conceptual cost estimating
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conceptual cost estimationTRANSCRIPT
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CONCEPTUAL COSTESTIMATING
MANUALS E C O N D E D I T I O N
J O H N S . P A G E
An Imprint ofElsevier
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Conceptual CostEstimating
Manual2nd Edition
Copyright 1984, 1996 by Elsevier. All rights reserved.Printed in the United States of America. This book,or parts thereof, may not be reproduced in any form withoutpermission of the publisher.Permissions may be sought directly from Elsevier's Science and Technology Rights Department inOxford, UK. Phone: (44) 1865 843830, Fax: (44) 1865 853333, e-mail: [email protected] may also complete your request on-line via the Elsevier homepage: http://www.elsevier.com byselecting "Customer Support" and then "Obtaining Permissions".
Originally published by Gulf Publishing Company,Houston, TX.
For information, please contact:Manager of Special SalesElsevier200 Wheeler RoadBurlington, MA 01803-2041Tel: 781-313-4700Fax:781-313-4882
For information on all Gulf Professional Publishing titlesavailable, contact our World Wide Web home page at:http://www.bh.com/gulfG | P Gulf Professional PublishingP l H An Imprint of Elsevier
10 9 8 7 6
Library of Congress Cataloging-in-Publication DataPage, John S.
Conceptual cost estimating manual / John S.Page. 2nd ed.
p. cm.ISBN 0-88415-267-71. Chemical plantsDesign and construction
EstimatesHandbooks, manuals, etc. I. Title.TH4524.P34 1996690'.54dc20 95-52313
CIPPrinted in the United States of America.Printed on acid-free paper (oo).
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PREFACE
Long has been the need for a manual on conceptual cost estimating that allowsthe construction industry and the engineering/management staff of chemical, refin-ery, and industrial plants to arrive at a reasonable cost for a specified facility. Sim-ply to rely on past records and say that a certain type plant will cost ten dollars perpound produced, and the product can be sold for fifteen dollars per pound, by nomeans justifies the construction cost of the plant. Management of all organizationsconcerned demands more reasoning and is certainly within its rights to do so.
When a project is in its planning and evaluating stages, the cost of a completedesign and definitive estimate would be, in most cases, too great to justify thedesign and estimate. Therefore, it becomes apparent that a less expensive methodis needed to determine the feasibility of the plant in mind. By using a very moder-ate flow sheet design, specifications, and/or equipment lists, by properly applyingman-hours, dollars, percentage values (as are shown throughout this manual ingraph and table form), and construction indexes, and by considering other itemsoutlined in the Introduction, a total cost very close to the as-built cost of a com-plete plant should be obtainable for any location in the world.
The Human Factor in Estimating
In this high-tech world of sophisticated software packages, including several forlabor and cost estimating, you might wonder what an estimating manual offers thata computer program does not. The answer is the human factor. In preparing a com-plete estimate for a refinery, petrochemical, or other heavy industrial project oneoften confronts 12-18 major accounts, and each account has 5-100 or more sub-accounts, depending on the project and its engineering design. While it would seemthat such numerous variables provide the perfect opportunity for computerizedalgorithmic solution, accurate, cost-effective, realistic estimating is still largely afunction of human insight and expertise. Each project has unique aspects that stillrequire the seasoned consideration of an experienced professional, such as gener-al economy, projects supervision, labor relations, job conditions, constructionequipment, and weather, to name a few.
Computers are wonderful tools. They can solve problems as no human can, butI do not believe construction estimating is their forte. I have reviewed several con-struction estimating software packages and have yet to find one that I would com-pletely rely on. Construction estimating is an art, a science, and a craft, and I rec-ommend that it be done by those who understand and appreciate all three of thesefacets. This manual is intended for those individuals.
John S. Page
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INTRODUCTION
This manual contains two methods of conceptual estimating for determining the bud-get amount or estimated cost to design and construct refineries, chemical/petrochemi-cal, and some other types of industrial plants.
Method one, when properly applied, produces a semi-definitive conceptual estimatewith an accuracy of 10%.
Method two uses conceptual ratio estimating, and based on the known equipmentmaterial dollar value and the application of weighted percentage costs for all otheritems, it produces an estimate with an accuracy of 30%.
The information required and procedures to follow for using these two methods ofestimating are defined later in this introduction.
All equipment and material dollar graph and tables throughout this manual are basedon average cost as of January 1,1996.
Due to the ever-changing economic conditions, the use of what is known throughoutthe industry as indices must be considered and applied against all equipment and mate-rial graphs and tables. This will result in a more realistic equipment and material valuefor a project to be designed and constructed at some future date. Indices are simplynumbers for a time frame indicating a percentage of change in regard to a relative costof a base time frame. There have been many pro and con discussions as to the use ofindices; however, they are still the only means for achieving an acceptable estimatewhere limited information and time are available.
There are several indices from which one might choose. I favor the Nelson Refinery(Inflation) Index, which appears in the first weekly edition of each month in the Oil andGas Journal. The engineer/estimator may wish to use other indices that he is morefamiliar with and has more confidence in. Should this be the case, it is to be recognizedthat as far as this manual is concerned January 1, 1996 is equal to 100.
All labor manhour graphs and tables are based on an average productivity of 70%. Theengineer/estimator must determine the labor productivity he feels he can achieve foreach project and may acjjust the graph and table manhours as may be required. Majoritems that one should consider in determining productivity are:
1. General Economy2. Project Supervision3. Labor Relations4. Job Conditions5. Construction Equipment6. WeatherIn determining the dollar rate to apply against the estimated manhours the engi-
neer/estimator should first establish weighted composite crew rates. This is simply thelisting by craft of the various personnel required for a crewsuch as general foreman,foreman, craftsmen, and apprentices/helpersand the weighted percentage of theirtime that will be devoted to the crew. The weighted percentage of each classificationmultiplied by the hourly rate for that classification will result in the weighted hourly ratefor each. The sum of all weighted rates will equal the composite crew hourly rate. Thetotal percent of all crew personnel is to equal 100. Using the composite crews and rates,activity crews and rates are to be formed. List the composite crew rates and the weight-ed percent of time each crew will be devoted to the activity. The weighted percent ofeach composite crew multiplied by the weighted composite crew rate will result in theweighted hourly activity rate for that crew. The sum of all weighted crew rates for theactivity will equal the hourly weighted activity rate. The total percent of all compositecrew personnel is to equal 100. See Section One for description of disciplines of workto determine activity crew personnel needed.
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All manhour tables and graphs include the total manhours, based on 70% productivi-ty, to complete the unit of work as listed.
All equipment and material dollar graphs and tables are based on cost as of January1, 1996, and include the total unit equipment or material cost as outlined.
All graphs and tables that reflect shop fabrication, packaged units, and subcontract-ed items include the total cost of labor, material, overhead and profit of the supplier, andvendor or subcontractor.
If the project under consideration is to be located in an area outside the continentalforty-eight states, the engineer/estimator must consider other items not covered in thismanual. Additives for any or all of the following items may be required and since theircosts vary widely for different parts of the world, they must be researched individuallyfor each foreign project.
1. Mobilization and demobilization of personnel and equipment2. Foreign differential labor pay3. Permits, licenses, fees, duties4. Load out, tie down and material handling5. Transportation and ocean or air freight6. Camp, family quarters, field office, and storage facilities7. Rest and recreation for personnel
Method OneAccuracy Level of 10%A method one, semi-definitive conceptual estimate is defined as one that will produce
major discipline quantities, manhours and labor, material, subcontract and total dollarsfor their cost. As an example, using concrete as a major discipline of work, and apply-ing this method, the total cubic yards of concrete for equipment foundations would bethe result. Based on the total cubic yards of concrete, all inclusive of foundation earth-work, forms, reinforcing steel, embedments, finishing, etc., the total manhours and costwould be achieved. With the overall results of all major disciplines of work the projectcan be scheduled and fast-track cost-controlled until such time as a total definitive esti-mate is available.
To achieve a degree of accuracy of 10% the following information will be required.1. Plant capacity, product form, basic process, and raw material2. Total general specifications3. Plant location (site conditions)4. Preliminary soils report with foundation recommendations5. Plot plan and equipment arrangements.6. P. & I.D.'s. (mechanical flow sheets)7. Equipment list8. Buildings listing type, size, and descriptionThis same type estimate can be assembled with far less information than that listed
above but the degree of accuracy, in all probability would be less than that stated.
Method TwoAccuracy Level of 30%
A method two, ratio conceptual estimate is defined as one that is based on the knowntotal process equipment material cost and that applies weighted percentages againstthat cost to achieve the cost of all other major disciplines of work.
Once the cost of all major disciplines of work has been established, quantities andmanhours can be achieved by dividing the material dollars by the pre-established unitdollar rate, as outlined in the graphs and tables, and the labor dollars by a pre-estab-lished composite activity rate.
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With the established quantities and manhours the project can be scheduled and fast-track cost-controlled until such time as a more definitive type estimate is available.
