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• Emanuel Frutis

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CONCEPTUAL COST ESTIMATING MANUAL SECOND

JOHN

EDITION

S. PAGE

An Imprint ofElsevier

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Conceptual Cost Estimating Manual 2nd 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 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".

Originally published by Gulf Publishing Company, Houston, TX. For information, please contact: Manager of Special Sales Elsevier 200 Wheeler Road Burlington, MA 01803-2041 Tel: 781-313-4700 Fax:781-313-4882 For information on all Gulf Professional Publishing titles available, contact our World Wide Web home page at: http://www.bh.com/gulf G

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Gulf Professional Publishing 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. Printed on acid-free paper (oo).

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

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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 Manhours ................................................................ 34 This page has been reformatted by Knovel to provide easier navigation.

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Two-stage, Two-cylinder, Water-cooled – Equipment Cost ........................................................................ 35 Two-stage, Two-cylinder, Water-cooled – Equipment Cost ........................................................................ 36 Two-stage, Two-cylinder, Water-cooled – Erection Manhours ................................................................ 37 Dryers – Air .................................................................................... 38 Automatic, Refrigerated – Equipment Cost ...................... 38 Automatic, Refrigerated – Equipment Cost ...................... 39 Automatic, Refrigerated – Erection Manhours ................. 40 Automatic, Refrigerated – Erection Manhours ................. 41 Chiller – Equipment Cost ................................................. 42 Chiller – Erection Manhours ............................................ 43 Surge Arresters ............................................................................. 44 Hydrocarbon and Water Service – Equipment Cost ......... 44 Hydrocarbon, Water, and Sewage Service – Equipment Cost ...................................................... 45 Hydrocarbon, Water, and Sewage Service – Erection Manhours ................................................................ 46 Blenders, Mixers, Packers, and Feeders ...................................... 47 Dry Material Auger and Rotary Drum Blenders – Equipment Cost ...................................................... 47 Dry Material Auger and Rotary Drum Blenders – Erection Manhours .................................................. 48 Fixed Side Mounted Mixers with Top Motors – Equipment Cost ...................................................... 49 Fixed Side Mounted Mixers with Top Motors – Erection Manhours .................................................. 50 Plate Mounted Open Tank Mixers – Equipment Cost ...... 51

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

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Condensers and Receivers ........................................................... 73 Vertical Tube Surface – Equipment Cost ......................... 73 Vertical Tube Surface – Erection Manhours .................... 74 Conveying Equipment ................................................................... 75 Conveyors – Open Belt – Equipment Cost ...................... 75 Conveyors – Open Belt – Erection Manhours .................. 76 Conveyors – Belt Enclosed with Walkway – Equipment Cost ...................................................... 77 Conveyors – Belt Enclosed with Walkway – Erection Manhours ................................................................ 78 Conveyors – Spaced, Bucket Elevators, Belt-driven – Equipment Cost ...................................................... 79 Conveyors – Spaced, Bucket Elevators, Chain Driven – Equipment Cost ...................................................... 80 Conveyors – Spaced, Bucket Elevators, Chain- or Belt-driven – Erection Manhours ............................. 81 Conveyors – Continuous, Bucket Elevators, Beltdriven – Equipment Cost ......................................... 82 Conveyors – Continuous, Bucket Elevators, Chaindriven – 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 This page has been reformatted by Knovel to provide easier navigation.

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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

