John S. Page, Conceptual Cost Estimating Manual

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CONCEPTUAL COST

ESTIMATING

MANUAL

S E C O N D E D I T I O N

J O H N S . P A G E

An Imprint ofElsevier

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Conceptual Cost

Estimating

Manual

2nd Edition

or parts thereof, may not be reproduced in any form without permission of the publisher.

Permissions may be sought directly from Elsevier's Science and Technology Rights Department in Oxford, UK. Phone: (44) 1865 843830, Fax: (44) 1865 853333, e-mail: [email protected]. You may also complete your request on-line via the Elsevier homepage: http://www.elsevier.com by selecting "Customer Support" and then "Obtaining Permissions".

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Gulf Professional Publishing

P l H An Imprint of Elsevier

10 9 8 7 6

Library of Congress Cataloging-in-Publication Data Page, John S.

Conceptual cost estimating manual / John S. Page. — 2nd ed.

p. cm.

ISBN 0-88415-267-7

1. Chemical plants—Design and construction— Estimates—Handbooks, manuals, etc. I. Title. TH4524.P34 1996

690'.54—dc20 95-52313 CIP Printed in the United States of America.

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PREFACE

Long has been the need for a manual on conceptual cost estimating that allows the 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 per pound produced, and the product can be sold for fifteen dollars per pound, by no means justifies the construction cost of the plant. Management of all organizations concerned 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 complete design and definitive estimate would be, in most cases, too great to justify the design and estimate. Therefore, it becomes apparent that a less expensive method is 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 applying man-hours, dollars, percentage values (as are shown throughout this manual in graph and table form), and construction indexes, and by considering other items outlined 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 for labor and cost estimating, you might wonder what an estimating manual offers that a 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 one often 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 seem that such numerous variables provide the perfect opportunity for computerized algorithmic solution, accurate, cost-effective, realistic estimating is still largely a function of human insight and expertise. Each project has unique aspects that still require the seasoned consideration of an experienced professional, such as gener-al economy, projects supervision, labor relations, job conditions, construction equipment, and weather, to name a few.

Computers are wonderful tools. They can solve problems as no human can, but I 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 these facets. This manual is intended for those individuals.

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INTRODUCTION

This manual contains two methods of conceptual estimating for determining the bud-get amount or estimated cost to design and construct refineries, chemical/petrochemi-cal, and some other types of industrial plants.

Method one, when properly applied, produces a semi-definitive conceptual estimate with an accuracy of ±10%.

Method two uses conceptual ratio estimating, and based on the known equipment material dollar value and the application of weighted percentage costs for all other items, it produces an estimate with an accuracy of ±30%.

The information required and procedures to follow for using these two methods of estimating are defined later in this introduction.

All equipment and material dollar graph and tables throughout this manual are based on average cost as of January 1,1996.

Due to the ever-changing economic conditions, the use of what is known throughout the 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 matemate-rial value for a project to be designed and constructed at some future date. Indices are simply numbers for a time frame indicating a percentage of change in regard to a relative cost of a base time frame. There have been many pro and con discussions as to the use of indices; however, they are still the only means for achieving an acceptable estimate where 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 and

Gas Journal. The engineer/estimator may wish to use other indices that he is more

familiar with and has more confidence in. Should this be the case, it is to be recognized that 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%. The engineer/estimator must determine the labor productivity he feels he can achieve for each project and may acjjust the graph and table manhours as may be required. Major items that one should consider in determining productivity are:

1. General Economy 2. Project Supervision 3. Labor Relations 4. Job Conditions 5. Construction Equipment 6. Weather

In determining the dollar rate to apply against the estimated manhours the engi-neer/estimator should first establish weighted composite crew rates. This is simply the listing by craft of the various personnel required for a crew—such as general foreman, foreman, craftsmen, and apprentices/helpers—and the weighted percentage of their time that will be devoted to the crew. The weighted percentage of each classification multiplied by the hourly rate for that classification will result in the weighted hourly rate for each. The sum of all weighted rates will equal the composite crew hourly rate. The total 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 devotweight-ed to the activity. The weightweight-ed percent of each composite crew multiplied by the weighted composite crew rate will result in the weighted hourly activity rate for that crew. The sum of all weighted crew rates for the activity will equal the hourly weighted activity rate. The total percent of all composite crew personnel is to equal 100. See Section One for description of disciplines of work to determine activity crew personnel needed.

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All manhour tables and graphs include the total manhours, based on 70% productivi-ty, to complete the unit of work as listed.

