filters, grinders, centrifuges, electric power generators and drivers, scales, baggers, material dryers, mixers, etc. including their drivers.
Includes
o Special package systems.
o Elevators not in a building.
o Erection and startup supervision by vendor if required.
o All major vacuum equipment - etc.
Excludes
o Machine tools and laboratory equipment within refinery buildings.
o Monorails and building service cranes, hoists, etc.
o Structures and foundations supporting this equipment.
o Elevators within a building to be charged to .14 "R" Accounts.
o Vacuum equipment furnished with condenser.
o All major vacuum equipment (i.e. - ejectors, vacuum pump, and exhausters). Minor vacuum specialties are included with piping specialities.
"J" - INSTRUMENTS
GENERAL Includes
The installing, supporting, testing and calibration of instruments used for the purpose of controlling, measuring, observing, indicating or recording process and utility variables in the permanent plant facilities.
This instrumentation system may be electronic and or neumatic. It also includes the instrument air supply piping fro the first block valve of an air header to the instrument and weatherproofing (except steam tracing and insulation) of this instrument to ensure satisfactory operation regardless of climatic conditions.
Excludes
The installing and supporting of conduit and wire, steam tracing, insulation, steam and condensate piping to instrument shelter heater coils, instrument Air Headers (sub-headers are inluded in this account), and instruments supplied as an integral part of a piece of equipment.
Control Code Description Fld. Lbr. Code
J-01 Prefabricate instrument supports (Labor only) J-01
J-11 Field mounted receivers, controllers J-10
J-12 Field mounted flow instruments J-10
J-14 Field mounted level instruments J-10
J-16 Field mounted pressure instruments J-10
J-18 Field mounted temperature instruments J-10
J-19 Miscellaneous field mounted instruments J-10
J-21 Main control panel and rack J-21
J-22 Main panel instruments and control systems J-22
J-26 Process contrrol computer J-26
J-31 Local control panels J-31
J-32 Local panel mounted instruments J-32
J-41 Control valves (material only)
-J-44 Relief valves (material only)
-J-50 Instrument shelters J-50
J-60 Analkyzzers and package control systems J-60
J-71 Single tubing (pneumatic transmission) J-71
J-72 Mutitubing (pneumatic transmission) J-72
J-73 Raceway and tray J-73
J-74 Instrument air subheader (labor only) J-74
J-75 Installation and support materials (material only)
-J-81 Loop check (labor only) J-81
J-82 Calibration and testing (labor only) J-82
J-01 Prefabricate Instrument Supports (Labor only). Fld. Lbr. Code J-01
Note: Direct field labor costs for on site prefabrication and preassembly of bulk materials are charged to cost accounts in the series 00 to 09 for the particular letter category (e.g., J-01, On-site
Fabrication of Instrument Stands). Excludes Hours to install (with J-1*)
Prefabrication and Assembly Unit Man-hours
Fabricate Strong Backs ea.
Fabricate Pipe Stands ea. 12
Fabricate Pipe Saddles ea. 6
Fabricate Steel Pots ea. 9
J-11 Field mounted receivers, controllers. Fld. Lbr. Code J-10
Includes
Labor for installing and supporting all field mounted instruments including any piping, tubing, fittings, etc., necessary to connect an instrument to a process or utility variable. (This material is normally itemized on the " Instrument Installation").
Identification and tagging of instruments.
Excludes
Installation labor for control and relief valves (L account), the
first block valve on a process or utility stream ot vessel (E or L account), pneumatic signal transmission tubing (J-22 and J-71 Accounts), instrument air subheader piping (J-74 account), main and local control panel mounted instruments (J-22 account), electrical wiring (P account), other installation material (J-70 account), and electrical instruments in the motor control center or switchgear areas.
Testing, Inspection and calibration of field instruments and instrument connection piping ( J-80 account).
