto.

[0051] Next, the method is subjected to the step (S3) of extracting only information on a part where an item-specific plate is used from all of the object data for each item converted into the second format and generating total part list data interlocking with an MPS number sheet in information data for the extracted part where the item-specific plate is used. First, only information about the part where the item-specific plate is used is extracted from all of the object data for each item converted into the second format. Only the information of the part where the item-specific plate is used needs to be extracted from the CSV file. FIGS. 2 and 3 illustrate examples of the CSV file. FIG. 2 illustrates extracting information about a shell, a head, a cone, a nozzle neck, a reinforced pad, a wear plate, and a stiffener ring, which are parts where the item-specific plate is used, from the CSV film including all of the object data. FIG. 2 illustrates extracting information of the part where the item-specific plate is used with respect to shell CSV data 10, and FIG. 3 illustrates extracting information of the part where the item-specific plate is used with respect to heard CSV data 10′. FIGS. 2 and 3 express extracting only plate-related information in the part where the item-specific plate is used, wherein the extraction information is name information 11 and 11′ of each part, type information 14 of each part, size information 12 and 12′ of each part, and material information 13 and 13′ of each part. Only the plate-related information is extracted and used as data that calculates BM later. FIG. 4 illustrates a program screen 20 for loading all object data in all CSV file forms and generating a total part list for calculating BM from all of the loaded object data. As illustrated in the drawing, first, the CSV file with all the object data is loaded, and then an Import CSV button 22 is clicked to load the CSV file. When the CSV file including all the object data is loaded, next, a Convert to Part List button 23 is clicked to extract only information for the part where the item-specific plate is used to extract only specific-part plate-related information. Next, an Import MPS No. button 24 is clicked to call MPS number related information from MPS No. SHEET. The MPS number related information is described in FIG. 5. The MPS No. SHEET 30 includes a plurality of information in a data sheet 31. In detail, as illustrated in the drawing, the MPS No. SHEET 30 includes information about a project number, a Requisition No., a Requisition Name, a unit, an Item No., description, main material, MPS grouping, and the like. When the Import MPS No. button 24 is clicked, only some information from the MPS No. SHEET is included in the part list data screen 21 of FIG. 4. As the data included in the part list data screen 21 of FIG. 4, a project number 32, data information 33 about a Requisition No., a Requisition Name, a unit, and an Item No., data information 34 on a material, and data information 35 about the MPS number are included in the part list. FIG. 4 illustrates only some information, and REQ NO., ITEM NO., PIECE, MAIN MATERIAL, and MPS NO. are displayed on the part list screen 21. To interlock the MPS No. SHEET 30, an item number displayed on an item number display window 29 which is a unique number of the stationary machine displayed on the screen matches the MPS No. SHEET 30 to interlock data. On the entire screen 20 of the part list extraction and conversion program of FIG. 4, the requisition No., the item No., the main material, and the MPS number are interlocked and expressed together. Next, an Export Part List button 27 is clicked to generate a total part list 40. The total part list 40 is generated based on the project number input to a project number input window 25 and the requisition No. input to a requisition No. input window 26. A “clear” and “clear all” button 28 of the entire screen 20 of the part list extraction and conversion program has a function of deleting some data. FIG. 6 illustrates a data sheet 41 of the total part list 40. In the total part list 40, data of the requisition No. (REQ. NO.), the item No. (ITEM NO.), the MPS number, and the main dimensions are illustrated. Specifically, the total part list data 40 is generated in a part list form of size information, material information, shape information, MPS No. information, and information on other related dimensions of the part where the item-specific plate is applied. The total part list data 40 also has a CSV file form.

[0052] Next, the method is subjected to the step (S4) of loading the total part list data 40 as input data in the BM calculation program. FIG. 7 illustrates a start screen 51 of a BM calculation program 50. On the start screen 51, a bill of material automatic system (BOMAS) as a program name is displayed, and at the lower end, an option setting button 52 and an Import CSV button 53 for inputting the CSV file are provided sequentially from the left side. When the option setting button 52 is clicked, a screen 520 capable of selecting an option is popped up, and on the popped-up option setting screen 520, a margin option button 521 for settings of the cutting and fabrication margins for each part and a sheet option button 522 for setting the standard of the purchasing plate are displayed. The Import CSV button 53 is a button for inputting the total part list data 40 as the input data. Accordingly, when the Import CSV button 53 is clicked, the total part list data 40 in the CSV file form is loaded and used as the input data.