All equipment and material dollar graphs and tables are based on cost as of January 1, 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, and vendor or subcontractor.

If the project under consideration is to be located in an area outside the continental forty-eight states, the engineer/estimator must consider other items not covered in this manual. Additives for any or all of the following items may be required and since their costs vary widely for different parts of the world, they must be researched individually for each foreign project.

1. Mobilization and demobilization of personnel and equipment 2. Foreign differential labor pay

3. Permits, licenses, fees, duties

4. Load out, tie down and material handling 5. Transportation and ocean or air freight

6. Camp, family quarters, field office, and storage facilities 7. Rest and recreation for personnel

Method One—Accuracy 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 dollars for 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 be the 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 cost would be achieved. With the overall results of all major disciplines of work the project can 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 material

2. Total general specifications 3. Plant location (site conditions)

4. Preliminary soils report with foundation recommendations 5. Plot plan and equipment arrangements.

6. P. & I.D.'s. (mechanical flow sheets) 7. Equipment list

8. Buildings listing type, size, and description

This 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 Two—Accuracy Level of ±30%

A method two, ratio conceptual estimate is defined as one that is based on the known total process equipment material cost and that applies weighted percentages against that 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 and manhours can be achieved by dividing the material dollars by the pre-established unit dollar rate, as outlined in the graphs and tables, and the labor dollars by a pre-estab-lished composite activity rate.

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With the established quantities and manhours the project can be scheduled and fast-track cost-controlled until such time as a more definitive type estimate is available.

To achieve a degree of accuracy of ±30%, the following information will be required. 1. Plant capacity, product form, basic process, and raw material

2. Knowledge of general specifications 3. 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 averaground-ing 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 because the items tend to average each other out.

I sincerely hope the foregoing will enable the engineer/estimator engaged in this type work to turn out more realistic conceptual estimates and assist in the elimination of much guesswork.

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v

This page has been reformatted by Knovel to provide easier navigation.

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

Acid Coolers with Pump and Motor ... 12

Equipment Cost ... 12

Erection Manhours ... 13

Activators – Vibrating Bin ... 14

Erection Manhours ... 15

Aerators – Mechanical ... 16

High-speed – Equipment Cost ... 16

High-speed – Erection Manhours ... 17

Low-speed – Equipment Cost ... 18

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vi Contents

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

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Contents vii

This page has been reformatted by Knovel to provide easier navigation. 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

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viii Contents

This page has been reformatted by Knovel to provide easier navigation. Portable Clamp and Flanged Mounted Mixers –

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

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Contents ix

This page has been reformatted by Knovel to provide easier navigation. Condensers and Receivers ... 73

Vertical Tube Surface – Equipment Cost ... 73

Vertical Tube Surface – Erection Manhours ... 74

Conveying Equipment ... 75

Conveyors – Open Belt – Equipment Cost ... 75

Conveyors – Open Belt – Erection Manhours ... 76

Conveyors – Belt Enclosed with Walkway – Equipment Cost ... 77

Conveyors – Belt Enclosed with Walkway – Erection Manhours ... 78

Conveyors – Spaced, Bucket Elevators, Belt-driven – Equipment Cost ... 79

Conveyors – Spaced, Bucket Elevators, Chain Driven – Equipment Cost ... 80

Conveyors – Spaced, Bucket Elevators, Chain- or Belt-driven – Erection Manhours ... 81

Conveyors – Continuous, Bucket Elevators, Belt-driven – Equipment Cost ... 82

Conveyors – Continuous, Bucket Elevators, Chain-driven – Equipment Cost ... 83

Conveyors – Continuous, Bucket Elevators, Belt- or Chain-driven – Erection Manhours ... 84

Screw Conveyors – Equipment Cost ... 85

Screw Conveyors – Erection Manhours ... 86

Dryers – Drum ... 87

Atmospheric Single Drum Type – Equipment Cost ... 87

Atmospheric Double and Twin Drum Types – Equipment Cost ... 88

Atmospheric Single, Double, and Twin Drum Types – Erection Manhours ... 89

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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

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Contents xi

This page has been reformatted by Knovel to provide easier navigation. 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

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xii Contents

This page has been reformatted by Knovel to provide easier navigation. Gravity Filtration Units – Total Unit Installation