Instrument Installation Field Major Vendor Unit Man-hours
Flow Transmitters, Controllers, Level Indicator, Recorders E or P ea. 24
Pressure Indicator, Recorders E or P ea. 18
Temperature Indicator, Recorders E or P ea. 5
Note: When insulated and traced tubing is used for process connections add 20% to above man-hours for flow, level and pressure instruments only.
J-12 Field mounted flow instruments Fld. Lbr. Code J-10
Unit Man-hours
Orifice Plates (flgs. And meter runs "L" Acct.) ea. 3
Flow Tubes and Venturis (In "L"Account)
Ratometer and sight glasses (Sight Glass "L" Account) ea. 3
Magnetic Flow Meters (In "L" Account) Turbine Meters (In "L" Account)
Flow Switches Target Type ea. 4
Flow Switches D/P Type ea. 24
Pitot Tubes ea. 6
J-14 Field mounted level instruments Fld. Lbr. Code J-10
Unit Man-hours
Displacement Level Instrument Ext. Cage ea. 28
Displacement Level Instruments
Internal Displ. ea. 8
Float Level Switches ea. 18
Capacitance Level Instruments ea. 10
Gauge Glasses ea. 16
Tank Gauges ea. 20
Boiler Sight Glasses ea. 10
Water Columns ea. 27
J-16 Field mounted pressure instruments Fld. Lbr. Code J-10
Unit Man-hours
Pressure Gauges ea. 2
Draft Gauges (Incl. Tubing) ea. 47
Differential Pressure Gauges ea. 24
Differential Pressure Switches ea. 24
Pressure Switches ea. 8
Incl. W/Piping Fabrication &
Installation
Note: When diaphragm seals, siphons or dampeners are used with above instrument add one hour to above man-hours
J-18 Field mounted temperature instruments Fld. Lbr. Code J-10
Unit Man-hours
Termocouples Assemblies and Wells ea. 2
Reactor Thermocouples ea. 15
Dial Thermometers and Wells ea. 2
Remote Thermometers ea. 5
Temperature Switches ea. 5
J-19 Miscellaneous field mounted instruments Fld. Lbr. Code J-10
Unit Man-hours
Solenoid Valves ea. 3
Miscellaneous Relays ea. 3
J-21 Main control panel and rack Fld. Lbr. Code J-21
Unit Man-hours
Solenoid Valves ea. 3
Miscellaneous Relays ea. 3
Includes
Labor to handle the main control panel section (unloading, moving to control house, uncrating), setting, bolting sections together, installing filler sections and console desks.
Control House Panels and Unit Manhours Panel Mounted Instruments
Unit Man-hours / lf
Unload Panel board from truck, skid into position & set on foundation lf. 3
Note: If control panel is shipped in sections add for each unit connection 4.0 manhours.
Console Desk ea. 4
J-22 Main panel instruments and control systems Fld. Lbr. Code J-22
Includes
Field labor to install the instruments on the panel or mounted in racks behind the panel.
Field labor to connect panel instruments to the panel bulkheads, terminal strips and air header.
Note: If ading new cut out and hook up add 8.0 manhours.
Excludes
Labor to connect electrical wire from the field to the board and terminal stips for both pneumatic and electronic systems (P account). Labor to connect instrument leads at the panel bulkhead connectors for pneumatic signal transmission to and from the field instruments.
(Singlee Tubing, J-71 account; multitubing, J-72 account)
Unit Man-hours
Panel Mounted Instruments (Face of Panel) ea. 5
J-26 Process contrrol computer Fld. Lbr. Code J-26
Includes
Labor to handle the main section (unloading, moving to control house, uncrating), setting, bolting sections together, installing filler sections and console desks.
Setting of auxiliary equipment such as key punch machine, decollator, etc.
Unit Man-hours
Process computer - Set in Place ea. 60
Excludes
Labor to connect electrical wire from the field to the computer (P account).
Any equipment required to maintain a suitable environment in the computer room (R account).
J-31 Local control panels Fld. Lbr. Code J-26
Includes
The material and labor for furnishing and installing local control panels.
Note: Some local panels are small in size such as 2' - 0" H x 2' - 0" W.