To achieve a degree of accuracy of 30%, the following information will be required.1. Plant capacity, product form, basic process, and raw material2. Knowledge of general specifications3. Plant location (site conditions)4. Equipment list (priced out)In assembling a method one or two estimate it should be recognized that in the round-
ing off and averaging of material and labor cost and the application of average indices,a certain degree of accuracy is lost insofar as the individual item costs are concerned.However, it is believed that the overall estimate is not seriously affected by this becausethe items tend to average each other out.
I sincerely hope the foregoing will enable the engineer/estimator engaged in this typework to turn out more realistic conceptual estimates and assist in the elimination ofmuch guesswork.
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Contents
Preface .................................................................................... xv The Human Factor in Estimating .................................................. xv
Introduction .............................................................................. xvi
Section 1. Disciplines of Work .......................................... 1 Section Introduction ....................................................................... 1 Direct Cost Items ........................................................................... 1 Construction Equipment ................................................................ 3 Overhead and Indirects ................................................................. 3 Home Office Cost .......................................................................... 10
Section 2. Process Equipment ......................................... 11 Section Introduction ....................................................................... 11 Acid Coolers with Pump and Motor .............................................. 12
Equipment Cost ............................................................... 12 Erection Manhours .......................................................... 13
Activators Vibrating Bin .............................................................. 14 Equipment Cost ............................................................... 14 Erection Manhours .......................................................... 15
Aerators Mechanical .................................................................. 16 High-speed Equipment Cost ......................................... 16 High-speed Erection Manhours .................................... 17 Low-speed Equipment Cost .......................................... 18 Low-speed Erection Manhours ..................................... 19
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Compressors ................................................................................. 20 Air Power Synchronous Motor Driven Equipment
Cost ........................................................................ 20 Air Power Induction Motor Driven Equipment
Cost ........................................................................ 21 Air Power Synchronous and Induction Motor Driven
Erection Manhours ............................................... 22 Automotive and Industrial Service Air Equipment
Cost ........................................................................ 23 Automotive and Industrial Service Air Erection
Manhours ................................................................ 24 Centrifugal Air Plant and High-pressure
Equipment Cost ...................................................... 25 Centrifugal Air Plant and High-pressure Erection
Manhours ................................................................ 26 Industrial Air Air-cooled, Two-stage Equipment
Cost ........................................................................ 27 Industrial Air Air-cooled, Two-stage Erection
Manhours ................................................................ 28 Integral Gas Engine Four Cylinder Equipment
Cost ........................................................................ 29 Integral Gas Engine Four Cylinder Erection
Manhours ................................................................ 30 Packaged Air Single-stage, Water-cooled
Equipment Cost ...................................................... 31 Packaged Air Single-stage, Water-cooled Erection
Manhours ................................................................ 32 Reciprocating Electric Motor Driven Equipment
Cost ........................................................................ 33 Reciprocating Electric Motor Driven Erection
Manhours ................................................................ 34
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Two-stage, Two-cylinder, Water-cooled Equipment Cost ........................................................................ 35
Two-stage, Two-cylinder, Water-cooled Equipment Cost ........................................................................ 36
Two-stage, Two-cylinder, Water-cooled Erection Manhours ................................................................ 37
Dryers Air .................................................................................... 38 Automatic, Refrigerated Equipment Cost ...................... 38 Automatic, Refrigerated Equipment Cost ...................... 39 Automatic, Refrigerated Erection Manhours ................. 40 Automatic, Refrigerated Erection Manhours ................. 41 Chiller Equipment Cost ................................................. 42 Chiller Erection Manhours ............................................ 43
Surge Arresters ............................................................................. 44 Hydrocarbon and Water Service Equipment Cost ......... 44 Hydrocarbon, Water, and Sewage Service
Equipment Cost ...................................................... 45 Hydrocarbon, Water, and Sewage Service Erection
Manhours ................................................................ 46 Blenders, Mixers, Packers, and Feeders ...................................... 47
Dry Material Auger and Rotary Drum Blenders Equipment Cost ...................................................... 47
Dry Material Auger and Rotary Drum Blenders Erection Manhours .................................................. 48
Fixed Side Mounted Mixers with Top Motors Equipment Cost ...................................................... 49
Fixed Side Mounted Mixers with Top Motors Erection Manhours .................................................. 50
Plate Mounted Open Tank Mixers Equipment Cost ...... 51
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Portable Clamp and Flanged Mounted Mixers Equipment Cost ...................................................... 52
Flanged Top Tank Mounted and Plate Mounted Open Tank Mixers Erection Manhours ........................... 53
Gearmotor Mixers Equipment Cost ............................... 54 Gearmotor Mixers Erection Manhours .......................... 55 Batch and Pipeline Homogenizer Mixers Equipment
Cost ........................................................................ 56 Batch and Pipeline Homogenizer Mixers Erection
Manhours ................................................................ 57 High-intensity Mixers Equipment Cost .......................... 58 High-intensity Mixers Erection Manhours ...................... 59 Bag and Rigid Container Vibrating Packers
Equipment Cost ...................................................... 60 Bag and Rigid Container Vibrating Packers Erection
Manhours ................................................................ 61 Boilers ............................................................................................ 62
Package Type Equipment Cost .................................... 62 Package Type Erection Manhours ................................ 63 Boiler Stacks Equipment Cost ...................................... 64 Boiler Stacks Erection Manhours .................................. 66
Classification Equipment ............................................................... 67 Cone Pelletizers Equipment Cost ................................. 67 Cone Pelletizers Erection Manhours ............................. 68 Turbo-screen Cyclone and Pressure Sifter
Equipment Cost ...................................................... 69 Turbo-screen Cyclone and Pressure Sifter Erection
Manhours ................................................................ 70 Rotary Screens Equipment Cost ................................... 71 Rotary Screens Erection Manhours .............................. 72
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Condensers and Receivers ........................................................... 73 Vertical Tube Surface Equipment Cost ......................... 73 Vertical Tube Surface Erection Manhours .................... 74
Conveying Equipment ................................................................... 75 Conveyors Open Belt Equipment Cost ...................... 75 Conveyors Open Belt Erection Manhours .................. 76 Conveyors Belt Enclosed with Walkway
Equipment Cost ...................................................... 77 Conveyors Belt Enclosed with Walkway Erection
Manhours ................................................................ 78 Conveyors Spaced, Bucket Elevators, Belt-driven
Equipment Cost ...................................................... 79 Conveyors Spaced, Bucket Elevators, Chain Driven
Equipment Cost ...................................................... 80 Conveyors Spaced, Bucket Elevators, Chain- or
Belt-driven Erection Manhours ............................. 81 Conveyors Continuous, Bucket Elevators, Belt-
driven Equipment Cost ......................................... 82 Conveyors Continuous, Bucket Elevators, Chain-
driven Equipment Cost ......................................... 83 Conveyors Continuous, Bucket Elevators, Belt- or
Chain-driven Erection Manhours .......................... 84 Screw Conveyors Equipment Cost ............................... 85 Screw Conveyors Erection Manhours ........................... 86
Dryers Drum ............................................................................... 87 Atmospheric Single Drum Type Equipment Cost .......... 87 Atmospheric Double and Twin Drum Types
Equipment Cost ...................................................... 88 Atmospheric Single, Double, and Twin Drum Types
Erection Manhours .................................................. 89
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Dryers Vacuum ........................................................................... 90 Conical Rotating Equipment Cost ................................. 90 Double Drum and Rotary Equipment Cost .................... 91 Conical Rotating and Double Drum Erection
Manhours ................................................................ 92 Rotary Carbon and Stainless Steel Erection
Manhours ................................................................ 93 Dust Collectors .............................................................................. 94
Centrifugal Scrubbers High Capacity, Hot-rolled Steel Equipment Cost .......................................... 94
Centrifugal Scrubbers Medium Capacity, Hot-rolled Steel Equipment Cost .......................................... 95
Centrifugal Scrubbers High Capacity, Stainless Steel Equipment Cost .......................................... 96
Centrifugal Scrubbers Medium Capacity, Stainless Steel Equipment Cost .......................................... 97
Centrifugal Scrubbers High- and Medium-capacity, Hot-rolled and Stainless Steel Erection Manhours ................................................................ 98
Cyclones Hot-rolled Steel Equipment Cost ................ 99 Cyclones Stainless Steel Equipment Cost ................. 100 Cyclones Hot-rolled and Stainless Steel Erection
Manhours ................................................................ 101 Filter Cartridge or Tube House Filters Equipment
Cost ........................................................................ 102 Filter Cartridge or Tube House Filters Erection
Manhours ................................................................ 103 Packaged Motor Operated Blowers Equipment Cost .... 104 Packaged Motor Operated Blowers Erection
Manhours ................................................................ 105
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Fans and Blowers .......................................................................... 106 Blowers Rotary Equipment Cost ................................ 106 Blowers Rotary Erection Manhours ........................... 107 Centrifugal Fans Equipment Cost ................................. 108 Centrifugal Fans Erection Manhours ............................ 109 Cast Iron Industrial Fans Equipment Cost .................... 110 Cast Iron Industrial Fans Erection Manhours ................ 111 Heavy Sheet Steel Industrial Fans Equipment Cost ...... 112 Heavy Sheet Steel Industrial Fans Erection