Manhours ... 127

Pressure Type – Equipment Cost ... 128

Pressure Type – Erection Manhours ... 129

Rubber-lined – Equipment Cost ... 130

Rubber-lined – Erection Manhours ... 131

Vibrating Screens – Equipment Cost ... 132

Vibrating Screens – Erection Manhours ... 133

Flakers ... 134

Cooling Drum – Equipment Cost ... 134

Cooling Drum – Erection Manhours ... 135

Generators ... 136

Inert Gas – Equipment Cost ... 136

Inert Gas – Erection Manhours ... 137

Gas Pulsation Dampers ... 138

Dampers – Equipment Cost ... 138

Dampers – Erection Manhours ... 139

Heaters ... 140

Deaerating Feedwater – Equipment Cost ... 140

Deaerating Feedwater – Erection Manhours ... 141

Gas-, Oil-, and Dual-fired – Equipment Cost ... 142

Gas-, Oil-, and Dual-fired – Erection Manhours ... 143

Heat Exchangers ... 144

Hairpin Type – Equipment Cost ... 144

Hairpin Type – Erection Manhours ... 145

Shell and Tube, Fixed Tube, and U-tube – Equipment Cost ... 146

Shell and Tube, Fixed Tube, and U-tube – Erection Manhours ... 147

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Contents xiii

This page has been reformatted by Knovel to provide easier navigation. For Heating Water – Equipment Cost ... 148

For Heating Water – Equipment Cost ... 149

For Heating Water – Erection Manhours ... 150

Pumps ... 151

Centrifugal – Single-stage, Vertical Split Case – Equipment Cost ... 151

Centrifugal – Single-stage, Horizontal Split Case – Equipment Cost ... 152

Centrifugal – Single-stage, ANSI and API 610 – Equipment Cost ... 153

Centrifugal – Two-stage and Multi-stage – Equipment Cost ... 154

Centrifugal – Single-stage, in-line – Equipment Cost ... 155

Gear – Light and Heavy Duty – Equipment Cost ... 156

Sewage – Horizontal and Vertical, 1,750 rpm – Equipment Cost ... 157

Sewage – Horizontal, 1,750 rpm – Equipment Cost ... 158

Sewage – Horizontal and Vertical, 1,150 rpm – Equipment Cost ... 159

Sump and Plunger – Equipment Cost ... 160

Vertical Turbine – Single and Multi-stage – Equipment Cost ... 161

Centrifugal – Single, Two, Multi, and in-line Single Stage – Erection Manhours ... 162

Gear – Light and Heavy Duty – Erection Manhours ... 163

Sewage – Horizontal and Vertical – Erection Manhours ... 164

Sump and Plunger – Erection Manhours ... 165

Vertical Turbine – Single and Multi-stage – Erection Manhours ... 166

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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

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Contents xv

This page has been reformatted by Knovel to provide easier navigation. 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

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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

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

Earth Backfill Materials – Cubic Yards ... 223

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Contents xvii

This page has been reformatted by Knovel to provide easier navigation. 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

Structural Steel – Tons Required ... 237

Miscellaneous Iron – Tons Required ... 238

Pipe Rack Steel – Tons Required ... 239

Structural Steel – Equipment Supports and Structures – Material Cost ... 240

Structural Steel for Pipe Racks – Miscellaneous Iron for Equipment – Material Cost ... 241

Structural Steel and Miscellaneous Iron – Equipment, Equipment Supports and Structures, and Pipe Racks – Erection Manhours ... 242

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xviii Contents

Section 7. Buildings ... 243

Building Types and Descriptions ... 243

Building Materials – Cost per Square Foot ... 245

Building Erection – Manhours per Square Foot ... 246

Section 8. Piping ... 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

Electrical Power – Material Cost ... 263

Electrical Power – Installation Manhours ... 264

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Contents xix

This page has been reformatted by Knovel to provide easier navigation. Electrical Lighting – Installation Manhours ... 266

Miscellaneous Instrumentation – Material Cost ... 267

Miscellaneous Instrumentation – Installation Manhours ... 268

Section 10. Instrumentation ... 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

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

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

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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

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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

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xxii Contents

Section 19. Estimate Adjustments ... 325

Design Allowance ... 325 Quantity Allowance ... 325 Escalation ... 325 Contingencies ... 326 Risk ... 326 Fees ... 326

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Section 1 DISCIPLINES OF WORK

The following is a broad description of the major items included in the various 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 specific project that are not included. Should this occur, the estimator should give consideration to these items and add or deduct accordingly.