For this type of local panel allow 4 manhours each.
Excludes
Labor to connect pneumatic signal transmission tubing from field instruments to terminal bulkheads (with J-71 or J-72) and the labor to connect electronic or thermocouple wire from field instruments to their terminals (with P-33).
Unit Man-hours/lf
Local Control Panels lf. 3
J-32 Local panel mounted instruments Fld. Lbr. Code J-32
Includes
The material and labor cost for furnishing and installing instruments and other control devices associated with local panels. Normally installed by panel Vendor.
Unit Man-hours/lf
Local Panel Mounted Instrument ea. 4
Excludes
The labor to connect Pneumatic signal transmission tubing from field instrument to terminal bulkheads with J-71 ro J-72 and the labor to connect electronic or thermocouple wire from field instruments to their terminals (with P-33). If Installed in field use 6-8 mhrs ea.
J-50 Instrument shelters Fld. Lbr. Code J-50
Includes
Labor for Pre-assembling and installing instrument housing or shelters of the heated or unheated type.
Excludes
Labor fro steam tracing ( L - 10 account) and insulation (N-30 account) of instruments and inbstruments connection lines or general requirements for outdoor equipment or piping (N-30 account).
Steam supply and condensate return piping and the instrument shelter heater coils (L-10 account).
Weather Conditioning Unit Man-hours/lf
instrument Shelters - Walk-In Type ea. 60
Instrument Enclosure ea. 4
Heater Shelter ea. 10
J-60 Analkyzzers and package control systems Fld. Lbr. Code J-60
Inscludes
Labor to install all parts of instrument systems puchased as a unit ( Boiler Control Sydtem, etc.).
Instruments identified on the P&ID as one instrument, but which actually consist of several instrument, I.e., density analyzer, chromatograph, moisture analyzer.
These instruments maybe mounted on a separate local panel with a separate recorder on the main control panel. This local panel with all the instruments is still considered as a package and inclded in this account.
Excludes
Installation labor for instruments or systems forming an integral part of a piece of equipment (I.e., compressor controls).
Package Control Systems Unit Man-hours/lf
Analyzers - with sampling conditioning systems ea. 250
Analyzers - Portable type such as ph analyzers ea. 10
Boiler Control System Syst.
Treat as normal estimate, count instrument and apply unit manhours per instrument, and compile total manhours for this package.
Other package controls - Allow 25 mhrs/$1,000 Syst.
Noter: 25 mhrs/$1,000 is not standard. This allowance depends on type of system, escalation, etc.
J-71 Single tubing (pneumatic transmission) Fld. Lbr. Code J-71
Includes
Labor to install and support all pneumatic signal transmission single tubing, including connectors, fittings and cut-off valves.
Labor to connect single tubing to the control panel bulkheads when no multitube bundles are used for connecting the field mounted instruments to the control panels.
Unit Man-hours/lf
Single Tubing - Pneumatic Transmisssion lf. 0.3
(Copper or Plastic) Excludes
Labor to test and inspect single tubing (J-80 account).
Labor to install the tubing to connect an instrument to a process or utility variable (J-X account).
Labor to connect single tubing to the control panel bulkheads when all or part of the lead-in to the control panel is made with multitube bundles (J-72 account).
J-72 Mutitubing (pneumatic transmission) Fld. Lbr. Code J-72
Includes
Installation labor of all multitube bundles transmitting pneumatic signals, including connectors and junction boxes.
Labor to connect single tubing and multitubing to the control panel bulkheads, when all or part of the lead-in to the control panel is made with multitube bundles.
Excludes
Multitube supports unistrut or other (J-73 account).
Single tubing installation (J-71 account).
Multitube and Junction Box Unit Man-hours
Multitube lf. 0.5
Connections ea. 1
Junction Box ea. 4
J-73 Raceway and tray Fld. Lbr. Code J-73
Includes
Installation labor for all raceway and tray used specifically for the support of instrumentation multitube bundles.
Unit Man-hours
Raceway and Tray lf. 1
Excludes
Support specifically for single tubing (J-71 account).
