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C O N C E P T U L C O S T

E S T I M T I N G

M N U L

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

J O H N   S P G E

An Imprint ofElsevier

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  o n c e p t u a l o s t

E s t i m a t i n g

M a n u a l

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: permissions@elsevier.co.uk.

You may also comp lete your request on-line via the Elsevier homepag e: http://www .elsevier.com by

selecting Customer Support and then Obtaining Permissions .

Originally published by Gulf Publishing Com pany,

Houston, TX.

For information, please contact:

Manager of Special Sales

Elsevier

200 Wheeler Road

Burlington, MA 01803-2041

T e l :  781-313-4700

Fax:781-313-4882

For information on all Gulf Professional Publishing titles

available, contact our World W ide W eb home page at:

http://www.bh.com/gulf

G

|

P

  Gulf Professional Publishing

P l H

  n

  mprint 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

 

Chemical plants—D esign and construction—

Estimates—H andbooks, manuals, etc. I. Title.

TH4524.P34 1996

690'.54—dc20 95-52313

CIP

Printed in the U nited States of America.

Printed on acid-free paper (oo).

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PREF E

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 pa st reco rds and say that a certain type plant will cost ten dollars pe r

pound produced, and the p roduct 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 app arent th at a less expensive m ethod

is needed to d etermine the feasibility of the plant in mind. By using a very m oder-

ate flow sheet design, specifications, and/or equipment lists, by prope rly 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 obtainab le 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 cos t estimating, you might wo nder wha t an estimating manual offers tha t

a com puter 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 h as unique aspec ts 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 nam e 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 p ackages 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 w ho unde rstand and appreciate all three of these

facets. This manua l is intended for those individuals.

 o n S age

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INTRODU TION

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 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

  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 ra tes and the weight-

ed 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 ra te for that crew. The sum of all weighted crew ra tes 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 m ust 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 m aterial 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 arrangem ents.

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 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.

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

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 ......................................... 16High-speed – Erection Manhours .................................... 17

Low-speed – Equipment Cost .......................................... 18

Low-speed – Erection Manhours ..................................... 19

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vi Contents

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Compressors ................................................................................. 20

 Air Power – Synchronous Motor Driven – Equipment

Cost ........................................................................ 20

 Air Power – Induction Motor Driven – EquipmentCost ........................................................................ 21

 Air Power – Synchronous and Induction Motor Driven

 – Erection Manhours ............................................... 22

 Automotive and Industrial Service Air – Equipment

Cost ........................................................................ 23

 Automotive and Industrial Service Air – ErectionManhours ................................................................ 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 – EquipmentCost ........................................................................ 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

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Contents vii

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Two-stage, Two-cylinder, Water-cooled – Equipment

Cost ........................................................................ 35

Two-stage, Two-cylinder, Water-cooled – Equipment

Cost ........................................................................ 36Two-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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viii Contents

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Portable Clamp and Flanged Mounted Mixers –

Equipment Cost ...................................................... 52

Flanged Top Tank Mounted and Plate Mounted Open

Tank Mixers – Erection Manhours ........................... 53Gearmotor 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 – ErectionManhours ................................................................ 70

Rotary Screens – Equipment Cost ................................... 71

Rotary Screens – Erection Manhours .............................. 72

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Contents ix

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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, 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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Dryers – Vacuum ........................................................................... 90

Conical Rotating – Equipment Cost ................................. 90

Double Drum and Rotary – Equipment Cost .................... 91

Conical Rotating and Double Drum – ErectionManhours ................................................................ 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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Contents xi

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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 .............. 117Pre-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 ................... 121Dry 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 – ErectionManhours ................................................................  125

Filters ............................................................................................. 126

Gravity Filtration Units – Total Material Cost .................... 126

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Gravity Filtration Units – Total Unit Installation

Manhours ................................................................  127

Pressure Type – Equipment Cost .................................... 128

Pressure Type – Erection Manhours ............................... 129Rubber-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 ................................................................ 138Dampers – 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

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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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Contents xv

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Water Softener System ................................................................. 188

Hot Process Water – Total Process Material and

Equipment Cost ...................................................... 188

Hot Process Water – Total System InstallationManhours ................................................................  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 ............................ 201Vessels .......................................................................................... 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 ......................................................................... 204Vertical with Anchor Ring and Skirts, Shop Fabricated