Direct Cost Items

1. Process Equipment—The equipment cost, labor, material and subcon-tracts necessary to set and erect or install the process equipment in the final position and condition for mechanical operation.

2. Site Preparation—AU general preparation of the plant site for con-struction including, but not necessarily limited to, clearing, rough grading, cut, fill, borrow, disposal, soil stabilization and finish grad-ing.

3. Site Improvements—Includes items of work that provide permanent improvements to the plant site, such as drainage ditches, culverts, storm drain pipe, canals, dikes, all base materials for roads, parking lots, and railroads including ballast, railroads, and fencing. Pave-ments for roads, process areas and parking areas are included under "Discipline, Paving."

4. Concrete—All earthwork, forms, reinforcing steel, miscellaneous embedded items and placing, finishing and curing of concrete for equipment foundations and equipment structures are included here. All building concrete including foundations is included under "Disci-pline, Buildings."

5. Structural Steel—All cost of procuring, fabricating, and erecting structural and miscellaneous steel, not embedded, for framed struc-tures, equipment supports, equipment platforms, walkways, ladders,

(26)

handrails and pipe supports. Steel for buildings is included under "Discipline, Buildings"

6. Buildings—AU cost of buildings including earthwork, foundations and other concrete, total superstructure, HVAC, plumbing and utility pip-ing to five feet outside of buildpip-ing, insulation, electrical, paintpip-ing, and all architectual finishes.

7. Underground Piping—AU project underground piping serving the project including fire water loops and their components, water lines and special process lines.

8. Above Ground Piping—Includes the fabrication and erection of all above ground process pipe, valves and fittings required for plant op-eration. Installation only of relief valves, control valves, and orifice fittings for instrumentation are also included. The material cost of these items is included under "Discipline, Instrumentation."

9. Underground Electrical—All labor and material for underground power and lighting, ducts, conduit, wire, cable, etc. Also includes earthwork and concrete for embedments.

10. Above Ground Electrical—AU items required for the complete above ground power and lighting systems for the total project, excluding buildings. Also includes the installation of all electrical instruments and their hook-up.

11. Instrumentation—Includes 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 instrument items plus the tubing, tube bundles, and tray materials required to install 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 Electrielectri-cal."

• All header piping labor and material costs are included under "Above Ground Piping."

12. Insulation—AU labor and material cost of insulation, refractories, and linings for process equipment and piping. Building insulation is in-cluded with buildings.

13. Painting—Includes all preparation and protective coating of surfaces with paint and/or epoxy for the total project excluding buildings. 14. Paving—Includes the furnishing and placing of concrete, asphalt, or

gravel used for the final surfacing of roads, sidewalks, parking areas, and process work areas as required.

(27)

15. Proratables—Includes the labor and material cost for daily area clean up, all required scaffolding and final test, startup, and pre-commis-sioning assistance.

Construction Equipment

1. Rental or Purchase—Cost of rental or purchase of construction equip-ment required to construct the project. Does not include small tools. 2. Service Labor—AU labor required to service and maintain the

con-struction equipment. Does not include the operation of the equipment when working. Operators are included in the Direct Account Labor. 3. Fuel, Oil, Grease, Supplies—Includes 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 the individual 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 indirect Office hourly indirects Field hourly indirects

The distribution will vary depending upon the type of project, local la-bor practices, and contractor preferences.

Description

Engineering salaries-estimating

Engineering salaries-field technical support

To Include

Civil, cost, electrical, general, mechani-cal and structural estimating salaries. Project chief engineer; assistant project chief engineer; chief field engineer; civil, electrical, mechanical, structural, field, staff, office, piping, instrument engi-neers; coordinators; engineering drafts-men; party chiefs, instrument men,

(28)

Watchmen and Janitors—labor Holiday pay Salaries—office clerical Quality assurance—labor Salaries—subcontract administration Salaries—cost engineering Salaries—scheduling and planning Salaries—technical clerks Material control labor

Move in/out—labor

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, labor for supplying drinking water. Note: Does not include contract security personnel. Pay for holidays not worked. Personnel covered by overhead and indirect esti-mate only.

Administrative clerks, office clerks, and secretaries.

Chief construction inspector, construc-tion inspectors, welding inspector, piping inspector, electrical inspector, boiler in-spector and civil inin-spector.

Salaries for subcontract coordinators.

Salaries for cost/schedule supervisor, chief field cost engineer and cost engi-neers.

Salaries for chief field scheduler and planner/schedulers.

Salaries for technical clerical personnel. Material control coordinators and mate-rial control personnel assigned to imple-ment and follow-up the material control program.