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Fans and Blowers .......................................................................... 106 Blowers – Rotary – Equipment Cost ................................ 106 Blowers – Rotary – Erection Manhours ........................... 107 Centrifugal Fans – Equipment Cost ................................. 108 Centrifugal Fans – Erection Manhours ............................ 109 Cast Iron Industrial Fans – Equipment Cost .................... 110 Cast Iron Industrial Fans – Erection Manhours ................ 111 Heavy Sheet Steel Industrial Fans – Equipment Cost ...... 112 Heavy Sheet Steel Industrial Fans – Erection Manhours ................................................................ 113 Feeders ......................................................................................... 114 Heavy Duty Belt – Equipment Cost .................................. 114 Heavy Duty Belt – Erection Manhours ............................. 115 Pre-wetting Dry Chemical – Equipment Cost ................... 116 Pre-wetting Dry Chemical – Erection Manhours .............. 117 Pre-wetting Dry Chemical, Package Units – Equipment Cost ........................................................................ 118 Pre-wetting Dry Chemical, Package Units – Erection Manhours ................................................................ 119 Dry Material, Vibrating – Equipment Cost ........................ 120 Dry Material, Vibrating – Erection Manhours ................... 121 Dry Material, Volumetric and Gravimetric – Equipment Cost ........................................................................ 122 Dry Material, Volumetric and Gravimetric – Erection Manhours ................................................................ 123 Dry Material, Wing and Conveyor – Equipment Cost ....... 124 Dry Material, Wing and Conveyor – Erection Manhours ................................................................ 125 Filters ............................................................................................. 126 Gravity Filtration Units – Total Material Cost .................... 126 This page has been reformatted by Knovel to provide easier navigation.

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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

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For Heating Water – Equipment Cost .............................. 148 For Heating Water – Equipment Cost .............................. 149 For Heating Water – Erection Manhours .......................... 150 Pumps ........................................................................................... 151 Centrifugal – Single-stage, Vertical Split Case – Equipment Cost ...................................................... 151 Centrifugal – Single-stage, Horizontal Split Case – Equipment Cost ...................................................... 152 Centrifugal – Single-stage, ANSI and API 610 – Equipment Cost ...................................................... 153 Centrifugal – Two-stage and Multi-stage – Equipment Cost ........................................................................ 154 Centrifugal – Single-stage, in-line – Equipment Cost ....... 155 Gear – Light and Heavy Duty – Equipment Cost ............. 156 Sewage – Horizontal and Vertical, 1,750 rpm – Equipment Cost ...................................................... 157 Sewage – Horizontal, 1,750 rpm – Equipment Cost ......... 158 Sewage – Horizontal and Vertical, 1,150 rpm – Equipment Cost ...................................................... 159 Sump and Plunger – Equipment Cost .............................. 160 Vertical Turbine – Single and Multi-stage – Equipment Cost ........................................................................ 161 Centrifugal – Single, Two, Multi, and in-line Single Stage – Erection Manhours ..................................... 162 Gear – Light and Heavy Duty – Erection Manhours ......... 163 Sewage – Horizontal and Vertical – Erection Manhours ................................................................ 164 Sump and Plunger – Erection Manhours ......................... 165 Vertical Turbine – Single and Multi-stage – Erection Manhours ................................................................ 166 This page has been reformatted by Knovel to provide easier navigation.

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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

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Water Softener System ................................................................. 188 Hot Process Water – Total Process Material and Equipment Cost ...................................................... 188 Hot Process Water – Total System Installation Manhours ................................................................ 189 Tanks ............................................................................................. 190 API Cone Roof Storage – Subcontract Installed Price ..... 190 API Cone Roof Storage – Subcontract Installed Price ..... 191 API Floating Roof Storage – Subcontract Installed Price ....................................................................... 192 ASME Spheres – Subcontract Installed Price .................. 193 Fintube Heating Coils – Equipment Cost ......................... 194 Fintube Heating Coils – Erection Manhours ..................... 195 Fired Heaters, Fintube Type – Equipment Cost ............... 196 Fired Heaters, Fintube Type – Erection Manhours .......... 197 Suction and Line Type Fuel Oil Heaters – Equipment Cost ........................................................................ 198 Suction and Line Type Fuel Oil Heaters – Erection Manhours ................................................................ 199 Propane Storage – Equipment Cost ................................ 200 Propane Storage – Erection Manhours ............................ 201 Vessels .......................................................................................... 202 Shop Fabricated – Average Weight, Pounds per Linear Foot .............................................................. 202 Horizontal, Shop Fabricated – Cost per Ton .................... 203 Vertical with Angle Legs, Shop Fabricated – Cost per Ton ......................................................................... 204 Vertical with Anchor Ring and Skirts, Shop Fabricated – Cost per Ton ........................................................ 205 Tray Rings, Shop Fabricated – Cost Each ....................... 206 This page has been reformatted by Knovel to provide easier navigation.