 – Cost per Ton ........................................................ 205

Tray Rings, Shop Fabricated – Cost Each ....................... 206

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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 ........................................................................ 220Drainage ........................................................................................ 221

Catch Basins and Manholes ......................................................... 221

Road Culverts ................................................................................ 221

Section 5. Concrete  ...........................................................  222

Section Introduction ....................................................................... 222Earth 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 ............................ 226Forms, 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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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 ofEquipment ............................................................................ 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 ofEquipment ............................................................................ 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

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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  ..........................................................  276Section 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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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 ........................... 307Payroll 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 Pieceof 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  .................................  316Section 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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Section 1

DISCIPLINES OF WORK

The following is a broad description of the m ajor item s 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 t hat are no t included. Should thi s occur, th e estim ator should give

consideration to these items and add or deduct accordingly.

D i r e c t C o s t I t e m s

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—

  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 ear thw ork , form s, 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 und er Disci-

pline, Buildings.

5.  Structural Steel—A ll

  cost of procuring, fabricating, and erecting

structural and miscellaneous steel, not embedded, for framed struc-

tures,

 equipment s upports, equipment platforms, w alkways, ladders,

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handrails and pipe supports. Steel for buildings is included under

  Discipline, Buildings

6.  uildings—

 

cost of buildings including earthw ork , foundations and

othe r concrete, total supe rstru ctu re, HVAC, plumbing and utility pip-

ing 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 p rocess pipe, valves and fittings requ ired for plan t op-

eration. Installation only of relief valves, control valves, and orifice

fittings for instrumentation are also included. The material cost of

thes e items is included und er Discipline, Instrum entation .

9.  Underground Electrical—All labor and m aterial for unde rground

power and lighting, ducts, conduit, wire, cable, etc. Also includes

earthwork and concrete for embedments.

10.  Above Ground Electrical—

  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 m aterial and labor cost of instrum enta -

tion work delineated as follows:

• Material cost includes instruments, control valves, relief valves,

control panels, m ete r run s, orifice fittings and all othe r instrum ent

items plus the tubing, tube bund les, and tra y m aterials 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 un der Above Ground Elec trical.

• All header piping labor and material costs are included under

  Above Ground Piping.

12.  Insulation—

  labor and m aterial 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.

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15.  Proratables— Includes the labor and m aterial cost for daily area clean

up,

  all required scaffolding and final test, startup, and pre-commis-

sioning assistance.

C o n s t r u c t i o n E q u i p m e n t

1.

  Rental or Purchase—Cost of ren tal or purch ase of construction equip-

ment required to construct the project. Does not include small tools.

2.

  Service

 Labor—

  labor required to service and maintain the con-

struction equ ipment. 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 requ ired to ope rate and m aintain th e 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 Ex cept for Tem porary Fa cilitie s Labor)

 

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

Engineer ing salar ies-

estimating

Engineer ing salar ies-

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; par ty chiefs , ins t rument men,

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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

chainmen, rodmen, and laborers tempo-

rarily assigned to a field pa rty perform-

ing general layout work.

Security supervisor, security coordina-

tor, guards, watchmen, janitors, labor

for supplying drinking w ater. 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 inspec tors, welding inspector, piping

inspector, electrical inspector, boiler in-

spector and civil inspector.

Salaries for subcontract coordinators.

Salaries for cost/schedule supervisor,

chief field cost engineer and cost engi-

neers.

Salaries for chief field scheduler 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 equ ipmen t, tem porary 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 im mediate area of the

project.

Wages paid to hourly employees during a

temporary period when work is stopped.

Also wages paid to craftsmen for voting

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Safety and medical

expense—labor

Salaries—office

Salaries—supervision

Sick pay

Warehouse salaries

in accordance with union or governm ent

regulations. Welding test labor and ju ry

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 personnel man-

ager, personnel interviewer, data con-

trollers, data entry operators, purchas-

ing agents, and buyers.

Project manager, general superinten-

dent, craft superintendents, area super-

intendents, assistant project manager,

assistant superintendents, administra-

tive manager, office manager, area coor-

dinators and master mechanic.