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 tools and construction equipment at jobsite. Move-out is the return of tools and con-struction equipment to other approved destination, in the immediate area of the project.

Wages paid to hourly employees during a temporary period when work is stopped. Also wages paid to craftsmen for voting

(29)

Safety and medical expense—labor Salaries—office Salaries—supervision Sick pay Warehouse salaries

in accordance with union or government regulations. Welding test labor and jury pay differential. Note: Work stoppage due to weather and show-up time are considered in productivity factors used elsewhere.

Safety supervisor, safety inspectors, and medics.

Chief accountant, accountants, book-keepers, invoice auditors, expeditors, chief timekeeper, timekeepers, person-nel manager, assistant personperson-nel 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 due to personal illness, as approved by proj-ect construction manager.

Warehouse supervisor, assistant ware-house supervisor, wareware-housemen, tool-room attendants, warehouse laborers-assigned full time to warehouse opera-tion. Note: Must be on job payroll only.

Description

Temporary buildings and utilities—labor

To Include

Labor only for construction or erection, maintenance and dismantling of the tem-porary facilities, in accordance with but not limited to the following: Roads, ditches, bridges, storage areas, parking lots, fencing, buildings, water system, sanitary system, power distribution,

(30)

Labor Burdens and Overhead Personnel Benefits

Temporary buildings and utilities—material and supplies

ephone and communications systems, and plant air system. Note: Does not in-clude construction camp, quartering or catering facilities.

Material and supplies and maintenance for construction and dismantling of the temporary facilities in accordance with but not limited to the following. Also in-cludes rental of temporary field offices and warehouses, roads, ditches, bridges, storage areas, parking lots, fencing, buildings, water system, sanitary sys-tem, power distribution, telephone and communications systems, and plant air system. Note: Does not include construc-tion camp, quartering or catering

facili-Description

Retirement and savings plan (for overhead and indirect personnel only)

Insurance—employees' life and hospitalization (for overhead and indirect personnel only)

Insurance—W/C, B/I, and P/D

Taxes—payroll

Vacation pay (for overhead and indirect personnel only)

Tb Include

Actual cost fixed by the appropriate ac-counting office. Note: Does not include any like or similar item which is a part of a union fringe benefit.

Direct premium charges only. Note: Does not include any like or similar item which is a part of a union fringe benefit.

Premium expense based on payrolls. Limits conform to the requirements for the state as specified in the contract. FICA and Medicare, state ment insurance and federal unemploy-ment insurance.

Actual cost for overhead and indirect personnel only based on gross payroll as billed by the appropriate Accounting Of-fice. Note: Does not include any like or similar item which is a part of a union fringe benefit.

(31)

Small Tool and Consumables

Description

Construction supplies

Small tools (in accordance with contract limits)

Workmen's supplies

Other Indirects

Description Advertising Bond premiums Communications and postage TD Include

This account should include items that are consumed and, by their use, directly related to construction; for example, sandpaper, rope, chalk, soapstone, emery paper grinding wheels, moil points, saw blades, padlocks, threading dies, drill bits and reamers, rags, brooms and mops, air and water hose for general use.

Purchase or rental of hand tools, power operated hand tools, etc. Rental or re-pair parts for such tools will be included in this account. This account includes mi-nor equipment such as small pumps to 3", 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, by their use, directly beneficial to and for the convenience of workmen; for exam-ple, towels, toilet paper, drinking cups, ice drinking water, hard hats, protective clothing, gloves, boots, salt tablets, soap, drinking water barrels or containers, safety shoes, and work shoes. Credit is to 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

(32)

Containers

Dues

Engineering supplies

Expediting

Heat, light, water, and power

Insurance—general

Legal

Licenses and permits

Move in/out—supplies and services

Office supplies

Safety and medical expense, material

rented from a third party. Include data lines and couplers.

Deposits for returnable containers and reels.

Membership dues for clubs and profes-sional organizations, for overhead and direct personnel only. Note: Does not in-clude union dues.

Surveying instruments (purchase or rental) drafting supplies, surveying sup-plies, blueprint or photostat work, progress photos.

Cost for services supplied by expeditors who are not on the job payroll.

Public utility charges and heating fuels for job buildings. Cost for water not used 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 and P&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 construction equipment by others to project construc-tion area, and miscellaneous supplies consumed and services used, for move-in and -out purposes.