Manhours ................................................................ 113 Feeders ......................................................................................... 114
Heavy Duty Belt Equipment Cost .................................. 114 Heavy Duty Belt Erection Manhours ............................. 115 Pre-wetting Dry Chemical Equipment Cost ................... 116 Pre-wetting Dry Chemical Erection Manhours .............. 117 Pre-wetting Dry Chemical, Package Units Equipment
Cost ........................................................................ 118 Pre-wetting Dry Chemical, Package Units Erection
Manhours ................................................................ 119 Dry Material, Vibrating Equipment Cost ........................ 120 Dry Material, Vibrating Erection Manhours ................... 121 Dry Material, Volumetric and Gravimetric Equipment
Cost ........................................................................ 122 Dry Material, Volumetric and Gravimetric Erection
Manhours ................................................................ 123 Dry Material, Wing and Conveyor Equipment Cost ....... 124 Dry Material, Wing and Conveyor Erection
Manhours ................................................................ 125 Filters ............................................................................................. 126
Gravity Filtration Units Total Material Cost .................... 126
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Gravity Filtration Units Total Unit Installation Manhours ................................................................ 127
Pressure Type Equipment Cost .................................... 128 Pressure Type Erection Manhours ............................... 129 Rubber-lined Equipment Cost ....................................... 130 Rubber-lined Erection Manhours .................................. 131 Vibrating Screens Equipment Cost ............................... 132 Vibrating Screens Erection Manhours ........................... 133
Flakers ........................................................................................... 134 Cooling Drum Equipment Cost ..................................... 134 Cooling Drum Erection Manhours ................................. 135
Generators ..................................................................................... 136 Inert Gas Equipment Cost ............................................ 136 Inert Gas Erection Manhours ........................................ 137
Gas Pulsation Dampers ................................................................ 138 Dampers Equipment Cost ............................................. 138 Dampers Erection Manhours ........................................ 139
Heaters .......................................................................................... 140 Deaerating Feedwater Equipment Cost ........................ 140 Deaerating Feedwater Erection Manhours ................... 141 Gas-, Oil-, and Dual-fired Equipment Cost .................... 142 Gas-, Oil-, and Dual-fired Erection Manhours ............... 143
Heat Exchangers ........................................................................... 144 Hairpin Type Equipment Cost ....................................... 144 Hairpin Type Erection Manhours .................................. 145 Shell and Tube, Fixed Tube, and U-tube Equipment
Cost ........................................................................ 146 Shell and Tube, Fixed Tube, and U-tube Erection
Manhours ................................................................ 147
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For Heating Water Equipment Cost .............................. 148 For Heating Water Equipment Cost .............................. 149 For Heating Water Erection Manhours .......................... 150
Pumps ........................................................................................... 151 Centrifugal Single-stage, Vertical Split Case
Equipment Cost ...................................................... 151 Centrifugal Single-stage, Horizontal Split Case
Equipment Cost ...................................................... 152 Centrifugal Single-stage, ANSI and API 610
Equipment Cost ...................................................... 153 Centrifugal Two-stage and Multi-stage Equipment
Cost ........................................................................ 154 Centrifugal Single-stage, in-line Equipment Cost ....... 155 Gear Light and Heavy Duty Equipment Cost ............. 156 Sewage Horizontal and Vertical, 1,750 rpm
Equipment Cost ...................................................... 157 Sewage Horizontal, 1,750 rpm Equipment Cost ......... 158 Sewage Horizontal and Vertical, 1,150 rpm
Equipment Cost ...................................................... 159 Sump and Plunger Equipment Cost .............................. 160 Vertical Turbine Single and Multi-stage Equipment
Cost ........................................................................ 161 Centrifugal Single, Two, Multi, and in-line Single
Stage Erection Manhours ..................................... 162 Gear Light and Heavy Duty Erection Manhours ......... 163 Sewage Horizontal and Vertical Erection
Manhours ................................................................ 164 Sump and Plunger Erection Manhours ......................... 165 Vertical Turbine Single and Multi-stage Erection
Manhours ................................................................ 166
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Reactors ........................................................................................ 167 Glass-lined, Agitated, Jacketed Equipment Cost .......... 167 Glass-lined, Agitated, Jacketed Erection Manhours ...... 168
Steam Jet Ejectors ........................................................................ 169 Single-stage Equipment Cost ....................................... 169 Single-stage Erection Manhours ................................... 170
Gas Scrubbers .............................................................................. 171 High-energy Venturi Type Equipment Cost ................... 171 High-energy Venturi Type Erection Manhours .............. 172
Separators ..................................................................................... 173 Vane Type Equipment Cost .......................................... 173 Vane Type Equipment Cost .......................................... 174 Vane Type Erection Manhours ..................................... 175 Vibrating Equipment Cost ............................................. 176 Vibrating Erection Manhours ........................................ 177 API Type Oil/Water Equipment Cost ............................. 178 API Type Oil/Water Erection Manhours ......................... 179
Size Reduction Equipment ............................................................ 180 Crushers Equipment Cost ............................................. 180 Crushers Erection Manhours ........................................ 181 Impact Breakers Equipment Cost ................................. 182 Impact Breakers Erection Manhours ............................. 183 Reversible and Non-reversible Hammermills
Equipment Cost ...................................................... 184 Reversible and Non-reversible Hammermills Erection
Manhours ................................................................ 185 Ring Type Granulators Equipment Cost ....................... 186 Ring Type Granulators Erection Manhours ................... 187
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Water Softener System ................................................................. 188 Hot Process Water Total Process Material and
Equipment Cost ...................................................... 188 Hot Process Water Total System Installation
Manhours ................................................................ 189 Tanks ............................................................................................. 190
API Cone Roof Storage Subcontract Installed Price ..... 190 API Cone Roof Storage Subcontract Installed Price ..... 191 API Floating Roof Storage Subcontract Installed
Price ....................................................................... 192 ASME Spheres Subcontract Installed Price .................. 193 Fintube Heating Coils Equipment Cost ......................... 194 Fintube Heating Coils Erection Manhours ..................... 195 Fired Heaters, Fintube Type Equipment Cost ............... 196 Fired Heaters, Fintube Type Erection Manhours .......... 197 Suction and Line Type Fuel Oil Heaters Equipment
Cost ........................................................................ 198 Suction and Line Type Fuel Oil Heaters Erection
Manhours ................................................................ 199 Propane Storage Equipment Cost ................................ 200 Propane Storage Erection Manhours ............................ 201
Vessels .......................................................................................... 202 Shop Fabricated Average Weight, Pounds per
Linear Foot .............................................................. 202 Horizontal, Shop Fabricated Cost per Ton .................... 203 Vertical with Angle Legs, Shop Fabricated Cost per
Ton ......................................................................... 204 Vertical with Anchor Ring and Skirts, Shop Fabricated
Cost per Ton ........................................................ 205 Tray Rings, Shop Fabricated Cost Each ....................... 206
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Column Trays, Shop Installation Cost Each .................. 207 Demisting Pads, Shop Installation Cost Each ............... 208 Shop Stress Relief Cost per Ton .................................. 209 Removable Type Trays Material Cost Each .................. 210 Removable Type Trays Material Cost Each .................. 211 Demisting Pads Material Cost Each ............................. 212 Demisting Pads Material Cost Each ............................. 213 Vessels Field Erection Manhours per Ton .................... 214 Tray Installation Field Erection Manhours Each ............ 215 Demisting Pads Field Erection Manhours Each ............ 216
Section 3. Site Preparation ............................................... 217 Section Introduction ....................................................................... 217 Area Clear and Grub Manhours per Acre .................................. 217 Area Cuts and Fills Manhours and Material Cost per Acre ....... 218
Section 4. Site Improvements ........................................... 219 Security Fencing ............................................................................ 219 Railroad and Spurs ........................................................................ 219 Tank Dikes ..................................................................................... 220 Concrete Trenches ........................................................................ 220 Drainage ........................................................................................ 221 Catch Basins and Manholes ......................................................... 221 Road Culverts ................................................................................ 221
Section 5. Concrete ........................................................... 222 Section Introduction ....................................................................... 222 Earth Backfill Materials Cubic Yards .......................................... 223 Excavation and Backfill Labor Manhours .................................. 224
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Earthwork for Equipment Structures, Pipe Racks, and Sleepers Labor Manhours ................................................ 225
Concrete Required for Equipment, Equipment Structures, Pipe Racks and Sleepers Cubic Yards ............................ 226
Forms, Reinforcing, Embedments and Concrete Material Cost ...................................................................................... 227
Forms, Reinforcing, Embedments and Concrete Installation Manhours ............................................................................. 228