Raceway cable tray for thermocouple and other instrument wire in electronic systems (P account).
J-74 Instrument air subheader Fld. Lbr. Code J-74
Includes
Labor for installing and supporting instrument air subheader piping.
Excludes
Labor for testing and inspection of instrument air subheader piping (J-82 account).
Labor for installing the first block valve on the main instrument air header (L account).
Labor for installing the instrument air pipng to an instrument after the first block valve on the instrument air subheader (J-X account).
Instrument Air Subheader Unit Man-hours/ft
Galvanized Pipe 1" and under lf. 0.5
Galvanized Pipe 2" and up lf. 0.6
J-81 Loop check (labor only) Fld. Lbr. Code J-81
Includes the labor necessary to ensure that:
a all instruments perform their intended function.
b all components are properly connected.
c all components respond correctly.
also
Includes testing and inspection of instrument air subheader and connection lines.
Unit Man-hours
Loop Check ea. 4
Teting of instrument air subheader lf. 0.04
Testing instrument connection lines lf. 0.04
Testing thermocouple leads ea. 1
Alarm loops ea. 1
J-82 Calibration and testing (labor only) Fld. Lbr. Code J-82 Includes
Labor necessary for testing and inspection of instruments.Calibrating instruments, testing of relief valves (test set pressure) and pneumatically stroking control valves.
Excludes
Labor for connecting "moan lists" resulting from P&ID checks, testing and calibration. (See respective
"J" installation account).
Test and Calibration Unit Man-hours
Field Instruments ea. 4
Panel Instruments ea. 4
Control and Relief Valves ea. 4
Analyzers (May vary with type) ea. 25
Note: In definitive estimates use above unit rates. In conceptual estimates use allowance of 12% of other "J" manhours.
(Y10) Instrumentation Scaffolding
That portion of the scaffolding manhours (Y10) attributable to instruments may be estimated at:
3% of total "J" manhours.
4% of total "J" manhours, excluding J21, J22, J26 and J60.
"M" - STEEL
GENERAL Includes
steel pipe stanchions.
for safety. Includes platforms, stairs, ladder and cages, handrail and toe plates, grating. Checkered plate not supplied with equipment.
associated with steel or concrete structure to act as protection from the elements during operation or maintenance. Includes pumps or compressor shelters, elevator shaft siding, conveyor covers, etc.
Excludes
Concrete pipe slippers poured as foundation. - "Q" Account.
Steel framing for buildings. - "R" Account.
Pipe hangers and insulation shoes. - "L" Account.
Instrument tubing raceway or raceway supports. - "J" Account.
Electrical or instrument supports, hangers, stands. - "P" or "J" Account Fireproofing of structural steel or vessel skirts. - "N" Account.
Welding rod or other consumables. - Distributable Account.
Foundation. "Q" Account.
Field Painting. - "X" Account.
Temporary slabs used for precasting concrete. - Distributable Account.
Marine Structures. - "Q" Account.
Concrete Pipe Stanchions. "Q" Account.
Concrete Structures. - "Q" Account.
Control Code
Fld. Lbr. Code
** M-10 Steel structures and Enclosures
M-10
the furnishing and erection, bolting, riveting, cutting, welding and burning of steel structures supporting and/or
Steel Structures Normally supporting equipment or piping. Includes
Access Steel - Provided for operation and maintenance convenience and
Structural Enclosures - Including siding, roofing, doors, etc.
Includes the labor cost associated with
enclosing permanent plant equipment.
stair, ladder and handrailing which are an integral part of said structures.
platforming, stairs, ladder and handrail associated with buildings unless it is subcontracted. In this case, said steel willl be included in the "R" account.
windows and doors) attached to said structures (with code R25) and concrete decking (with Q Account).
Light Steel (Less than 17LB/LF) 40 MH/TON
Heavy Steel (17 to 45 LB/LF) 20 MH/TON
Very Heavy Steel (Over 45 LB/LF) 10 MH/TON
For Precast Fireproofed Steel Members add 6 MH/TON of steel.