Wages paid overhead and indirect em-

ployees only for authorized absence due

to personal illness, as approved by

  proj-

ect construction manager.

Warehouse supervisor, assistant ware-

house supervisor, warehousemen, tool-

room attendants, warehouse laborers-

assigned full time to warehouse opera-

tion.  Note: Must b e on job payroll only.

Description

Temporary buildings and

utilities—labor

To Include

Labor only for construction or erection,

maintenance and dism antling 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, pow er distribution, tel-

Temporary C onstruction Fa cilities Labor and M aterial)

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Labor Bu rden s and Overhead Person nel B ene fits

Temporary buildings and

utilities—material and

supplies

ephone and communications systems,

and plant air system.

 Note:

 Does no t 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,

s torage areas , parking lots , fencing,

buildings, water system, sanitary sys-

tem, power distribution, telephone and

communications systems, and plant air

system. Note: Does no t 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 w hich is a pa rt of

a union fringe benefit.

D irect premium charges only. Note: Does

not include any like or similar item

which is a pa rt 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 unemploy-

ment insurance and federal unemploy-

ment insurance.

Actual cost for overhead and indirect

personne l only based on gross payroll as

billed by the app rop riate A ccounting Of-

fice.  Note: Does not include any like or

similar item which is a part of a union

fringe benefit.

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Sm all Tool and Co nsum ables

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 , cha lk , soaps tone ,

emery paper g r ind ing whee ls , moi l

points, saw blades, padlocks, threading

dies, drill bits and ream ers, rags , brooms

and mops, air and w ater 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 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 h ats, protective

clothing, gloves, boots, salt tab lets , 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

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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 in-

direc t personnel only. Note:  Does not in-

clude union dues.

Surveying ins t ruments (purchase or

rental) drafting supplies, surveying sup-

p l ie s ,  b luepr in t o r photos ta t 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-

tende d 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.

A bstra cts, law yers fees, court costs, no-

tary fees, sign-up expense.

Business perm its, construction perm its,

export/import licenses, government in-

spection fees, hauling permits.

Transp ortation of

 tools,

 and construction

equipm ent by othe rs to project construc-

tion area, and miscellaneous supplies

consumed and servic es used , for move-in

and -out purposes.

Sta t ion ery su pplies , pr int ing , 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, first-

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Testing and laboratory

analysis

Traveling

Welding supplies

Unclassified

Data processing services

Consulting services

Trad e journals, books,

publications, and

subscriptions

Contract Guard Service

Quali ty 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 m aterial, supplies, and tools required

by a w elder, 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.

Flow ers, we ather re po rts and forecasts,

and bank service charges.

Cost for da ta processing services for th e

project. Terminal rental, supplies, com-

puter charges f rom outs ide jobs i te

sources, etc.

Cost for outside consulting services

which might be required in connection

with the projects which are not a pa rt 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.

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H o m e O f f ic e C o s t

1.  Engineering/Design Services—

Total labor and m aterial cost for th e

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

requ ired 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

con tractor's managem ent staff applies in rega rd to overall direction of

the project.

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Section 2

PROCESS EQUIPMENT

The m ost important component of physical plant cost is tha t 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

prese nte d, an equipm ent list can be compiled noting the type , size, capac-

ity and material of construction. From the logarithmic graph s tha t appear

on the following pa ges, an avera ge 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 ap pea rs on the individual graphs , I rely on the estimato r s ability

to realize that the items covered are of a standard nature for chemical

plants, refineries, and industrial plants.

All installation m anho urs include offloading equipm ent at job site, haul-

ing 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, lad-

ders,

  walkways, platforms, or handrails. See other sections for these

items.

AU shop fabricated equ ipment g rap hs , as in the case of vessels, include

the to tal 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-

m ent and piping, electrical components and instrum entation, 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.