Nonshrink, Nonmetallic Grout Average Square Feet ................ 229 Nonshrink, Nonmetallic Grout Material Cost ............................. 230 Nonshrink, Nonmetallic Grout Installation Manhours ................ 231 Fireproofing Structural Steel Total Material Cost ....................... 232 Fireproofing Structural Steel Installation Manhours .................. 233 Fireproofing Vessel Skirts Material Cost .................................... 234 Fireproofing Vessel Skirts Erection Manhours .......................... 235
Section 6. Structural Steel and Miscellaneous Iron ........ 236 Section Introduction ....................................................................... 236 Structural Steel Tons Required .................................................. 237 Miscellaneous Iron Tons Required ........................................... 238 Pipe Rack Steel Tons Required ................................................. 239 Structural Steel Equipment Supports and Structures
Material Cost ........................................................................ 240 Structural Steel for Pipe Racks Miscellaneous Iron for
Equipment Material Cost ................................................... 241 Structural Steel and Miscellaneous Iron Equipment,
Equipment Supports and Structures, and Pipe Racks Erection Manhours ............................................................... 242
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Section 7. Buildings ........................................................... 243 Section Introduction ....................................................................... 243 Building Types and Descriptions ................................................... 243 Building Materials Cost per Square Foot ................................... 245 Building Erection Manhours per Square Foot ............................ 246
Section 8. Piping ................................................................ 247 Section Introduction ....................................................................... 247 Shop Furnish and Fabricate Pipe and Fittings ............................. 248
Quantities Required for Pieces of Equipment .................. 248 Cost for Pieces of Equipment .......................................... 249
Field Furnish, Fabricate and Erect Pipe, Fittings and Valves ...... 251 Quantities Required for Pieces of Equipment .................. 251 Material Cost for Pieces of Equipment ............................. 252
Field Erect Shop Fabricated Spools Manhours for Pieces of Equipment ............................................................................ 256
Field Furnish, Fabricate and Erect Pipe, Fittings, and Valves Labor Manhours for Pieces of Equipment ........................ 257
Miscellaneous Pipe Items Material Cost for Pieces of Equipment ............................................................................ 259
Miscellaneous Pipe Items Total Manhours for Pieces of Equipment ............................................................................ 260
X-ray and Stress Relieving Total Subcontract Cost for Pieces of Equipment ............................................................ 261
Section 9. Electrical ........................................................... 262 Section Introduction ....................................................................... 262 Electrical Power Material Cost ................................................... 263 Electrical Power Installation Manhours ...................................... 264 Electrical Lighting Material Cost ................................................. 265
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Electrical Lighting Installation Manhours ................................... 266 Miscellaneous Instrumentation Material Cost ............................ 267 Miscellaneous Instrumentation Installation Manhours .............. 268
Section 10. Instrumentation ................................................ 269 Section Introduction ....................................................................... 269 Instruments Total Number of Instruments Required ................. 270 Instruments Total Material Cost ................................................. 271 Instruments Total Instrument Installation Manhours ................. 272 Control Valves Total Material Cost ............................................ 273 Standards, Tray Supports, Trays, Tubes, and Tube Bundles
Total Material Cost ............................................................ 274 Standards, Tray Supports, Trays, Tubes, and Tube Bundles
Total Installation Manhours ............................................... 275
Section 11. Insulation .......................................................... 276 Section Introduction ....................................................................... 276 Insulating Material Total Square Feet ........................................ 277 Insulating Material for Equipment Total Material Cost ............... 278 Insulating Material for Piping Total Material Cost ..................... 279 Insulating Labor for Piping and Equipment Total
Manhours ............................................................................. 280
Section 12. Painting ............................................................. 281 Section Introduction ....................................................................... 281 Painting Equipment Square Feet Area ................................... 282 Painting Structural Steel and Piping Square Feet Area ......... 283 Painting Miscellaneous and Pipe Rack Steel Square Feet
Area ...................................................................................... 284 Painting Equipment Total Material Cost ................................. 285
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Painting Equipment Total Manhours ...................................... 286 Painting Structural Steel Total Material Cost .......................... 287 Painting Structural Steel Total Manhours ............................... 288 Painting Piping Total Material Cost ......................................... 289 Painting Piping Total Manhours .............................................. 290 Painting Miscellaneous and Pipe Rack Steel Total
Material Cost ........................................................................ 291 Painting Miscellaneous and Pipe Rack Steel Total
Manhours ............................................................................. 292
Section 13. Paving ............................................................... 293 Section Introduction ....................................................................... 293 Asphalt Pavement Total Subcontract Price ............................... 294 Concrete and Gravel Pavements Total Material Cost ............... 295 Concrete and Gravel Pavements Total Manhours .................... 296
Section 14. Proratables ....................................................... 297 Section Introduction ....................................................................... 297 Proratable Materials Total Material Cost ................................... 298 Proratable Labor Total Manhours .............................................. 299
Section 15. Construction Equipment ................................. 300 Section Introduction ....................................................................... 300 Equipment Base Rental or Purchase Cost Fuel, Oil, Grease
and Supplies Cost ................................................................ 301 Equipment Service Labor Total Manhours ................................ 302
Section 16. Overhead and Indirects ................................... 303 Section Introduction ....................................................................... 303 Engineering and Supervision Personnel Total Manhours ......... 304
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Office Personnel Total Manhours .............................................. 305 Other Indirect and Temporary Construction Labor Total
Manhours ............................................................................. 306 Temporary Construction Materials Total Cost ........................... 307 Payroll Burdens and Benefits and Other Indirect Materials
Total Cost ............................................................................. 308
Section 17. Home Office Cost ............................................. 309 Section Introduction ....................................................................... 309 Engineering Design Manhour Range Allowance per Piece
of Equipment ........................................................................ 310 Engineering Design Other Cost as a Percent of
Engineering Labor Dollars ................................................... 314 Engineering Design Manhour Spread Percentages .................. 315
Section 18. Ratio Estimating Factors ................................. 316 Section Introduction ....................................................................... 316 Refinery Process Systems Direct Cost Percentages ................ 318 Liquid Type Chemical Plant Direct Cost Percentages .............. 319 Solid Type Chemical Plants Direct Cost Percentages .............. 320 Liquid/Solid Type Chemical Plants Direct Cost
Percentages ......................................................................... 321 Liquid High-pressure Chemical Plants Direct Cost
Percentages ......................................................................... 322 Liquid High-alloy Chemical Plants Direct Cost
Percentages ......................................................................... 323 Construction Equipment as a Percent of Direct Field Labor ........ 324 Overhead and Indirects as a Percent of Direct Field Labor ......... 324 Home Office Services as a Percent of Total Cost and Indirect
Cost ...................................................................................... 324
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xxii Contents
This page has been reformatted by Knovel to provide easier navigation.
Section 19. Estimate Adjustments ..................................... 325 Design Allowance .......................................................................... 325 Quantity Allowance ........................................................................ 325 Escalation ...................................................................................... 325 Contingencies ................................................................................ 326 Risk ................................................................................................ 326 Fees ............................................................................................... 326
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Section 1
DISCIPLINES OF WORK
The following is a broad description of the major items included in thevarious disciplines of work as outlined within this manual.
It should be recognized that all items listed will not necessarily be re-quired for a given project. There may also be other items for a specificproject that are not included. Should this occur, the estimator should giveconsideration to these items and add or deduct accordingly.
Direct Cost Items
1. Process EquipmentThe equipment cost, labor, material and subcon-tracts necessary to set and erect or install the process equipment inthe final position and condition for mechanical operation.
2. Site PreparationAU general preparation of the plant site for con-struction including, but not necessarily limited to, clearing, roughgrading, cut, fill, borrow, disposal, soil stabilization and finish grad-ing.
3. Site ImprovementsIncludes items of work that provide permanentimprovements to the plant site, such as drainage ditches, culverts,storm drain pipe, canals, dikes, all base materials for roads, parkinglots, and railroads including ballast, railroads, and fencing. Pave-ments for roads, process areas and parking areas are included under"Discipline, Paving."
4. ConcreteAll earthwork, forms, reinforcing steel, miscellaneousembedded items and placing, finishing and curing of concrete forequipment foundations and equipment structures are included here.All building concrete including foundations is included under "Disci-pline, Buildings."
5. Structural SteelAll cost of procuring, fabricating, and erectingstructural and miscellaneous steel, not embedded, for framed struc-tures, equipment supports, equipment platforms, walkways, ladders,
-
handrails and pipe supports. Steel for buildings is included under"Discipline, Buildings"
6. BuildingsAU cost of buildings including earthwork, foundations andother concrete, total superstructure, HVAC, plumbing and utility pip-ing to five feet outside of building, insulation, electrical, painting, andall architectual finishes.
7. Underground PipingAU project underground piping serving theproject including fire water loops and their components, water linesand special process lines.