[0053] Next, the method is subjected to the step (S5) of setting the standard of the purchasing plate built with a library within the BM calculation program and the step (S6) of setting cutting and fabrication margins for each part for preparing cutting plan drawings built with the library within the BM calculation program. The order of the two steps may be changed to each other. FIG. 8 illustrates the step (S6) of setting cutting and fabrication margins for each part and FIG. 9 illustrates the step (S5) of setting the standard of the purchasing plate. FIG. 8 illustrates an input screen 5210 of margins displayed when the margin option button 521 is clicked. On the input screen 5210, margins for a consumed amount generated by cutting the plate for fabrication of each part and a consumed amount generated in the fabrication step of welding and attaching the cut plates of predetermined parts to each other. The configuration of the input screen 5210 of the margin option is first provided with a cutting margin input unit 5211 for the consumed amount generated by cutting the plate for each part, fabrication margin input units 5213: 5213a and 5213b for the consumed amount generated in the fabrication process, and a storage unit 5214 for storing a default value formed at the lower end (Restore to Default), saving the input margins, or exiting the screen. The margins are constructed and used in the library within the program. FIG. 9 is an input screen 5220 of a sheet option popped-up when the sheet option button 522 is clicked. On the input screen 5220, a sheet option input unit 5221 and a storage unit 5222 are configured, and the sheet option input unit 5221 may be configured by a sheet option input unit 5221a for a width and a sheet option input unit 5221b for a length. According to each part, the sheet option input unit may be added with various values. The sheet options are also constructed with the library within the program.

[0054] Next, the method is subjected to the step (S7) of calculating BM related data by executing the BM calculation program. When the margin options and the sheet options are set, the BM output program is executed. The BM calculation program is configured by (g-1) preparing a cutting plan drawing according to the set cutting and fabrication margins for each part (S7-1), (g-2) preparing a nesting plan drawing optimized by disposing the cutting plan drawing in the standard of the set purchasing plate (S7-2), and (g-3) generating BOM list and cutting plan part list data based on the nesting plan drawing (S7-3). FIGS. 10 to 15 illustrate outputs generated in the step of executing the BM calculation program and a screen of the BM calculation program.

[0055] First, the method is subjected to the step (S7-1) of preparing the cutting plan drawing. The cutting plan drawing is a drawing of a state where the margins are input. An execution screen 54 of the BM calculation program is configured by a main screen unit 540 and respective execution buttons. The main screen unit 540 is configured by an entire data screen unit 5401 on which the entire data is displayed, and an individual data screen unit 5402 for data in which a cursor is located. The respective execution buttons are configured by a cutting plan button 541 for preparing the cutting plan drawing, a nesting button 542 for optimizing and disposing the cutting plan drawing, a BOM List button 543 for outputting a BOM list calculated from the entire data, an Import CSV button 544 for inputting the total part list data, and a setting button 545 for screen settings. FIG. 10 illustrates a cutting plan drawing generated when the cutting plan button 541 is clicked. The cutting plan drawing is prepared as a drawing for each part according to a predetermined cutting margin. The cutting plan drawing is a part-specific deployed diagram for fabrication the stationary machine, and is a drawing prepared by cutting a plate according to a cutting plan, and using the cutting plate as it is, or bending and using the cutting plate to a specific shape. FIG. 11 is a cutting plan drawing generated when the cutting plan button 541 is clicked. As illustrated in the drawing, the cutting plan drawings include a drawing 5411a for the shell, a drawing 5411b for the cone, a drawing 5411c for the nozzle, the pad, and the stiffener ring, and a drawing 5411d for the head, and a cutting plan drawing for all stationary machine items having the same requisition No. of the corresponding project is generated.