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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

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Earthwork for Equipment Structures, Pipe Racks, and Sleepers – Labor Manhours ................................................ 225 Concrete Required for Equipment, Equipment Structures, Pipe Racks and Sleepers – Cubic Yards ............................ 226 Forms, Reinforcing, Embedments and Concrete – Material Cost ...................................................................................... 227 Forms, Reinforcing, Embedments and Concrete – Installation Manhours ............................................................................. 228 Nonshrink, Nonmetallic Grout – Average Square Feet ................ 229 Nonshrink, Nonmetallic Grout – Material Cost ............................. 230 Nonshrink, Nonmetallic Grout – Installation Manhours ................ 231 Fireproofing Structural Steel – Total Material Cost ....................... 232 Fireproofing Structural Steel – Installation Manhours .................. 233 Fireproofing Vessel Skirts – Material Cost .................................... 234 Fireproofing Vessel Skirts – Erection Manhours .......................... 235

Section 6.

Structural Steel and Miscellaneous Iron ........ 236

Section Introduction ....................................................................... 236 Structural Steel – Tons Required .................................................. 237 Miscellaneous Iron – Tons Required ........................................... 238 Pipe Rack Steel – Tons Required ................................................. 239 Structural Steel – Equipment Supports and Structures – Material Cost ........................................................................ 240 Structural Steel for Pipe Racks – Miscellaneous Iron for Equipment – Material Cost ................................................... 241 Structural Steel and Miscellaneous Iron – Equipment, Equipment Supports and Structures, and Pipe Racks – Erection Manhours ............................................................... 242

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

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Electrical Lighting – Installation Manhours ................................... 266 Miscellaneous Instrumentation – Material Cost ............................ 267 Miscellaneous Instrumentation – Installation Manhours .............. 268

Section 10. Instrumentation ................................................ 269 Section Introduction ....................................................................... 269 Instruments – Total Number of Instruments Required ................. 270 Instruments – Total Material Cost ................................................. 271 Instruments – Total Instrument Installation Manhours ................. 272 Control Valves – Total Material Cost ............................................ 273 Standards, Tray Supports, Trays, Tubes, and Tube Bundles – Total Material Cost ............................................................ 274 Standards, Tray Supports, Trays, Tubes, and Tube Bundles – Total Installation Manhours ............................................... 275

Section 11. Insulation .......................................................... 276 Section Introduction ....................................................................... 276 Insulating Material – Total Square Feet ........................................ 277 Insulating Material for Equipment – Total Material Cost ............... 278 Insulating Material for Piping – Total Material Cost ..................... 279 Insulating Labor for Piping and Equipment – Total Manhours ............................................................................. 280

Section 12. Painting ............................................................. 281 Section Introduction ....................................................................... 281 Painting – Equipment – Square Feet Area ................................... 282 Painting – Structural Steel and Piping – Square Feet Area ......... 283 Painting – Miscellaneous and Pipe Rack Steel – Square Feet Area ...................................................................................... 284 Painting – Equipment – Total Material Cost ................................. 285

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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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Office Personnel – Total Manhours .............................................. 305 Other Indirect and Temporary Construction Labor – Total Manhours ............................................................................. 306 Temporary Construction Materials – Total Cost ........................... 307 Payroll Burdens and Benefits and Other Indirect Materials – Total Cost ............................................................................. 308

Section 17. Home Office Cost ............................................. 309 Section Introduction ....................................................................... 309 Engineering Design – Manhour Range Allowance per Piece of Equipment ........................................................................ 310 Engineering Design – Other Cost as a Percent of Engineering Labor Dollars ................................................... 314 Engineering Design – Manhour Spread Percentages .................. 315

Section 18. Ratio Estimating Factors ................................. 316 Section Introduction ....................................................................... 316 Refinery Process Systems – Direct Cost Percentages ................ 318 Liquid Type Chemical Plant – Direct Cost Percentages .............. 319 Solid Type Chemical Plants – Direct Cost Percentages .............. 320 Liquid/Solid Type Chemical Plants – Direct Cost Percentages ......................................................................... 321 Liquid High-pressure Chemical Plants – Direct Cost Percentages ......................................................................... 322 Liquid High-alloy Chemical Plants – Direct Cost Percentages ......................................................................... 323 Construction Equipment as a Percent of Direct Field Labor ........ 324 Overhead and Indirects as a Percent of Direct Field Labor ......... 324 Home Office Services as a Percent of Total Cost and Indirect Cost ...................................................................................... 324