8. Above Ground PipingIncludes the fabrication and erection of allabove ground process pipe, valves and fittings required for plant op-eration. Installation only of relief valves, control valves, and orificefittings for instrumentation are also included. The material cost ofthese items is included under "Discipline, Instrumentation."
9. Underground ElectricalAll labor and material for undergroundpower and lighting, ducts, conduit, wire, cable, etc. Also includesearthwork and concrete for embedments.
10. Above Ground ElectricalAU items required for the complete aboveground power and lighting systems for the total project, excludingbuildings. Also includes the installation of all electrical instrumentsand their hook-up.
11. InstrumentationIncludes material and labor cost of instrumenta-tion work delineated as follows:
Material cost includes instruments, control valves, relief valves,control panels, meter runs, orifice fittings and all other instrumentitems plus the tubing, tube bundles, and tray materials required toinstall these items.
Labor cost includes the installation of the above except as noted. Labor cost to install relief and control valves and orifice fittings is
included under Above Ground Piping. Labor cost to install electri-cal hook-up is included under "Above Ground Electrical."
All header piping labor and material costs are included under"Above Ground Piping."
12. InsulationAU labor and material cost of insulation, refractories, andlinings for process equipment and piping. Building insulation is in-cluded with buildings.
13. PaintingIncludes all preparation and protective coating of surfaceswith paint and/or epoxy for the total project excluding buildings.
14. PavingIncludes the furnishing and placing of concrete, asphalt, orgravel used for the final surfacing of roads, sidewalks, parking areas,and process work areas as required.
-
15. ProratablesIncludes the labor and material cost for daily area cleanup, all required scaffolding and final test, startup, and pre-commis-sioning assistance.
Construction Equipment
1. Rental or PurchaseCost of rental or purchase of construction equip-ment required to construct the project. Does not include small tools.
2. Service LaborAU labor required to service and maintain the con-struction equipment. Does not include the operation of the equipmentwhen working. Operators are included in the Direct Account Labor.
3. Fuel, Oil, Grease, SuppliesIncludes the cost of all fuels, lubricants,and supplies required to operate and maintain the construction equip-ment.
Overhead and Indirects
The following is a comprehensive list of inclusions, and the scope of theindividual project will dictate the actual item requirements.Indirect Labor (Except for Temporary Facilities Labor)
AU or part of the items described below are used to establish costs for:
Salaried indirectOffice hourly indirectsField hourly indirects
The distribution will vary depending upon the type of project, local la-bor practices, and contractor preferences.
Description
Engineering salaries-estimatingEngineering salaries-field technical support
To Include
Civil, cost, electrical, general, mechani-cal and structural estimating salaries.Project chief engineer; assistant projectchief engineer; chief field engineer; civil,electrical, mechanical, structural, field,staff, office, piping, instrument engi-neers; coordinators; engineering drafts-men; party chiefs, instrument men,
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Watchmen andJanitorslabor
Holiday pay
Salariesoffice clerical
Quality assurancelabor
SalariessubcontractadministrationSalariescost engineering
Salariesscheduling andplanningSalariestechnical clerksMaterial control labor
Move in/outlabor
Non-productive labor
chainmen, rodmen, and laborers tempo-rarily assigned to a field party perform-ing general layout work.Security supervisor, security coordina-tor, guards, watchmen, janitors, laborfor supplying drinking water. Note: Doesnot include contract security personnel.Pay for holidays not worked. Personnelcovered by overhead and indirect esti-mate only.Administrative clerks, office clerks, andsecretaries.Chief construction inspector, construc-tion inspectors, welding inspector, pipinginspector, electrical inspector, boiler in-spector and civil inspector.Salaries for subcontract coordinators.
Salaries for cost/schedule supervisor,chief field cost engineer and cost engi-neers.Salaries for chief field scheduler andplanner/schedulers.Salaries for technical clerical personnel.Material control coordinators and mate-rial control personnel assigned to imple-ment and follow-up the material controlprogram.Job payroll labor for loading, unloading,and transporting from facilities to proj-ect construction area tools and construc-tion equipment, temporary facilities, etc.Move-in is defined as assembly of toolsand construction equipment at jobsite.Move-out is the return of tools and con-struction equipment to other approveddestination, in the immediate area of theproject.Wages paid to hourly employees during atemporary period when work is stopped.Also wages paid to craftsmen for voting
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Safety and medicalexpenselaborSalariesoffice
Salariessupervision
Sick pay
Warehouse salaries
in accordance with union or governmentregulations. Welding test labor and jurypay differential. Note: Work stoppagedue to weather and show-up time areconsidered in productivity factors usedelsewhere.Safety supervisor, safety inspectors, andmedics.Chief accountant, accountants, book-keepers, invoice auditors, expeditors,chief timekeeper, timekeepers, person-nel manager, assistant personnel man-ager, personnel interviewer, data con-trollers, data entry operators, purchas-ing agents, and buyers.Project manager, general superinten-dent, craft superintendents, area super-intendents, assistant project manager,assistant superintendents, administra-tive manager, office manager, area coor-dinators and master mechanic.Wages paid overhead and indirect em-ployees only for authorized absence dueto personal illness, as approved by proj-ect construction manager.Warehouse supervisor, assistant ware-house supervisor, warehousemen, tool-room attendants, warehouse laborers-assigned full time to warehouse opera-tion. Note: Must be on job payroll only.
Description
Temporary buildings andutilitieslabor
To Include
Labor only for construction or erection,maintenance and dismantling of the tem-porary facilities, in accordance with butnot limited to the following: Roads,ditches, bridges, storage areas, parkinglots, fencing, buildings, water system,sanitary system, power distribution, tel-
Temporary Construction Facilities (Labor and Material)
-
Labor Burdens and Overhead Personnel Benefits
Temporary buildings andutilitiesmaterial andsupplies
ephone and communications systems,and plant air system. Note: Does not in-clude construction camp, quartering orcatering facilities.Material and supplies and maintenancefor construction and dismantling of thetemporary facilities in accordance withbut not limited to the following. Also in-cludes rental of temporary field officesand warehouses, roads, ditches, bridges,storage areas, parking lots, fencing,buildings, water system, sanitary sys-tem, power distribution, telephone andcommunications systems, and plant airsystem. Note: Does not include construc-tion camp, quartering or catering facili-
Description
Retirement and savingsplan (for overhead andindirect personnel only)
Insuranceemployees'life and hospitalization (foroverhead and indirectpersonnel only)InsuranceW/C, B/I, andP/D
Taxespayroll
Vacation pay (foroverhead and indirectpersonnel only)
Tb Include
Actual cost fixed by the appropriate ac-counting office. Note: Does not includeany like or similar item which is a part ofa union fringe benefit.Direct premium charges only. Note: Doesnot include any like or similar itemwhich is a part of a union fringe benefit.
Premium expense based on payrolls.Limits conform to the requirements forthe state as specified in the contract.FICA and Medicare, state unemploy-ment insurance and federal unemploy-ment insurance.Actual cost for overhead and indirectpersonnel only based on gross payroll asbilled by the appropriate Accounting Of-fice. Note: Does not include any like orsimilar item which is a part of a unionfringe benefit.
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Small Tool and Consumables
Description
Construction supplies
Small tools (in accordancewith contract limits)
Workmen's supplies
Other Indirects
Description
AdvertisingBond premiums
Communications andpostage
TD Include
This account should include items thatare consumed and, by their use, directlyrelated to construction; for example,sandpaper, rope, chalk, soapstone,emery paper grinding wheels, moilpoints, saw blades, padlocks, threadingdies, drill bits and reamers, rags, broomsand mops, air and water hose for generaluse.Purchase or rental of hand tools, poweroperated hand tools, etc. Rental or re-pair parts for such tools will be includedin this account. This account includes mi-nor equipment such as small pumps to3", vibrators, light plants (800 watt-3,000 watt), chain saws, pipe threaders,tar pots, small, sand blasting machines,air and chain hoists.This cost will include items that are, bytheir use, directly beneficial to and forthe convenience of workmen; for exam-ple, towels, toilet paper, drinking cups,ice drinking water, hard hats, protectiveclothing, gloves, boots, salt tablets, soap,drinking water barrels or containers,safety shoes, and work shoes. Credit isto be received for sales by payroll deduc-tion for items charged here.
