starting point for scope discussions with clients.
Checklists for Typical Offplot Facilities
Site Development (Figure 212-1) Storage and Blending (Figure 212-2) Product Distribution (Figure 212-3) Interconnecting Piping (Figure 212-4) Control Systems (Figure 212-5) Electrical Distribution (Figure 212-6) Cooling Water Facilities (Figure 212-7) Relief Facilities (Figure 212-8)
Checking the Estimate
Refer to Sections 202 for cost correlations for Class 1 estimates and for checking estimates made by other methods.
As these cost correlations are based on the West Coast, you need to adjust them to the project’s location. Also refer to Section 211 for an additional Class 1 method and for checking estimates made by other methods.
Investigate significant variations between estimates to determine the reasons for the differences.
✓ Items to Consider1 Specific Notes
Site Survey Include these costs in Technical Services (Sections 511 and 512). Note that the site survey and soils report usually determine the piling requirements for a project. Soils Report
Rough Grading/Fill Roads
Area Paving/Parking Lot Bridges
Fencing Storm Sewers
Normally include treating and storm-water impounding in Effluent Treating plant.
Process Sewers Chemical Sewers Railroad Spurs/Trackage Landscaping Soil Stabilization Temporary Construction
Facilities In addition to permanent facilities, site development mayinclude temporary construction facilities such as roads and railroad spurs, fencing, parking lots, etc. Include these in the estimate as part of Indirect Field Costs (Section 501). Disposal of Hazardous
Waste Include this cost in Special Charges (Section 521). NOTES: When site-development facilities interface with other onplot or offplot plants, such as sewer systems and paving, establish match lines at appropriate interface points to define the basis of the estimate.
1 This list does not include infrastructure items that must be estimated separately. Infrastructure
items are those facilities not located on Company property but required to make the plant site function—such as electrical service, transmission lines, access roads, rail spurs, pipelines, and water supply.
✓ Items to Consider Specific Notes Feed Tankage1
Establish match lines at appropriate interface points with other onplot and offplot plants to define the basis of the estimate.
The tankage volume and number in each service can vary widely due to operating needs and maintenance
requirements. Sizing of product tankage depends on the methods of product distribution. See Figure 212-3. Establish a firm basis for the estimate with the client. Intermediate Tankage2
Blend Stock Tankage3 Product Tankage4 Recovered Oil Tankage Fuel Oil Tankage Chemical Tankage Coke/Bulk Material Storage Product Blending Systems Pipeline Termination Facilities
1 Provide 10 days for crude supplied by pipeline. For crude supplied by tanker, provide one
tanker load plus 15 days, or two tanker loads (whichever is larger).
2 Provide 10 days of feed to downstream process units. 3 Provide 15 days of blend stocks.
4 Provide 15 days of product sales.
NOTES: Cost data for tanks is generally based on the nominal capacity of tanks in barrels. Operating capacity (or working capacity) is the usable volume or the volume available to meet operating requirements. Operating capacity is generally less for floating roof tanks than cone roof tanks and varies with safe filling heights, pump suction requirements or minimum allowable floating roof level, and allowable tank height. Refer to the Tank Manual, S. 420. Determine operating capacity requirements first and then determine nominal capacity, making appropriate allowances for tank volume that is not usable.
Include costs for tank field piping, feed and transfer pumps, heaters, refrigeration, mixers, insulation, walkways, berms, impounding areas, fire fighting systems, purge and vapor recovery systems, etc., as appropriate.
✓ Items to Consider Product Pipeline Pump Station
Tank Truck Loading Facilities Tank Car Loading Facilities Marine Loading Facilities Marketing Tankage Product Metering Systems Meter Provers
Weigh Scales Bagging Facilities
Vapor Recovery or Relief Systems
NOTES: Establish match lines at appropriate interface points with other offplot plants to define the basis of the estimate.
Define product shipping rates, frequency of shipping, and method of shipping in order to size product-distribution facilities.
✓ Items to Consider Process Piping
Feed Piping from Storage to Process Units Interconnecting Piping between Process Units Product Piping from Process Units to Storage Process Gas or Hydrogen
Offtest (Recovered Oil) Piping Waste Streams
Start Up and Shutdown Piping Including Flush Headers Amine Streams
Sour Gas Sour Water Stripped Sour Water Utility Piping
Steam Condensate Boiler Feed Water Fuel Oil
Fuel Gas
Raw Water Supply Drinking Water Utility Water Process Water Fire Water
Nitrogen or Inert Gas
Chemicals (acids, caustics, etc.) Cooling Water Relief Lube Oil Utility Air Instrument Air Breathing Air
NOTES: Establish match lines at appropriate interface points with other onplot and offplot plants to define the estimate basis. The match line must clearly define which plant includes the valves at plant plot limits.
Use the Onplot & Offplot Connections form, PIM-EF-468 (in the Piping Manual), to tabulate and account for the piping at each plant plot limit. In addition to the basic piping requirements, consider the need for expansion loops, grade level versus elevated pipe supports (which may also carry electrical conduit or trays), tracing, insulation, painting, and access platforms or walkways.
✓ Items to Consider Control House Requirements
Large Project/Central Control House Small Project/New Control House
Small Project/Modify Existing Control House Blast Resistant, if Necessary
Provisions for Expansion Other Items
Pneumatic Control Electronic Control
Distributed Control System (DCS) Distributed Control Interface Buildings Computer
UPS Systems
Tie-Ins to Existing Systems Redundancy
NOTES: Establish match lines at appropriate instrument signal interface points with other onplot and offplot plants to define the basis of the estimate. Figure 212-5. Checklist for Control Systems
✓ Items to Consider
Substation Locations Power Distribution Layout Emergency Power Direct Burial Cable Buried Conduit Banks Above-Ground Conduits Above-Ground Cable Trays Cogeneration
Voltage Levels
Communications/Microwave, Phone, Voice Power Redundancy
Type of Substation Building
Power Supply—Single- or Double-Ended Tie-Ins to Existing Systems
NOTES: Establish match lines at appropriate interface points with other onplot and offplot plants and the power-supply source. If a power company is involved, define the interfaces with their system. Normally this plant includes the power-supply facilities, the main substation, and the distribution systems up to the transformer connection at other plants.
✓ Items to Consider Specific Notes
Tower Cooling tower costs can vary widely depending on the design wet bulb for the specific location and the approach. See Heat Exchanger and Cooling Tower Manual, S. 2200, for guidelines on selecting design variables.
Basin Cooling tower basin costs can vary widely depending on depth of the basin, requirements for piles, and requirements for isolating portions of the tower and basin for maintenance.
Number of Pumps Types of Drivers
Above-Ground Distribution System Cooling water distribution piping may be included with Interconnecting Piping (see Figure 212-4).
Buried Distribution System Water Treatment Facilities Provisions for Expansion
NOTES: Establish match lines at appropriate interface points with other onplot and offplot plants to define the basis of the estimate.
Figure 212-7. Checklist for Cooling Water Facilities
✓ Items to Consider
Types of Flares Required Elevated Ground
Special Purpose (NH3, H2S, etc.)
Other Items
Relief Flow Metering Systems Flare Location
Flare Monitoring Devices K.O. Drum at Flare Pump Out Facilities Vapor Recovery Facilities Pilot, Ignitor, Purge Systems
NOTES: Establish match lines at appropriate interface points with other onplot and offplot plants to define the basis of the estimate.
Preliminary relief load data will be required to size the relief headers and the flare.
A portion of the header may be included with Interconnecting Piping (see Figure 212-4).