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

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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, refinery, and industrial plants to arrive at a reasonable cost for a specified facility. Simply 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 moderate 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 complete 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 complete 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 subaccounts, 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 general 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 construction estimating software packages and have yet to find one that I would completely rely on. Construction estimating is an art, a science, and a craft, and I recommend that it be done by those who understand and appreciate all three of these facets. This manual is intended for those individuals. John S. Page

INTRODUCTION This manual contains two methods of conceptual estimating for determining the budget amount or estimated cost to design and construct refineries, chemical/petrochemical, 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 material graphs and tables. This will result in a more realistic equipment and material 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 engineer/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 weighted percent of time each crew will be devoted to the activity. The weighted 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.

All manhour tables and graphs include the total manhours, based on 70% productivity, 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 subcontracted 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,fieldoffice, 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 applying 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 earthwork, 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 estimate 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-established composite activity rate.

With the established quantities and manhours the project can be scheduled and fasttrack 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 rounding 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 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.

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 required 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 subcontracts 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 construction including, but not necessarily limited to, clearing, rough grading, cut, fill, borrow, disposal, soil stabilization and finish grading. 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. Pavements 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 "Discipline, Buildings." 5. Structural Steel—All cost of procuring, fabricating, and erecting structural and miscellaneous steel, not embedded, for framed structures, equipment supports, equipment platforms, walkways, ladders,

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 piping to five feet outside of building, insulation, electrical, painting, 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 operation. 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 instrumentation 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 electrical hook-up is included under "Above Ground Electrical." • 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 included 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.

15. Proratables—Includes the labor and material cost for daily area clean up, all required scaffolding and final test, startup, and pre-commissioning assistance. Construction Equipment 1. Rental or Purchase—Cost of rental or purchase of construction equipment required to construct the project. Does not include small tools. 2. Service Labor—AU labor required to service and maintain the construction 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 equipment.

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 labor practices, and contractor preferences. Description

To Include

Engineering salariesestimating Engineering salariesfield technical support

Civil, cost, electrical, general, mechanical and structural estimating salaries. Project chief engineer; assistant project chief engineer; chief field engineer; civil, electrical, mechanical, structural, field, staff, office, piping, instrument engineers; coordinators; engineering draftsmen; party chiefs, instrument men,

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 temporarily assigned to a field party performing general layout work. Security supervisor, security coordinator, 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 estimate only. Administrative clerks, office clerks, and secretaries. Chief construction inspector, construction inspectors, welding inspector, piping inspector, electrical inspector, boiler inspector and civil inspector. Salaries for subcontract coordinators. Salaries for cost/schedule supervisor, chief field cost engineer and cost engineers. Salaries for chief field scheduler and planner/schedulers. Salaries for technical clerical personnel. Material control coordinators and material control personnel assigned to implement and follow-up the material control program. Job payroll labor for loading, unloading, and transporting from facilities to project construction area tools and construction 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 construction 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

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, bookkeepers, invoice auditors, expeditors, chief timekeeper, timekeepers, personnel manager, assistant personnel manager, personnel interviewer, data controllers, data entry operators, purchasing agents, and buyers. Project manager, general superintendent, craft superintendents, area superintendents, assistant project manager, assistant superintendents, administrative manager, office manager, area coordinators and master mechanic. Wages paid overhead and indirect employees only for authorized absence due to personal illness, as approved by project construction manager. Warehouse supervisor, assistant warehouse supervisor, warehousemen, toolroom attendants, warehouse laborersassigned full time to warehouse operation. Note: Must be on job payroll only.