To Include
Classified ads, public advertisements.Bid bonds, performance bonds, mainte-nance bonds, and fidelity bonds.Telephone, telegraph, teletype, postage,radio rental or communications system
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Containers
Dues
Engineering supplies
Expediting
Heat, light, water, andpower
Insurancegeneral
Legal
Licenses and permits
Move in/outsupplies andservices
Office supplies
Safety and medicalexpense, material
rented from a third party. Include datalines and couplers.Deposits for returnable containers andreels.Membership dues for clubs and profes-sional organizations, for overhead and in-direct personnel only. Note: Does not in-clude union dues.Surveying instruments (purchase orrental) drafting supplies, surveying sup-plies, blueprint or photostat work,progress photos.Cost for services supplied by expeditorswho are not on the job payroll.Public utility charges and heating fuelsfor job buildings. Cost for water notused for construction purposes.Premiums for builder's risk, fire and ex-tended coverage, equipment floater cov-erage, non-owned automotive liability,independent contractors' liability, con-tractual liability, special risk coverage,such as war risk and heavy lift, hull andP&I, umbrella.Abstracts, lawyers fees, court costs, no-tary fees, sign-up expense.Business permits, construction permits,export/import licenses, government in-spection fees, hauling permits.Transportation of tools, and constructionequipment by others to project construc-tion area, and miscellaneous suppliesconsumed and services used, for move-inand -out purposes.Stationery supplies, printing, officeequipment purchase, rental or repair, of-fice and warehouse forms and supplies,jobsite reproduction costs and furniture.Medical examination fees, medical sup-plies, safety signs and literature, first-
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Testing and laboratoryanalysis
Traveling
Welding supplies
Unclassified
Data processing services
Consulting services
Trade journals, books,publications, andsubscriptionsContract Guard ServiceQuality Assurance-Material and SuppliesEmployee EducationalAssistance
aid equipment, fire extinguishers, andrefills.Soil surveys, concrete cylinder tests, in-dependent inspectors. Lab charges totest welders.Transportation and subsistence expenseof overhead and indirect employees onbusiness trips (excluding quality assur-ance personnel travel).All material, supplies, and tools requiredby a welder, i.e., acetylene, oxygen, flux,welding rods, lighters, flints, chipping,hammers, wire brushes, stingers, hel-mets, lenses, asbestos gloves, goggles,gauges, welding qualification test mate-rial, etc.Flowers, weather reports and forecasts,and bank service charges.Cost for data processing services for theproject. Terminal rental, supplies, com-puter charges from outside jobsitesources, etc.Cost for outside consulting serviceswhich might be required in connectionwith the projects which are not a part ofengineering.Cost of books or subscriptions.
Cost of subcontract guard serviceNormally includes travel costs for qual-ity control personnel.Cost of employee educational assistance,for overhead and indirect personnel only.
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Home Office Cost
1. Engineering/Design ServicesTotal labor and material cost for thecomplete engineering and design of the project including engineeringfee.
2. Construction ServicesServices furnished by various home office de-partments such as estimating, scheduling, expediting, etc., as may berequired to assist the project. Services are charged to the project onlyfor time actually spent on the project.
3. Project General ManagementIncludes the portion of time that thecontractor's management staff applies in regard to overall direction ofthe project.
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Section 2
PROCESS EQUIPMENT
The most important component of physical plant cost is that of processequipment. From it the prime basis can be formed for the estimation ofthe entire plant.
Once the production rate has been established and a rough flow sheetpresented, an equipment list can be compiled noting the type, size, capac-ity and material of construction. From the logarithmic graphs that appearon the following pages, an average cost of equipment material and instal-lation manhours can be computed.
Inasmuch as it is not practical within the scope of this manual to ade-quately describe each piece of equipment beyond the very minor descrip-tion as appears on the individual graphs, I rely on the estimator's abilityto realize that the items covered are of a standard nature for chemicalplants, refineries, and industrial plants.
All installation manhours include offloading equipment at job site, haul-ing up to 2,000 feet and rigging, picking, setting, and aligning of theequipment.
The equipment graphs include the total cost of the equipment, but donot include structural steel or miscellaneous iron such as supports, lad-ders, walkways, platforms, or handrails. See other sections for theseitems.
AU shop fabricated equipment graphs, as in the case of vessels, includethe total shop cost, overhead, and profit for fabricating and furnishing ofall material and components required for that piece of equipment.
Packaged unit graphs include the total skid-mounted cost of the equip-ment and piping, electrical components and instrumentation, which maybe an integral part of the package.
Sub-contract equipment graphs include the total sub-contractors costand profit for the furnishing and installing of the equipment.
All equipment graphs include an average allowance for freight costwithin the continental forty-eight states.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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ACID CCX)LERS WITH PUMPAND MOTOR
Equipment Cost
Equ
ipm
ent
Cos
t
Heat Exchanger Area Square Feet
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ACID COOLERS WITH PUMPAND MOTOR
Erection Manhours
Erec
tion
Manhours
Heat Exchanger Area Square Feet
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VIBRATING BIN ACTIVATORSEquipment Cost
Equ
ipm
ent
Cos
t
Diameter Inches
-
VIBRATING BIN ACTIVATORSErection Manhours
Ere
ctio
n
Man
hour
s
Diameter Inches
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HIGH-SPEED MECHANICALAERATORS
Equipment Cost
Equi
pmen
t C
ost
Motor Horsepower(D Basic unitductile iron/carbon steel Basic unitstainless steel
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HIGH-SPEED MECHANICALAERATORSErection Manhours
Erecti
on
Manho
urs
Motor Horsepower
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LOW-SPEED MECHANICALSURFACE AERATORS
Equipment Cost
Equi
pmen
t C
ost
Motor HorsepowerFixed low-speed unit Floating low-speed unit
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LOW-SPEED MECHANICALSURFACE AERATORS
Erection Manhours
Erec
tion Manhours
Motor Horsepower
Fixed low-speed unitFloating low-speed unit
Next Page
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AIR POWER COMPRESSORSSynchronous Motor Driven
Rated for Sea Level to 3,300 FeetAltitude at 125 psig Maximum
Discharge PressureEquipment Cost
Equ
ipm
ent
Cos
t
Motor Horsepower0)460,575, or 480 volts2300 or 4160 volts
Previous Page
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AIR POWER COMPRESSORSInduction Motor Driven
Rated for Sea Level to 3,300-FbotAltitude at 125 psig Maximum
Discharge PressureEquipment Cost
Equi
pmen
t C
ost
Motor Horsepower460,575, or 230-volt480or2,300-volt
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AIR POWER COMPRESSORSSynchronous and Induction Motor
Driven Rated for Sea Level to3,300-Foot Altitude at 125 psigMaximum Discharge Pressure
Erection Manhours
Erection
Manhours
Motor Horsepower
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AUTOMOTIVE ANDINDUSTRIAL SERVICE AIR
COMPRESSORSEquipment Cost
Equi
pmen
t C
ost
Motor Horsepower
(D Single-stage, air-cooledcapacity 7.9 to 37.0 acfin @ 80 psig.Two-stage, air-cooledcapacity 5.0 to 97.2 acfin @ 175 psig.
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AUTOMOTIVE ANDINDUSTRIAL SERVICE AIR
COMPRESSORSErection Manhours
Erection
Manhours
Motor Horsepower
(D Single-stage, air-cooledcapacity 7.9 to 37.0 acftn @ 80 psig.Two-stage, air-cooledcapacity 5.0 to 97.2 acftn @ 175 psig.
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CENTRIFUGAL AIR COMPRESSORSPlant and High-Pressure
(Soot Blower) Types100 to 350 psig Discharge
PressureEquipment Cost
Equ
ipm
ent
Cos
t
Nominal Motor Horsepower0 Plant air compressors(2) High-Pressure (soot blower) compressors
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CENTRIFUGAL AIB COMPRESSORSPlant and High-Pressure
(Soot Blower) Types100 to 350 psig Discharge
PressureErection Manhours
Ere
ctio
n
Man
hour
s
Nominal Motor Horsepower
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INDUSTRIAL AIRCOMPRESSORS
Air-Cooled, Two-Stage50 to250psig
Equipment Cost
Equ
ipm
ent
Cos
t
Motor Horsepower(D Two-stage50 to 125 psig,Two-stage-150 to 250 psig.
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INDUSTRIAL AIRCOMPRESSORS
Air-Cooled, Two-Stage50 to250psig
Erection Manhours
Erection Manhours
Motor Horsepower
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INTEGRAL GAS ENGINECOMPRESSOR
Fbur-Cylinder TypeEquipment Cost
Equ
ipm
ent
Cos
t
Rated Hp. (BHP)(D Cast iron cylinders, 1,000 psig discharge(2) Nodular cylinders, 1,500 psig dischargeForged steel cylinders, 2,500 psig discharge Forged steel cylinders, 6,000 psig discharge
-
INTEGRAL GAS ENGINECOMPRESSORS
Fbur-Cylinder Type1,CXX) TO 6,000 psig Discharge
Erection Manhours
Ere
ctio
n
Man
hour
s
Rated Horsepower (BHP)
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PACKAGED AIR COMPRESSORUNITS
Single-Stage, Water-CooledOil-Lubricated and Nonlubricated
TypesEquipment Cost
Equ
ipm
ent
Cos
t
Motor Horsepower(DOil-lubricated-208, 230, or 460-volt.Nonlubricated-208, 230, or 460-volt.