** M-20 Platforms, Stair, Ladders and Handrails
M-20 Includes the labor cost associated with
the furnishing and erection , bolting, riveting, welding, cutting and burning of platforms, ladders, handrails and stair and their structural steel supports attached to or to be used to provide access to columns, vessels, exchangers, instruments or valves.
Vessel Platforms, Stair treads, ladders 45 MH/TON For estimating weight, use the following data,
which includes AISC and connection allowance:
Vessel Platforms 30 LB/SF
Ladders and cages 22 LB/LF
Handrail and toe plate 11 LB/LF
Stair treads (Grating) 30 LB/EA
Grating for checkered plate other than 0.1 MH/SF
part of vessel platforms
** M-30 Steel Pipe Stanchions
M-30
Includes the labor costs associated 25 MH/TON
with the furnishing and erection, bolting, riveting, welding, cutting and burning of sructural steel pipeways or pipe stanchions.
For major pipeways use manhours listed on M-10.
** M-40 Miscellaneous Structural Steel
M-40
Includes the furnishing, fabricating and 50 MH/TON
erecting of structural steel not covered above such as pipe sleepers, stiles across grade level pipeways and tank dikes., and conduit support racks, pull box covers.
** M-50 Other Structures
M-50
Includes the furnishing, fabricating and erecting of wharves, bridges, loading platforms, etc.
** Add 10% for each 40 ft of elevation above initial 20 ft to each of the above accounts.
(Y10) Steel Scaffolding)
That portion of the scaffolding manhours (Y10) attributable to Includes steel platforming floor grating,
Includes grouting operation.
Also includes structural steel framing,
Excludes roofing and siding (including
steelwork is estimated at zero.
"N" - INSULATION & FIREPROOFING
Includes
All external vessel, equipment and pipe insulation.
Fireproofing of vessel skirts, vessel legs, structural steel and equipment support
Installation of heat transfer cement over tracers
Forming, pouring, tamping of Gilsulate, Gilsogard, Gilsotherm
Scaffolding labor for pipe insulation
Fireproofing studs (if not provided with piece of equipment), mesh, clips, Gunite concrete, curing, etc.
Fabricating formwork, mesh, concrete, stripping and cleaning, etc. for fireproofing
Handling of steel members from storage area to precasting area and return if they are to be fireproofed
Grouting for fireproofed steel members Insulation of instruments and instrument leads
Excludes
Earthwork and curing of Gilsulate on underground piping Installation of tracers
Building insulation of all types
Temporary insulation for stress relieving or dry-out Refractory interior linings
Stack and duct lining
Precasting slab
Rental or purchase price of Gunite nozzles, compressors, trowels, etc.
Erection of precast fireproofed steel members Scaffolding for columns and vessels (usually S/C)
Instrument Housing
N10 Piping Insulation
EFFECTIVE LINEAR FOOTAGE
Actual Take-off x Fitting Factor = Effective Linear Feet.
Fitting factors for the average Refinery type work should conform to the following standards. Chemical plants and boiler plants could run 10 percent to 15 percent higher.
Cryogenic
16 & larger 1.24 1.47 1.64
Off Plot
1/2 thru 6 1.13 1.35 2.18
8 & larger 1.09 1.15 1.27
Pipe Sizes
Traced & Chilled Water Includes
Flanges &
Valves 1/2 thru 1
1/2
Instruments are usually priced per each.
MANHOUR UNIT RATES
Manhour per Effective L.F. (ELF) Calcium Silicate w/ .016" Aluminum Jacket
1" Thick 1 1/2" Thick 2" Thick 2 1/2" Thick 3" Thick
Manhours include Supervision, Material Handling and Scaffolding.
For low temperature work, multiply the above by 3.