Stationery supplies, printing, office equipment 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,

(33)

first-Testing and laboratory analysis

Traveling

Welding supplies

Unclassified

Data processing services

Consulting services

Trade journals, books, publications, and subscriptions

Contract Guard Service Quality Assurance-Material and Supplies Employee Educational Assistance

aid equipment, fire extinguishers, and refills.

Soil surveys, concrete cylinder tests, in-dependent inspectors. Lab charges to test welders.

Transportation and subsistence expense of overhead and indirect employees on business trips (excluding quality assur-ance personnel travel).

All material, supplies, and tools required by 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 the project. Terminal rental, supplies, com-puter charges from outside jobsite sources, etc.

Cost for outside consulting services which might be required in connection with the projects which are not a part of engineering.

Cost of books or subscriptions.

Cost of subcontract guard service Normally includes travel costs for qual-ity control personnel.

Cost of employee educational assistance, for overhead and indirect personnel only.

(34)

Home Office Cost

1. Engineering/Design Services—Total labor and material cost for the complete engineering and design of the project including engineering fee.

2. Construction Services—Services furnished by various home office de-partments such as estimating, scheduling, expediting, etc., as may be required to assist the project. Services are charged to the project only for time actually spent on the project.

3. Project General Management—Includes the portion of time that the contractor's management staff applies in regard to overall direction of the project.

(35)

Section 2 PROCESS EQUIPMENT

The most important component of physical plant cost is that of process equipment. From it the prime basis can be formed for the estimation of the entire plant.

Once the production rate has been established and a rough flow sheet presented, an equipment list can be compiled noting the type, size, capac-ity and material of construction. From the logarithmic graphs that appear on 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 ability to realize that the items covered are of a standard nature for chemical plants, refineries, and industrial plants.

All installation manhours include offloading equipment at job site, haul-ing up to 2,000 feet and rigghaul-ing, pickhaul-ing, setthaul-ing, and alignhaul-ing of the equipment.

The equipment graphs include the total cost of the equipment, but do not include structural steel or miscellaneous iron such as supports, lad-ders, walkways, platforms, or handrails. See other sections for these items.

AU shop fabricated equipment graphs, as in the case of vessels, include the total shop cost, overhead, and profit for fabricating and furnishing of all 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 instruequip-mentation, which may be an integral part of the package.

Sub-contract equipment graphs include the total sub-contractors cost and profit for the furnishing and installing of the equipment.

All equipment graphs include an average allowance for freight cost within 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.

(36)

ACID CCX)LERS WITH PUMP

AND MOTOR

Equipment Cost Equipmen t Cos t

(37)

ACID COOLERS WITH PUMP

AND MOTOR

Erection Manhours Erectio n Manhour s

(38)

VIBRATING BIN ACTIVATORS

Equipment Cost Equipmen t Cos t Diameter Inches

(39)

VIBRATING BIN ACTIVATORS

Erection Manhours Erectio n Manhour s Diameter Inches

(40)

HIGH-SPEED MECHANICAL

AERATORS

Equipment Cost Equipmen t Cos t Motor Horsepower (D Basic unit—ductile iron/carbon steel © Basic unit—stainless steel

(41)

HIGH-SPEED MECHANICAL

AERATORS

Erection Manhours Erectio n Manhour s Motor Horsepower

(42)

LOW-SPEED MECHANICAL

SURFACE AERATORS

Equipment Cost Equipment Cos t Motor Horsepower ©Fixed low-speed unit

(43)

LOW-SPEED MECHANICAL

SURFACE AERATORS

Erection Manhours Erectio n Manhour s Motor Horsepower ® Fixed low-speed unit

©Floating low-speed unit Next Page

(44)

AIR POWER COMPRESSORS

Synchronous Motor Driven

Rated for Sea Level to 3,300 Feet

Altitude at 125 psig Maximum

Discharge Pressure

Equipment Cost Equipmen t Cos t Motor Horsepower 0)460,575, or 480 volts ©2300 or 4160 volts Previous Page

(45)

AIR POWER COMPRESSORS

Induction Motor Driven

Rated for Sea Level to 3,300-Fbot

Altitude at 125 psig Maximum

Discharge Pressure

Equipment Cost Equipmen t Cos t Motor Horsepower ©460,575, or 230-volt ©480or2,300-volt

(46)

AIR POWER COMPRESSORS

Synchronous and Induction Motor

Driven Rated for Sea Level to

3,300-Foot Altitude at 125 psig

Maximum Discharge Pressure

(47)

AUTOMOTIVE AND

INDUSTRIAL SERVICE AIR

COMPRESSORS

Equipment Cost Equipmen t Cos t Motor Horsepower

(D Single-stage, air-cooled—capacity 7.9 to 37.0 acfin @ 80 psig. ©Two-stage, air-cooled—capacity 5.0 to 97.2 acfin @ 175 psig.