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PACKAGED AIR COMPRESSOR UNITSSingle-Stage, Water-Cooled
Oil-Lubricated and NonlubricatedTypes
Erection Manhours
Ere
ctio
n
Man
hour
s
Motor Horsepower
For 208-, 230-, or 460-volt units.
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RECIPROCATINGCOMPRESSORS
Electric Motor DrivenEquipment Cost
Equ
ipm
ent
Cos
t
Compressor Horsepower
1) Cast Iron Cylinders 1000 PSI Discharge2) Nodular Iron Cylinders 1500 PSI Discharge3) Steel Cylinders 2500 PSI Discharge4) Steel Cylinders 6000 PSI Discharge
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RECIPROCATINGCOMPRESSORS
Electric Motor Driven1,000 to 6,000 psi Discharge
Erection Manhours
Ere
ctio
n M
anho
urs
Compressor Horsepower
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TWO-STAGE, TWO-CYLINDER,WATER-COOLED AIR COMPRESSORS
Oil-Lubricated and Nonlubricated150 to 350 psi Discharge
PressureEquipment Cost
Equi
pmen
t C
ost
Motor Horsepower0 Oil-lubricated Nonlubricated
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TWO-STAGE, TWO-CYLINDER,WATER-COOLED AIR COMPRESSORS
Oil-Lubricated and Nonlubricated350 to 500 psig Discharge
PressureEauimnent Cost
Equ
ipm
ent
Cos
t
Motor Horsepower(D Oil-Lubricated(D Nonlubricated
-
TWO-STAGE, TWO-CYLINDER,WATER-COOLED AIR COMPRESSORS
Oil-Lubricated and Nonlubricated150 to 500 psig Discharge
PressureErection Manhours
Erec
tion
Manhours
Motor Horsepower
Next Page
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REFRIGERATED AIR DRYERSAutomatic Type 15 to 1000 scfm
Equipment Cost
Equ
ipm
ent
Cos
t
Capacity SCFM
Previous Page
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REFRIGERATED AIR DRYERSAutomatic Type 1,200 to 15,000
scfmEquipment Cost
Equi
pmen
t C
ost
Capacity scfm
-
REFRIGEBATED AIR DRYERSAutomatic Type 15 to I9OOO scfm
Erection Manhours
Erection Manhours
Capacity SCFM
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REFRIGERATED AIR DRYERSAutomatic Type 1,200 to IS9OOO
scfmErection Manhours
Ere
ctio
n M
anho
urs
Capacity SCFM
-
CHILLER AIR DRYERSCapacity 3,000 to 28,000 scfm at
lOOpsigEquipment Cost
Equi
pmen
t C
ost
Capacity SCFM At 100 PSIG
-
CHILLER AIR DRYERSCapacity 3,000 to 28,000 scfm at
lOOpsigErection Manhours
Erectio
n Manhours
Capacity SCFM At 100 PSIG
Next Page
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SURGE ARRESTORSHydrocarbon and Water Service
500 psi Design Operating PressureASME CodeSection VIII
Division IEquipment Cost
Equ
ipm
ent
Cos
t
Nominal Size GallonsHydrocarbon ServiceWater Service
Previous Page
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SURGE ARRESTORSHydrocarbon, Water and Sewage Service
275 psi Design Operating PressureASME CodeSection VIII
Division IEquipment Cost
Equ
ipm
ent
Cos
t
Nominal Size Gallons
Hydrocarbon serviceWater service Sewage service
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SURGE ABBESTORSHydrocarbon, Water and Sewage Service
275 and 500 psi Design Operating PressuresASME CodeSection VIII
Division IErection Manhours
Erectio
n Manhours
Nominal Size Gallons
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DRY MATERIAL BLENDERS,PACKERS9 AND FEEDERS
Auger BlendersRotary Drum Blenders
Equipment Cost
Equi
pmen
t C
ost
iuaximum Mixing Cubic Feet Per Hour(D Auger blenders Rotary drum blenders
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DRY MATERIAL BLENDERS9PACKERS9 AND FEEDERS
Auger BlendersRotary Drum Blenders
Erection Manhours
Ere
ctio
n M
anho
urs
Maximum Mixing Cubic Feet Per HourAuger blenders Rotary drum blenders
-
MIXERS AND BLENDERSFixed Side Mounted Mixers with
Top MotorsEquipment Cost
Equ
ipm
ent
Cos
t
Rating Hors epower
-
MIXERS AND BLENDERSFixed Side Mounted Mixers
with Top MotorsErection Manhours
Erection Manhours
Rating Horsepower
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MIXERS AND BLENDERSPlate Mounted Open Tank Mixers
Equipment Cost
Equi
pmen
t C
ost
Rating Horsepower(D Plate-mounted, open tank mixersdirect drive.Plate-mounted, open tank mixersgear drive.
-
MIXERS AND BLENDERSPortable Clamp and Flanged
Mounted MixersEquipment Cost
Equi
pmen
t C
ost
Rating Horsepower Portable clamp mounted mixersdirect drive. Portable clamp mounted mixersgear drive. Flanged top tank mounted mixersdirect drive Flanged top tank mounted mixersgear drive.
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MIXERS AND BLENDERSFlanged Top Tank Mounted and
Plate Mounted Open Tank MixersErection Manhours
Ere
ctio
n
Man
hour
s
Rating Horsepower
Portable clamp mounted mixersDirect And GearDrive.
Flanged top tank and plate mounted open tank mix-ersdirect and gear drives.
-
MIXERS AND BLENDERSGearmotor Mixers
Equipment Cost
Equi
pmen
t C
ost
Approximate Weight - Pounds
(D For mounting on structural steel support above open tank For mounting on closed tank with stuffing box/shaft seal For mounting on closed tank with end face mechani cal sealsNote: Motor horsepower range 2-200, shaft length
range 100"-23O*, impeller range 29"-75".
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MIXERS AND BLENDERSGearmotor Mixers
Erection Manhours
Approximate Weight - Pounds(D For mounting on structural steel support above
open tank For mounting on closed tank with stuffing box/shaft
seals or end face mechanical sealsNote: Motor horsepower range 2-200, shaft length
range 100"-23O*, impeller range 29"-75".
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MIXERS AND BLENDERSBatch and Pipeline Homogenizer
MixersEquipment Cost
Equ
ipm
ent
Cos
t
Horsepower
(D Batch homogenizer mixers Pipeline homogenizer mixers
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MIXERS AND BLENDERSBatch and Pipeline Homogenizer
MixersErection Manhours
Ere
ctio
n
Man
hour
s
Horsepower
-
MIXERSHigh-Intensity
Equipment Cost
Equ
ipm
ent
Cos
t
Working Capacity Cubic Feet
-
MIXERSHigh-Intensity
Erection Manhours
Ere
ctio
n
Man
hour
s
Working Capacity Cubic Feet
-
DRY MATERIAL BLENDERS9PACKERS9 AND FEEDERS
Bag Vibrating PackersRigid Container Vibrating
PackersEquipment Cost
Equ
ipm
ent
Cos
t
Maximum Bag Width Or Container Diameter Inches Bag vibrating paekers Rigid container vibrating packers
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DRY MATERIAL BLENDERS9PACKERS9 AND FEEDERS
Bag Vibrating PackersRigid Container Vibrating
PackersErection Manhours
Ere
ctio
n
Man
hour
s
Maximum Bag Width Or Container Diameter Inches
(D Bag vibrating packers(2) Rigid container vibrating packers
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BOILERSPackage Type
Equipment Cost
Equ
ipm
ent
Cos
t
Pounds Per HourNote: Cost is for total boiler including forced draft fan
assembly. Boiler capacity pounds per hour-satu-rated steam at 100 to 235 psig.
-
BOILERSPackage Type
Erection Manhours
Ere
ctio
n
Man
hour
s
Pounds Per HourNote: Manhours are for installation of boiler including
forced draft fan. Boiler capacity pounds perhour-saturated steam at 100 to 235 psig.
-
BOILER STACKS1M-InCh Plate
Equipment Cost
Equ
ipm
ent
Cos
t
Linear Feet Of Stack(D 24-inch diameter (3) 42 to 48-inch diameter 30-inch diameter 54 to 60-inch diameter 36-inch diameterNote: Cost includes stack, cable, and clamps.
-
BOILER STACKS5/ie- and 3/s-Inch Plate
Equipment Cost
Equi
pmen
t Co
st
Linear Feet Of Stack %>-inch plate 42- to 48-inch diameter %3-inch plate 54- to 60-inch diameter %-inch plate 54- to 60-inch diameterNote: Cost includes stack, cable, and clamps.