[0056] Next, the method is subjected to the step (S7-2) of preparing a nesting plan drawing optimized by disposing the cutting plan drawing in the standard of the set purchasing plate. FIG. 12 illustrates a step of preparing a nesting plan drawing optimized by disposing the cutting plan drawing in a predetermined standard of plate after preparing the cutting plan drawing on the same BM calculation program. When the nesting button 542 shown in the drawing is clicked, the step in which the prepared cutting plan drawing is optimized and disposed with the same material of plate is subjected. The optimized disposition is performed while in the cutting plan drawing of the part having the matched MPS No., and the same material and thickness of the plate, the largest part is disposed according to a width on the purchasing standard upward from the left lower end and the cutting plan drawing for each part sequentially from the left side to the right side in a longitudinal direction is disposed in an empty space. FIG. 13 illustrates that the nesting plan drawing 5421 in which the optimized disposition of the cutting plan drawing for each part is performed is generated when the nesting button 542 is clicked. In the optimized nesting plan drawing 5421, a part-specific cutting plan drawing having the same MPS number, the same thickness, and the same material is disposed. Specifically, in the nesting plan drawing 5421, a project number, a requisition number, and an MPS No. are disclosed, a material and the size of the purchasing plate are disclosed, and the quantity and the weight are illustrated. In one nesting plan drawing, since each part used in the same plate is illustrated, it is obvious that the part having the same MPS No., the same thickness, and the same material is disclosed. In addition, abbreviation is displayed in the bottom. In a standardized plate drawing 5421-1, cutting plan drawings of a plurality of parts are illustrated, and in the bottom of the drawing 5421-1, matters 5421-2 for items used in the plurality of cutting plan drawings on the plate drawing are disclosed.

[0057] Next, the BM calculation method is terminated through the step (S7-3) of generating the BOM list and the cutting plan part list data based on the nesting plan drawing. Specifically, according to the nesting plan drawing in which the cutting plan drawing is optimized and disposed, a BOM list 5431 of FIG. 14 and a cutting plan part list 5432 of FIG. 15 are generated. It will be described in detail. When a BOM List button 543 of FIG. 13 is clicked, the BOM list and the cutting plan part list are generated, and in the BOM List, information about a BM number, a material, MPS No., and the standard (thickness, width, length, quantity, weight, plate usage degree, etc.) of the plate and an item applicable part where the corresponding plate is used are displayed. The BM number is written from SC6677-MFA110-BM-001, and the number is sequentially numbered along the leftmost number (No.). As described above, since the quantity of the accurate plate is displayed in the BOM list, the total purchase amount may be determined. Further, the cutting plan part list 5432 is data that describes a part used for the corresponding BM number. The left BM NO. is matched with the BOM list to specify the used item.

[0058] As described above, the BM automatic calculation method of the plant stationary equipment according to the present disclosure primarily performs processes of generating XML data from a strength calculation program, generating CSV type data by extracting object data from the XML data, and generating a total part list by extracting a part where a plate is used from all the object data. Next, the BM automatic calculation method secondarily performs a BM calculation program execution step of executing a program by receiving the total part list as input data. The primary process is performed in a general Window system and the secondary process is performed on AUTOCAD as a drawing preparation universal program. The BM calculation program required for the secondary process is a program using OpenDCL and Visual LISP programs of the AUTOCAD, and is executed on the AUTOCAD after the AUTOCAD is first executed.

[0059] Since the BM automatic calculation method of the plant stationary equipment according to the present disclosure can accurately calculate the quantity of plates for each part used for the stationary machine using the strength calculation result, it is possible to accurately determine costs required for fabricating the stationary equipment of the plant, and as a result, the cost reduction may be effective. In addition, since the BM calculation, which has been manually performed in the related art, may be easily performed by the program, the workforce reduction may be effective. Further, since the cutting plan may be accurately performed, there is an advantage of minimizing the scrap amount of the required plates.

[0060] As described above, the present disclosure can be made in various modifications, and preferred embodiments of the present disclosure have been described, but the present disclosure is not limited to these embodiments. In the claims and the detailed description of the present disclosure, it will be appreciated that the techniques that can be modified and used by those skilled in the art are included in the scope of the present disclosure.