(48)

AUTOMOTIVE AND

INDUSTRIAL SERVICE AIR

COMPRESSORS

(D Single-stage, air-cooled—capacity 7.9 to 37.0 acftn @ 80 psig. ©Two-stage, air-cooled—capacity 5.0 to 97.2 acftn @ 175 psig.

(49)

CENTRIFUGAL AIR COMPRESSORS

Plant and High-Pressure

(Soot Blower) Types

100 to 350 psig Discharge

Pressure

Nominal Motor Horsepower 0 Plant air compressors

(50)

CENTRIFUGAL AIB COMPRESSORS

Plant and High-Pressure

(Soot Blower) Types

100 to 350 psig Discharge

Pressure

(51)

INDUSTRIAL AIR

COMPRESSORS

Air-Cooled, Two-Stage—50 to

2 5 0 p s i g

(52)

INDUSTRIAL AIR

COMPRESSORS

Air-Cooled, Two-Stage—50 to

2 5 0 p s i g

(53)

INTEGRAL GAS ENGINE

COMPRESSOR

Fbur-Cylinder Type

Equipment Cost Equipmen t Cos t Rated Hp. (BHP)

(D Cast iron cylinders, 1,000 psig discharge (2) Nodular cylinders, 1,500 psig discharge ©Forged steel cylinders, 2,500 psig discharge ® Forged steel cylinders, 6,000 psig discharge

(54)

INTEGRAL GAS ENGINE

COMPRESSORS

Fbur-Cylinder Type

1,CXX) TO 6,000 psig Discharge

Erection Manhours Erectio n Manhour s Rated Horsepower (BHP)

(55)

PACKAGED AIR COMPRESSOR

UNITS

Single-Stage, Water-Cooled

Oil-Lubricated and Nonlubricated

Types

Equipment Cost Equipmen t Cos t Motor Horsepower (DOil-lubricated-208, 230, or 460-volt. ©Nonlubricated-208, 230, or 460-volt.

(56)

PACKAGED AIR COMPRESSOR UNITS

Single-Stage, Water-Cooled

Oil-Lubricated and Nonlubricated

Types

Erection Manhours Erectio n Manhour s Motor Horsepower For 208-, 230-, or 460-volt units.

(57)

RECIPROCATING

COMPRESSORS

Electric Motor Driven

Equipment Cost

Equipmen

t Cos

t

Compressor Horsepower 1) Cast Iron Cylinders 1000 PSI Discharge 2) Nodular Iron Cylinders 1500 PSI Discharge 3) Steel Cylinders 2500 PSI Discharge

(58)

RECIPROCATING

COMPRESSORS

Electric Motor Driven

1,000 to 6,000 psi Discharge

Erection Manhours Erectio n Manhour s Compressor Horsepower

(59)

TWO-STAGE, TWO-CYLINDER,

WATER-COOLED AIR COMPRESSORS

Oil-Lubricated and Nonlubricated

150 to 350 psi Discharge

Pressure

(60)

TWO-STAGE, TWO-CYLINDER,

WATER-COOLED AIR COMPRESSORS

Oil-Lubricated and Nonlubricated

350 to 500 psig Discharge

Pressure

Eauimnent Cost Equipmen t Cos t Motor Horsepower (D Oil-Lubricated (D Nonlubricated

(61)

TWO-STAGE, TWO-CYLINDER,

WATER-COOLED AIR COMPRESSORS

Oil-Lubricated and Nonlubricated

150 to 500 psig Discharge

Pressure

Erection Manhours Erectio n Manhour s Motor Horsepower Next Page

(62)

REFRIGERATED AIR DRYERS

Automatic Type 15 to 1 0 0 0 scfm

Equipment Cost Equipmen t Cos t Capacity SCFM Previous Page

(63)

REFRIGERATED AIR DRYERS

Automatic Type 1,200 to 15,000

scfm

Equipment Cost Equipmen t Cos t Capacity scfm

(64)

REFRIGEBATED AIR DRYERS

Automatic Type 15 to I

9

OOO scfm

Erection Manhours Erectio n Manhour s Capacity SCFM

(65)