-
BOILEB STACKS1Ai-, 5/i6-, 3/8-Inch Plate
Erection Manhours
Ere
ctio
n
Man
hour
s
Linear Feet Of Stack 24-inch diameter (D 42- to 48-inch diameter 30-inch diameter 54- to 60-inch diameter36-inch diameter
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CLASSIFICATION EQUIPMENTCone Pelletizers
Equipment Cost
Equ
ipm
ent
Cos
t
Cone Size Feet
Previous Page
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CLASSIFICATION EQUIPMENTCone Pelletizers
Erection Manhours
Ere
ctio
n
Man
hour
s
Cone Size Feet
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CLASSIFICATION EQUIPMENTTurbo-Screen Cyclone and
48"-Pressure Sifter (3-Screens)Equipment Cost
Equi
pmen
t
Diameter Inches Stainless steel turbo-screen cyclone Carbon steel turbo-screen cyclone 48-inch pressure sifter (3-screens)
Cos
t
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CLASSIFICATION EQUIPMENTTurbo-Screen Cyclone and
48"-Pressure Sifter (3-Screens)Erection Manhours
Erec
tion
Manhours
Diameter Inches
Carbon or stainless steel cyclone48-inch pressure sifter (3-screens)
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CLASSIFICATION EQUIPMENTRotary Screens
Equipment Cost
Equ
ipm
ent
Cos
t
Capacity Screen Area Square Feet
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CLASSIFICATION EQUIPMENTRotary Screens
Erection Manhours
Ere
ctio
n
Man
hour
s
Capacity Screen Area Square Feet
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VERTICAL TUBE SURFACECONDENSERS AND
RECEIVERSEquipment Cost
Equ
ipm
ent
Cos
t
Cooling Surface Square Feet
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VERTICAL TUBE SURFACECONDENSERS AND
RECEIVERSErection Manhours
Ere
ctio
n M
anho
urs
Cooling Surface Square Feet
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CONVEYING EQUIPMENTConveyorsOpen Belt
Equipment Cost
Equi
pmen
t C
ost
Linear Feet(D 18-inch belt
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CONVEYING EQUIPMENTConveyorsOpen Belt
Erection Manhours
Ere
ctio
n M
anho
urs
Linear Feet 18-inch belt 36-inch belt 24-inch belt 42-inch belt(S) 30-inch beltNote: See structural steel account for bents.
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CONVEYING EQUIPMENTConveyorsBelt Enclosed
with WalkwayEquipment Cost
Equ
ipm
ent
Cos
t
Linear Feet(D 18-inch belt 36-inch belt 24-inch belt 42-inch belt
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CONVEYING EQUIPMENTConveyorsBelt Enclosed
with WalkwayErection Manhours
Ere
ctio
n M
anho
urs
Linear Feet 18-inch belt (D 36-inch belt 24-inch belt 42-inch belt(E) 30-inch beltNote: See structural steel account for bents.
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CONVEYING EQUIPMENTConveyorsSpaced, Bucket
Elevators, Belt-DrivenEquipment Cost
Equi
pmen
t
Linear Feet 6-x 4-inch buckets(2) 12-x 7-inch buckets 16- x 8-inch buckets
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CONVEYING EQUIPMENTConveyorsSpaced, Bucket
Elevators, Chain-DrivenEquipment Cost
Equi
pmen
t C
ost
Linear Feet(D 6-x 4-inch buckets(D 12-x 7-inch buckets(S) 16-x 8-inch buckets
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CONVEYING EQUIPMENTConveyorsSpaced, Bucket
Elevators,Chain- or Belt-Driven
Erection Manhours
Ere
ctio
n
Man
hour
s
Linear Feet 6-x 4-inch buckets(2) 12-x 7-inch buckets 16- x 8-inch buckets
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CONVEYING EQUIPMENTConveyorsContinuous, Bucket
Elevators,Belt-Driven
Equipment Cost
Equ
ipm
ent
Cos
t
Linear Feet0 8- x 5-inch buckets(D 16-x 8-inch buckets 20-x 8-inch buckets
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CONVEYING EQUIPMENTConveyorsContinuous, Bucket
Elevators,Chain-Driven
Equipment Cost
Equ
ipm
ent
Cos
t
Linear Feet(D 8-x 5-inch buckets(2) 16-x 8-inch buckets 20-x 8-inch buckets
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CONVEYING EQUIPMENTConveyorsContinuous, Bucket
Elevator,Chain- or Belt-Driven
Erection Manhours
Ere
ctio
n
Man
hour
s
Linear Feet 8-x 5-inch buckets(2) 16-x 8-inch buckets 20-x 8-inch buckets
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SCREW CONVEYORSEquipment Cost
Overall Conveyor Length-Linear FeetScrew Diameter:(D 6-inch 16-inch9-inch 18-inch(E) 12-inch CD 20-inch014-inch 24-inch
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SCREW CONVEYORSErection Manhours
Ere
ctio
n M
anho
urs
Overall Conveyor Length-Linear FeetScrew Diameter: 6-inch 16-inch9-inch 18-inch12-inch 20-inch(D 14-inch 24-inch
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DRYERSDRUMAtmospheric Single Drum Type
Equipment Cost
Equi
pmen
t C
ost
Approximate Weight Pounds
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DRYERSDRUMAtmospheric Double and Twin
Drum TypesEquipment Cost
Equi
pmen
t C
ost
Approximate Weight Pounds(D Double drumTwin drum
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DRYERSDRUMAtmospheric Single, Double, and
Twin Drum TypesErection Manhours
Ere
ctio
n M
anho
urs
Approximate Weight Pounds(D Single DrumDouble DrumTwin Drum
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DRYERSVACUUMConical Rotating Type
Equipment Cost
Equi
pmen
t C
ost
Approximate Weight Pounds
Previous Page
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DRYERSVACUUMDouble Drum and Rotary Types
Equipment Cost
Equi
pmen
t C
ost
Approximate Weight Pounds0 Double drum Rotarystainless steel(H) Rotarycarbon steel
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DRYERSVACUUMConical Rotating and Double
Drum TypesErection Manhours
Ere
ctio
n M
anho
urs
Approximate Weight Pounds Conical rotatingDouble drum
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DRYERSVACUUMRotary Types Carbon Steel and
Stainless SteelErection Manhours
Ere
ctio
n M
anho
urs
Approximate Weight PoundsCarbon SteelStainless Steel
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DUST COLLECTORSCENTRIFUGAL SCRUBBERS
High Capacity, Low EnergyLoss Type
Hot-Rolled Steel ConstructionEquipment Cost
Equi
pmen
t C
ost
Capacity CFM At 4.5V Pressure Drop(D 12-gauge %6-inch plate(2) 10-gauge V4-inch plateNote: Cfin capacity at 2.0-inch pressure drop will equal
approximately 67% of above cftn.
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DUST COLLECTORSCENTRIFUGAL SCRUBBERS
Medium Capacity, MediumEnergy Loss
Hot-Rolled SteelEquipment Cost
Equi
pmen
t C
ost
Capacity CFM At 4.5" Pressure Drop 12-gauge (E) %6-inch plate
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DUST COLLECTORSCENTRIFUGAL SCRUBBERS
High Capacity, Low EnergyLoss Type
T304-2B Stainless Steel ConstructionEquipment Cost
Equi
pmen
t C
ost
Capacity CFK At 4.4" Pressure Drop 12-gauge ^16-inch plate 10-gauge V4-inch plateNote: Cfm capacity at 2.0-inch pressure drop will equal
approximately 67% of above cfm.
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DUST COLLECTORSCENTRIFUGAL SCRUBBERS
Medium Capacity, MediumEnergy Loss Type
T304-2B Stainless Steel ConstructionEquipment Cost
Equi
pmen
t C
ost
Capacity CFK At 4.5" Pressure Drop 12-gauge %6-inch plate(2) 10-gauge (D V4-inch plateNote: Cfrn capacity at 2.0-inch pressure drop will equal
approximately 71% of above cfm.
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DUST COLLECTORSCENTRIFUGAL SCRUBBERS
High- and Medium-Capacity UnitsHot-Rolled Steel and T304-2B
Stainless SteelErection Manhours
Ere
ctio
n
Man
hour
s
Capacity CFM At 4.5" Pressure Drop Hot-rolled steelall thicknessesT304-2B stainless steel-all thicknesses
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DUST COLLECTORSHot-Rolled SteelCyclones
Equipment Cost
Equi
pmen
t C
ost
Capacity CFM At 6.0" Pressure Drop(D 16-gauge (g) 12-gauge %6-inch plate(2) 14-gauge 0 10-gaugeNote: Cfin capacity at 2.5-inch pressure drop will equal
approximately two-thirds of above cfin.
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DUST COLLECTORS304 Stainless Steel Cyclones
Equipment Cost
Equi
pmen
t C
ost
Capacity CFM At 6,O" Pressure Drop 16-gauge 12-gauge %6-inch plate 14-gauge (D 10-gaugeNote: Cftn capacity at 2.5-inch pressure drop will equal
approximately two-thirds of above cfin.
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DUST COLLECTORSHot-Rolled Steel and 304Stainless Steel Cyclones
Erection Manhours
Ere
ctio
n
Man
hour
s
Capacity CFM At 6.0" Pressure Drop Hot-rolled steelall