Temporary Construction Facilities (Labor and Material) Description

To Include

Temporary buildings and utilities—labor

Labor only for construction or erection, maintenance and dismantling of the temporary 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, tel-

Temporary buildings and utilities—material and supplies

ephone and communications systems, and plant air system. Note: Does not include 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 includes rental of temporary field offices and warehouses, roads, ditches, bridges, storage areas, parking lots, fencing, buildings, water system, sanitary system, power distribution, telephone and communications systems, and plant air system. Note: Does not include construction camp, quartering or catering facili-

Labor Burdens and Overhead Personnel Benefits Description

Tb Include

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

Actual cost fixed by the appropriate accounting 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.

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)

Premium expense based on payrolls. Limits conform to the requirements for the state as specified in the contract. FICA and Medicare, state unemployment insurance and federal unemployment insurance. Actual cost for overhead and indirect personnel only based on gross payroll as billed by the appropriate Accounting Office. Note: Does not include any like or similar item which is a part of a union fringe benefit.

Small Tool and Consumables Description

TD Include

Construction supplies

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 repair parts for such tools will be included in this account. This account includes minor equipment such as small pumps to 3", vibrators, light plants (800 watt3,000 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 example, 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 deduction for items charged here.

Small tools (in accordance with contract limits)

Workmen's supplies

Other Indirects Description

To Include

Advertising Bond premiums

Classified ads, public advertisements. Bid bonds, performance bonds, maintenance bonds, and fidelity bonds. Telephone, telegraph, teletype, postage, radio rental or communications system

Communications and postage

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 professional organizations, for overhead and indirect personnel only. Note: Does not include union dues. Surveying instruments (purchase or rental) drafting supplies, surveying supplies, 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 extended coverage, equipment floater coverage, non-owned automotive liability, independent contractors' liability, contractual liability, special risk coverage, such as war risk and heavy lift, hull and P&I, umbrella. Abstracts, lawyers fees, court costs, notary fees, sign-up expense. Business permits, construction permits, export/import licenses, government inspection fees, hauling permits. Transportation of tools, and construction equipment by others to project construction area, and miscellaneous supplies consumed and services used, for move-in and -out purposes. Stationery supplies, printing, office equipment purchase, rental or repair, office and warehouse forms and supplies, jobsite reproduction costs and furniture. Medical examination fees, medical supplies, safety signs and literature, first-

Testing and laboratory analysis

Traveling

Welding supplies

Unclassified Data processing services

Consulting services

Trade journals, books, publications, and subscriptions Contract Guard Service Quality AssuranceMaterial and Supplies Employee Educational Assistance

aid equipment, fire extinguishers, and refills. Soil surveys, concrete cylinder tests, independent inspectors. Lab charges to test welders. Transportation and subsistence expense of overhead and indirect employees on business trips (excluding quality assurance 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, helmets, lenses, asbestos gloves, goggles, gauges, welding qualification test material, etc. Flowers, weather reports and forecasts, and bank service charges. Cost for data processing services for the project. Terminal rental, supplies, computer 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 quality control personnel. Cost of employee educational assistance, for overhead and indirect personnel only.

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 departments 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.

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, capacity and material of construction. From the logarithmic graphs that appear on the following pages, an average cost of equipment material and installation manhours can be computed. Inasmuch as it is not practical within the scope of this manual to adequately describe each piece of equipment beyond the very minor description 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, hauling up to 2,000 feet and rigging, picking, setting, and aligning 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, ladders, 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 equipment and piping, electrical components and instrumentation, 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 introduction to this manual before applying this information.

ACID CCX)LERS WITH PUMP AND MOTOR

Equipment Cost

Equipment Cost

Heat Exchanger Area

Square Feet

ACID COOLERS WITH PUMP AND MOTOR

Erection Manhours

Erection Manhours

Heat Exchanger Area

Square Feet

VIBRATING BIN ACTIVATORS

Equipment Cost

Equipment Cost

Diameter Inches

VIBRATING BIN ACTIVATORS

Erection

Manhours

Erection Manhours

Diameter Inches

HIGH-SPEED MECHANICAL AERATORS

Equipment Cost

Equipment Cost

Motor Horsepower

(D Basic unit—ductile iron/carbon steel © Basic unit—stainless steel

HIGH-SPEED MECHANICAL AERATORS

Erection

Manhours

Erection Manhours

Motor Horsepower

LOW-SPEED MECHANICAL SURFACE AERATORS

Equipment Cost

Equipment Cost

Motor Horsepower

©Fixed low-speed unit © Floating low-speed unit

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LOW-SPEED MECHANICAL SURFACE AERATORS