REFRIGERATED AIR DRYERS

Automatic Type 1,200 to IS

9

OOO

scfm

Erection Manhours Erectio n Manhour s C a p a c i t y SCFM

(66)

CHILLER AIR DRYERS

Capacity 3,000 to 28,000 scfm at

lOOpsig

Equipment Cost Equipmen t Cos t Capacity SCFM At 100 PSIG

(67)

CHILLER AIR DRYERS

Capacity 3,000 to 28,000 scfm at

lOOpsig

Erection Manhours Erectio n Manhour s C a p a c i t y SCFM At 100 PSIG Next Page

(68)

SURGE ARRESTORS

Hydrocarbon and Water Service

500 psi Design Operating Pressure

ASME Code—Section VIII

Division I

Equipment Cost

Equipmen

t Cos

t

©Water Service

(69)

SURGE ARRESTORS

Hydrocarbon, Water and Sewage Service

275 psi Design Operating Pressure

ASME Code—Section VIII

Division I

Equipment Cost

Equipmen

t Cos

t

Nominal Size Gallons

©Water service

® Sewage service

(70)

SURGE ABBESTORS

Hydrocarbon, Water and Sewage Service

275 and 500 psi Design Operating Pressures

ASME Code—Section VIII

Division I

Erection Manhours Erectio n Manhour s Nominal S i z e Gallons

(71)

DRY MATERIAL BLENDERS,

PACKERS

9

AND FEEDERS

Auger Blenders

Rotary Drum Blenders

Equipment Cost

Equipmen

t Cos

t

iuaximum Mixing Cubic Feet Per Hour (D Auger blenders

(72)

DRY MATERIAL BLENDERS

9

PACKERS

9

AND FEEDERS

Auger Blenders

Rotary Drum Blenders

Erection Manhours

Erectio

n

Manhour

s

Maximum Mixing Cubic Feet Per Hour

(73)

MIXERS AND BLENDERS

Fixed Side Mounted Mixers with

Top Motors

Equipment Cost

Equipmen

t Cos

t

(74)

MIXERS AND BLENDERS

Fixed Side Mounted Mixers

with Top Motors

Erection Manhours Erectio n Manhour s Rating Horsepower

(75)

MIXERS AND BLENDERS

Plate Mounted Open Tank Mixers

Equipment Cost

Equipmen

t Cos

t

(76)

MIXERS AND BLENDERS

Portable Clamp and Flanged

Mounted Mixers

Equipment Cost Equipmen t Cos t Rating Horsepower ® Portable clamp mounted mixers—direct drive. © Portable clamp mounted mixers—gear drive. © Flanged top tank mounted mixers—direct drive ® Flanged top tank mounted mixers—gear drive.

(77)

MIXERS AND BLENDERS

Flanged Top Tank Mounted and

Plate Mounted Open Tank Mixers

Erection Manhours Erectio n Manhour s Rating Horsepower

(78)

MIXERS AND BLENDERS

Gearmotor Mixers

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 seals

Note: Motor horsepower range 2-200, shaft length

(79)

MIXERS AND BLENDERS

Gearmotor Mixers

Erection Manhours

Approximate Weight - Pounds (D For mounting on structural steel support above

open tank

Note: Motor horsepower range 2-200, shaft length

(80)

MIXERS AND BLENDERS

Batch and Pipeline Homogenizer

Mixers

Equipment Cost Equipmen t Cos t Horsepower (D Batch homogenizer mixers

(81)

MIXERS AND BLENDERS

Batch and Pipeline Homogenizer

Mixers

Erection Manhours Erectio n Manhour s Horsepower

(82)

MIXERS

High-Intensity

(83)

MIXERS

High-Intensity

(84)

DRY MATERIAL BLENDERS

9

PACKERS

9

AND FEEDERS

Bag Vibrating Packers

Rigid Container Vibrating

Packers

Equipment Cost

Equipmen

t Cos

t

Maximum Bag Width Or Container Diameter Inches ® Bag vibrating paekers

(85)

DRY MATERIAL BLENDERS

9

PACKERS

9

AND FEEDERS

Bag Vibrating Packers

Rigid Container Vibrating

Packers

Maximum Bag Width Or Container Diameter Inches (D Bag vibrating packers

(86)

BOILERS

Package Type

Pounds Per Hour

Note: Cost is for total boiler including forced draft fan

assembly. Boiler capacity pounds per hour-satu-rated steam at 100 to 235 psig.