N21 Hot Equipment Insulation
MH' per Effective Square Foot
Large Shells Exch. Shells Large Heads Exch. Heads
1 0.38 0.41 0.77 1.02
1 1/2 0.39 0.42 0.78 1.04
2 0.41 0.44 0.81 1.04
2 1/2 0.44 0.47 0.84 1.10
3 0.48 0.51 0.89 1.16
Square Footage is figured from the O.D. of the insulation Effective Square Foot - Actual Square Foot x Fitting Factor.
For typical refinery equipment, this fitting factor will be approximately 1.1.
For equipment with a large number of nozzle or stiffener rings, use a factor of 1.3.
For Mineral Wool use 95 percent of above manhours.
For Stainless Jacket use 105 percent of above manhours.
For each inner layer of multi-layer work, use 75 percent of above rates, which will exclude the jacket.
N22 Cold Equipment Insulation
MH' per Effective Square Foot
Large Shells Exch. Shells Large Heads Exch. Heads
1 0.86 0.92 1.73 2.30
1 1/2 0.88 0.95 1.76 2.34
2 0.92 0.99 1.82 2.41
2 1/2 0.99 1.06 1.89 2.48
3 1.08 1.15 2.00 2.61
These unit-rates include fitting of insulation, buttering joints, installing vapor barier and aluminum jacket.
Use above unit-rates for single layer work and the outer layer of multi-layer work.
For each inner layer of multi-layer work, use 30% of above rates, which will exclude the jacket, vapor-barier and mastic work.
N30 Fireproof Vessel Skirts
Usually required on skirt of all vertical vessels containing liquid hydrocarbons. Area includes outer surface and inner surface as
Pipe Size
required by specifications.
2" Gunite with 1/2" sq. mesh embedded Allow 0.2 MH/SF N40 Fireproof Structural Steel
Usually required where structural steel supports piping or equipment containing liquid hydrocarbons and is within process plant battery limits.
Poured-in-place concrete Allow 60 MH/CY
Joints by hand Allow 12°MM/SF
Intumescent Paint
2 Hour = 1/2" Thick build Up Allow .06 MH/SF 3 Hour = 1 1/16" Thick Build Up Allow .13 MH/SF
N50 Miscellaneous Fireproofing
Evaluated on an Includes labor lost for the fireproofing Individual Job basis of miscellaneous items such as conduit
and/or conduit supports or raceways and Instrument turbines and/or turbines supports or raceways.
N60 Soundproofed
Evaluated on an
(Y10) Insulation Scaffolds) Individual Job basis
That portion of the scaffolding manhours (Y10) attributable to insulation fireproofing may be estimated at zero since, for this letter account only, scaffolding manhours are included in all unit rates above.
* Suitable for pouring of joints and patching steelwork which has been fireproofed off site. Assume 0.7 CY for each field joint.
"P" - ELECTRICAL
GENERAL
These standard provides the estimator a referance tools to develop estimates. When the manhour units are used for the installation of electrical equipment and materials, the following must be considered:
1 Type of construction
2 Position relative to the ground level 3 Concentration of work in the area 4 Quantities
5 Weight
6 Associated items of material.
Includes
Installation of all electrical materials.
Distribution, power and control, emergency, lighting, fire alarm and communication equipment.
Interconnecting conduit, tray, wire and cable.
Grounding, cathodic protection, electric heat tracing and overhead distribution systems.
Excludes
Electrical equipment foundations.
Conduit racks and supports between pipe atanchions, when detailed and located on structural drawings.
Motor drivers.
Fences around Electrical equipment.
Electrical services in buildings, if subcontracted.
Temporary electrical facilities.
Excavation and concrete work.
Control Code
P-10 ELECTRICAL EQUIPMENT Fld. Lbr. Code
P-11 Distribution Equipment
P-11
and testing of the following electrical equipment: High voltage master substations, power transformer, 15 KV switchgear, distribution transformer associated with power distribution system (see Control Code P-50) and all device for the distribution and control of electrical power to plant
and testing of the following electrical equipment: High voltage master substations, power transformer, 15 KV switchgear, distribution transformer associated with power distribution system (see Control Code P-50) and all device for the distribution and control of electrical power to plant