Erection Manhours

Erection Manhours

Motor Horsepower

® Fixed low-speed unit ©Floating low-speed unit

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AIR POWER COMPRESSORS Synchronous Motor Driven Rated for Sea Level to 3,300 Feet Altitude at 125 psig Maximum Discharge Pressure

Equipment Cost

Equipment Cost

Motor Horsepower

0)460,575, or 480 volts ©2300 or 4160 volts

AIR POWER COMPRESSORS Induction Motor Driven Rated for Sea Level to 3,300-Fbot Altitude at 125 psig Maximum Discharge Pressure

Equipment Cost

Equipment Cost

Motor Horsepower

©460,575, or 230-volt ©480or2,300-volt

AIR POWER COMPRESSORS Synchronous and Induction Motor Driven Rated for Sea Level to 3,300-Foot Altitude at 125 psig Maximum Discharge Pressure

Erection

Manhours

Erection Manhours

Motor Horsepower

AUTOMOTIVE AND INDUSTRIAL SERVICE AIR COMPRESSORS

Equipment Cost

Equipment Cost

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.

AUTOMOTIVE AND INDUSTRIAL SERVICE AIR COMPRESSORS

Erection Manhours

Erection Manhours

Motor Horsepower

(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.

CENTRIFUGAL AIR COMPRESSORS Plant and High-Pressure (Soot Blower) Types 100 to 350 psig Discharge Pressure

Equipment Cost

Equipment Cost

Nominal Motor Horsepower

0 Plant air compressors (2) High-Pressure (soot blower) compressors

CENTRIFUGAL AIB COMPRESSORS Plant and High-Pressure (Soot Blower) Types 100 to 350 psig Discharge Pressure

Erection Manhours

Erection Manhours

Nominal Motor Horsepower

INDUSTRIAL AIR COMPRESSORS Air-Cooled, Two-Stage—50 to 250psig

Equipment Cost

Equipment Cost

Motor Horsepower

(D Two-stage—50 to 125 psig, ©Two-stage-150 to 250 psig.

INDUSTRIAL AIR COMPRESSORS Air-Cooled, Two-Stage—50 to 250psig

Erection Manhours

Erection Manhours

Motor Horsepower

INTEGRAL GAS ENGINE COMPRESSOR Fbur-Cylinder Type

Equipment Cost

Equipment Cost

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

INTEGRAL GAS ENGINE COMPRESSORS Fbur-Cylinder Type 1,CXX) TO 6,000 psig Discharge

Erection Manhours

Erection Manhours

Rated Horsepower (BHP)

PACKAGED AIR COMPRESSOR UNITS Single-Stage, Water-Cooled Oil-Lubricated and Nonlubricated Types

Equipment Cost

Equipment Cost

Motor Horsepower (DOil-lubricated-208, 230, or 460-volt. ©Nonlubricated-208, 230, or 460-volt.

PACKAGED AIR COMPRESSOR UNITS Single-Stage, Water-Cooled Oil-Lubricated and Nonlubricated Types

Erection Manhours

Erection Manhours

Motor Horsepower For 208-, 230-, or 460-volt units.

RECIPROCATING COMPRESSORS Electric Motor Driven

Equipment Cost

Equipment Cost

Compressor 1) 2) 3) 4)

Horsepower

Cast Iron Cylinders 1000 PSI Discharge Nodular Iron Cylinders 1500 PSI Discharge Steel Cylinders 2500 PSI Discharge Steel Cylinders 6000 PSI Discharge

RECIPROCATING COMPRESSORS Electric Motor Driven 1,000 to 6,000 psi Discharge

Erection Manhours

Erection Manhours

Compressor Horsepower

TWO-STAGE, TWO-CYLINDER, WATER-COOLED AIR COMPRESSORS Oil-Lubricated and Nonlubricated 150 to 350 psi Discharge Pressure

