Conceptual Cost Estimating

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

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".

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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).

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

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.

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.

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

vi Contents

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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

Contents vii


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

viii Contents


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

Contents ix


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

x Contents


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

Contents xi


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

xii Contents


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

Contents xiii


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

xiv Contents


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

Contents xv


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

xvi Contents


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

Contents xvii


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

xviii Contents


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

Contents xix


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

xx Contents


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

Contents xxi


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

xxii Contents


Section 19. Estimate Adjustments ..................................... 325 Design Allowance .......................................................................... 325 Quantity Allowance ........................................................................ 325 Escalation ...................................................................................... 325 Contingencies ................................................................................ 326 Risk ................................................................................................ 326 Fees ............................................................................................... 326

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,

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

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.

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

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-

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.

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.

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.

ACID CCX)LERS WITH PUMPAND MOTOR

Equipment Cost

Equ

ipm

ent

Cos

t

Heat Exchanger Area Square Feet

ACID COOLERS WITH PUMPAND MOTOR

Erection Manhours

Erec

tion

Manhours

Heat Exchanger Area Square Feet

VIBRATING BIN ACTIVATORSEquipment Cost

Equ

ipm

ent

Cos

t

Diameter Inches

VIBRATING BIN ACTIVATORSErection Manhours

Ere

ctio

n

Man

hour

s

Diameter Inches

HIGH-SPEED MECHANICALAERATORS

Equipment Cost

Equi

pmen

t C

ost

Motor Horsepower(D Basic unitductile iron/carbon steel Basic unitstainless steel

HIGH-SPEED MECHANICALAERATORSErection Manhours

Erecti

on

Manho

urs

Motor Horsepower

LOW-SPEED MECHANICALSURFACE AERATORS

Equipment Cost

Equi

pmen

t C

ost

Motor HorsepowerFixed low-speed unit Floating low-speed unit

LOW-SPEED MECHANICALSURFACE AERATORS

Erection Manhours

Erec

tion Manhours

Motor Horsepower

Fixed low-speed unitFloating low-speed unit

Next Page

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

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

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

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.

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.

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

CENTRIFUGAL AIB COMPRESSORSPlant and High-Pressure

(Soot Blower) Types100 to 350 psig Discharge

PressureErection Manhours

Ere

ctio

n

Man

hour

s

Nominal Motor Horsepower

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.

INDUSTRIAL AIRCOMPRESSORS

Air-Cooled, Two-Stage50 to250psig

Erection Manhours

Erection Manhours

Motor Horsepower

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)

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.

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.

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

RECIPROCATINGCOMPRESSORS

Electric Motor Driven1,000 to 6,000 psi Discharge

Erection Manhours

Ere

ctio

n M

anho

urs

Compressor Horsepower

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


Oil-Lubricated and Nonlubricated350 to 500 psig Discharge

PressureEauimnent Cost

Equ

ipm

ent

Cos

t

Motor Horsepower(D Oil-Lubricated(D Nonlubricated


Oil-Lubricated and Nonlubricated150 to 500 psig Discharge

PressureErection Manhours

Erec

tion

Manhours

Motor Horsepower

Next Page

REFRIGERATED AIR DRYERSAutomatic Type 15 to 1000 scfm

Equipment Cost

Equ

ipm

ent

Cos

t

Capacity SCFM

Previous Page

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

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

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

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

SURGE ABBESTORSHydrocarbon, Water and Sewage Service

275 and 500 psi Design Operating PressuresASME CodeSection VIII

Division IErection Manhours

Erectio

n Manhours

Nominal Size Gallons

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

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

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.

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".

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".

MIXERS AND BLENDERSBatch and Pipeline Homogenizer

MixersEquipment Cost

Equ

ipm

ent

Cos

t

Horsepower

(D Batch homogenizer mixers Pipeline homogenizer mixers

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


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


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

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

Next Page

CLASSIFICATION EQUIPMENTCone Pelletizers

Equipment Cost

Equ

ipm

ent

Cos

t

Cone Size Feet

Previous Page

CLASSIFICATION EQUIPMENTCone Pelletizers

Erection Manhours

Ere

ctio

n

Man

hour

s

Cone Size Feet

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

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)

CLASSIFICATION EQUIPMENTRotary Screens

Equipment Cost

Equ

ipm

ent

Cos

t

Capacity Screen Area Square Feet

CLASSIFICATION EQUIPMENTRotary Screens

Erection Manhours

Ere

ctio

n

Man

hour

s

Capacity Screen Area Square Feet

VERTICAL TUBE SURFACECONDENSERS AND

RECEIVERSEquipment Cost

Equ

ipm

ent

Cos

t

Cooling Surface Square Feet

VERTICAL TUBE SURFACECONDENSERS AND

RECEIVERSErection Manhours

Ere

ctio

n M

anho

urs

Cooling Surface Square Feet

CONVEYING EQUIPMENTConveyorsOpen Belt

Equipment Cost

Equi

pmen

t C

ost

Linear Feet(D 18-inch belt

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.

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

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.

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


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


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

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


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


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

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

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

DRYERSDRUMAtmospheric Single Drum Type

Equipment Cost

Equi

pmen

t C

ost

Approximate Weight Pounds

DRYERSDRUMAtmospheric Double and Twin

Drum TypesEquipment Cost

Equi

pmen

t C

ost

Approximate Weight Pounds(D Double drumTwin drum

DRYERSDRUMAtmospheric Single, Double, and

Twin Drum TypesErection Manhours

Ere

ctio

n M

anho

urs

Approximate Weight Pounds(D Single DrumDouble DrumTwin Drum

Next Page

DRYERSVACUUMConical Rotating Type

Equipment Cost

Equi

pmen

t C

ost

Approximate Weight Pounds

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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

DRYERSVACUUMConical Rotating and Double

Drum TypesErection Manhours

Ere

ctio

n M

anho

urs

Approximate Weight Pounds Conical rotatingDouble drum

DRYERSVACUUMRotary Types Carbon Steel and

Stainless SteelErection Manhours

Ere

ctio

n M

anho

urs

Approximate Weight PoundsCarbon SteelStainless Steel

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.


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


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.


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.


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

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.

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.

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

Conceptual Cost Estimating

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