Equipment Cost

Equipment Cost

Motor Horsepower 0 Oil-lubricated © Nonlubricated

TWO-STAGE, TWO-CYLINDER, WATER-COOLED AIR COMPRESSORS Oil-Lubricated and Nonlubricated 350 to 500 psig Discharge Pressure

Equipment Cost

Eauimnent Cost

Motor Horsepower (D Oil-Lubricated (D Nonlubricated

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TWO-STAGE, TWO-CYLINDER, WATER-COOLED AIR COMPRESSORS Oil-Lubricated and Nonlubricated 150 to 500 psig Discharge Pressure

Erection

Manhours

Erection Manhours

Motor Horsepower

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REFRIGERATED AIR DRYERS Automatic Type 15 to 1000 scfm

Equipment Cost

Equipment Cost

Capacity

SCFM

REFRIGERATED AIR DRYERS Automatic Type 1,200 to 15,000 scfm

Equipment Cost

Equipment Cost

Capacity scfm

REFRIGEBATED AIR DRYERS Automatic Type 15 to I9OOO scfm

Erection Manhours

Erection Manhours

Capacity SCFM

REFRIGERATED AIR DRYERS Automatic Type 1,200 to IS9OOO scfm

Erection Manhours

Erection Manhours

Capacity SCFM

CHILLER AIR DRYERS Capacity 3,000 to 28,000 scfm at lOOpsig

Equipment Cost

Equipment Cost

Capacity SCFM At 100 PSIG

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CHILLER AIR DRYERS Capacity 3,000 to 28,000 scfm at lOOpsig

Erection Manhours

Erection Manhours

C a p a c i t y SCFM At 100 PSIG

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SURGE ARRESTORS Hydrocarbon and Water Service 500 psi Design Operating Pressure ASME Code—Section VIII Division I

Equipment Cost

Equipment Cost

Nominal Size Gallons

©Hydrocarbon Service ©Water Service

SURGE ARRESTORS Hydrocarbon, Water and Sewage Service 275 psi Design Operating Pressure ASME Code—Section VIII Division I

Equipment Cost

Equipment Cost

Nominal Size Gallons

©Hydrocarbon service ©Water service ® Sewage service

SURGE ABBESTORS Hydrocarbon, Water and Sewage Service 275 and 500 psi Design Operating Pressures ASME Code—Section VIII Division I

Erection Manhours

Erection Manhours

Nominal Size Gallons

DRY MATERIAL BLENDERS, PACKERS9 AND FEEDERS Auger Blenders Rotary Drum Blenders

Equipment Cost

Equipment Cost

iuaximum Mixing Cubic Feet Per Hour

(D Auger blenders © Rotary drum blenders

DRY MATERIAL BLENDERS9 PACKERS9 AND FEEDERS Auger Blenders Rotary Drum Blenders

Erection Manhours

Erection Manhours

Maximum Mixing Cubic Feet Per Hour

©Auger blenders © Rotary drum blenders

MIXERS AND BLENDERS Fixed Side Mounted Mixers with Top Motors

Equipment Cost

Equipment Cost

Rating

Hors epower

MIXERS AND BLENDERS Fixed Side Mounted Mixers with Top Motors

Erection Manhours

Erection Manhours

Rating Horsepower

MIXERS AND BLENDERS Plate Mounted Open Tank Mixers

Equipment Cost

Equipment Cost

Rating Horsepower

(D Plate-mounted, open tank mixers—direct drive. ©Plate-mounted, open tank mixers—gear drive.

MIXERS AND BLENDERS Portable Clamp and Flanged Mounted Mixers

Equipment Cost

Equipment Cost

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.

MIXERS AND BLENDERS Flanged Top Tank Mounted and Plate Mounted Open Tank Mixers

Erection

Manhours

Erection Manhours

Rating Horsepower

©Portable clamp mounted mixers—Direct And Gear Drive. © Flanged top tank and plate mounted open tank mixers—direct and gear drives.

MIXERS AND BLENDERS Gearmotor Mixers

Equipment

Cost

Equipment Cost

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 range 100"-23O*, impeller range 29"-75".

MIXERS AND BLENDERS Gearmotor 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 seals Note: Motor horsepower range 2-200, shaft length range 100"-23O*, impeller range 29"-75".

MIXERS AND BLENDERS Batch and Pipeline Homogenizer Mixers

Equipment

Cost

Equipment Cost

Horsepower

(D Batch homogenizer mixers © Pipeline homogenizer mixers

MIXERS AND BLENDERS Batch and Pipeline Homogenizer Mixers

Erection Manhours

Erection Manhours

Horsepower

MIXERS High-Intensity

Equipment

Cost

Equipment Cost

Working Capacity Cubic Feet

MIXERS High-Intensity

Erection

Manhours

Erection Manhours

Working Capacity Cubic Feet

DRY MATERIAL BLENDERS9 PACKERS9 AND FEEDERS Bag Vibrating Packers Rigid Container Vibrating Packers

Equipment

Cost

Equipment Cost

Maximum Bag Width Or Container Diameter Inches

® Bag vibrating paekers © Rigid container vibrating packers

DRY MATERIAL BLENDERS9 PACKERS9 AND FEEDERS Bag Vibrating Packers Rigid Container Vibrating Packers

Erection Manhours

Erection Manhours

Maximum Bag Width Or Container Diameter Inches (D Bag vibrating packers (2) Rigid container vibrating packers

BOILERS Package Type

Equipment

Cost

Equipment Cost

Pounds Per Hour

Note: Cost is for total boiler including forced draft fan assembly. Boiler capacity pounds per hour-saturated steam at 100 to 235 psig.

BOILERS Package Type

Erection

Manhours

Erection Manhours

Pounds Per Hour

Note: Manhours are for installation of boiler including forced draft fan. Boiler capacity pounds per hour-saturated steam at 100 to 235 psig.

BOILER STACKS 1 M-InCh Plate

Equipment

Cost

Equipment Cost

Linear Feet Of Stack

(D 24-inch diameter (3) 42 to 48-inch diameter © 30-inch diameter © 54 to 60-inch diameter ® 36-inch diameter Note: Cost includes stack, cable, and clamps.

5

BOILER STACKS /ie- and 3/s-Inch Plate

Equipment

Cost

Equipment Cost

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 diameter Note: Cost includes stack, cable, and clamps.

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BOILEB STACKS Ai-, 5/i6-, 3/8-Inch Plate

1

Erection Manhours

Erection Manhours

Linear Feet Of Stack

® 24-inch diameter © 30-inch diameter ©36-inch diameter

(D 42- to 48-inch diameter ® 54- to 60-inch diameter

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CLASSIFICATION EQUIPMENT Cone Pelletizers

Equipment

Cost

Equipment Cost

Cone Size Feet

CLASSIFICATION EQUIPMENT Cone Pelletizers

Erection

Manhours

Erection Manhours

Cone Size Feet

CLASSIFICATION EQUIPMENT Turbo-Screen Cyclone and 48"-Pressure Sifter (3-Screens)

Equipment

Cost

Equipment Cost

Diameter Inches

® Stainless steel turbo-screen cyclone © Carbon steel turbo-screen cyclone ® 48-inch pressure sifter (3-screens)

CLASSIFICATION EQUIPMENT Turbo-Screen Cyclone and 48"-Pressure Sifter (3-Screens)

Erection

Manhours

Erection Manhours

Diameter

Inches

® Carbon or stainless steel cyclone ©48-inch pressure sifter (3-screens)

CLASSIFICATION EQUIPMENT Rotary Screens

Equipment

Cost

Equipment Cost

Capacity Screen Area Square Feet

CLASSIFICATION EQUIPMENT Rotary Screens

Erection

Manhours

Erection Manhours

Capacity Screen Area Square Feet

VERTICAL TUBE SURFACE CONDENSERS AND RECEIVERS

Equipment

Cost

Equipment Cost

Cooling Surface Square Feet

VERTICAL TUBE SURFACE CONDENSERS AND RECEIVERS

Erection Manhours

Erection Manhours

Cooling Surface Square Feet

CONVEYING EQUIPMENT Conveyors—Open Belt

Equipment

Cost

Equipment Cost

Linear Feet

(D 18-inch belt