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ACID CCX LERS W ITH P U M P

A N D MOTOR

Equipment Cost

E

p

m

e

n

 

Heat Exchanger rea Square Feet

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ACID COOLERS WITH PU M P

A N D MOTOR

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Heat Exchanger Area Square Fe et

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VIBRATING BIN ACTIVATORS

Equipment Cost

E

pm

e

n

 

Diameter Inches

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VIBRATING BIN ACTIVATORS

Erection Manhours

E

o

n

M

n

 iameter Inches

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HIGH-SPEED MECHANICAL

AERATORS

Equipment Cost

E

q

pm

e

n

 

o

Motor Horsepower

  Basic unit—ductile iron/carbon steel

© Basic unit—stainless steel

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HIGH-SPEED MECHANICAL

AERATORS

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Motor Horsepower

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LOW-SPEED MECHANICAL

SURFACE AERATORS

Equipment Cost

 

p

m

 

n

 

Motor Horsepower

©Fixed low-speed unit

© Floating low-speed unit

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LOW-SPEED MECHANICAL

SURFACE AERATORS

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Motor Horsepower

® Fixed low-speed unit

©Floating low-speed unit

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AIR POWER COM PRESSORS

Synchronous Motor Driven

Ra ted for Sea Level to 3 ,3 0 0 Feet

Alt i tude at 125 psig Maximum

Discharge Pressure

Equipment Cost

E

p

m

e

n

 

Motor Horsepower

0)460,575,

 or 480 volts

©2300 or 4160 volts

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AIR POWER COMPRESSORS

Induction Motor Driven

Rated for Sea Level to 3,300-Fbot

Alti tude at 125 psig Maximum

Discharge Pressure

Equipment Cost

 

p

m

 

n

 

Motor Horsepower

©460,575 , or 230-volt

©480or2,300-volt

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AIR POWER COMPRESSORS

Synchronous and Induction Motor

Driven Rated for Sea Level to

3,300-Foot Altitude at 12 5 ps ig

Maximum Discharge Pressure

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Motor Horsepower

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AUTOMOTIVE AND

INDU STR IAL SERVICE AIR

COMPRESSORS

Equipment Cost

 

p

m

 

n

 

Motor Horsepower

 D

 Single-stage, air-cooled—capacity 7.9 to 37.0 acfin

 @

 80 psig.

© Tw o-stag e, air-cooled—capacity 5.0 to 97.2 acfin @ 175 psig.

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AUTOMOTIVE AND

INDU STR IAL SERVICE AIR

COMPRESSORS

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

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.

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CENTRIFUGAL AIR COM PRESSORS

Plant and H igh-Pressure

  Soot Blower) Types

10 0 to 3 5 0 ps ig Discharge

Pressure

Equipment Cost

E

pm

e

n

 

Nominal Motor Horsepower

0 Plan t air compressors

 2)

 High-Pressure soot blower) compressors

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CENTRIFUGAL AIB COMPRESSORS

Plant and High-Pressure

  Soot Blower) Types

10 0 to 3 5 0 p s ig Discharge

Pr e ssur e

Erection Manhours

 

o

n

 

a

n

u

Nominal Motor Horsepower

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INDUST RIAL AIR

COMPRESSORS

Air-Cooled, Two-Stage—50 to

2 5 0 p s i g

Equipment Cost

E

pm

e

n

 

Motor Horsepower

 D

 Two-stage—50 to 125 psig,

© Tw o-stag e-15 0 to 250 psig.

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INDUSTR IAL AIR

COMPRESSORS

Air-Cooled, Two-Stage—50 to

2 5 0 p s i g

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Motor Horsepower

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INTEGRAL GAS ENG INE

COMPRESSOR

Fbur-Cylinder Type

Equipment Cost

E

p

m

e

n

 

R ate d Hp. BHP)

 D

 Cast iron cylinders, 1,000 psig discharge

 2)

 Nodular cylinders, 1,500 psig discharge

© F o rg ed steel cylinders, 2,500 psig discharge

® Forged steel cylinders, 6 000 psig discharge

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INTEGRAL GAS ENG INE

COMPRESSORS

Fbur-Cylinder Type

1,CXX

TO

 6,000

 ps ig D ischarge

Erection Manhours

 

o

n

 

a

n

u

Rated Horsepow er BHP)

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PACKAGED AIR COM PRESSOR

U N I T S

Single-Stage, Water-Cooled

Oil-Lubricated and Nonlubricated

Types

Equipment Cost

E

p

m

e

n

 

Motor Horsepower

  D Oil-lubricated-208 , 230, or 460-volt.

© N on lub rica ted -20 8, 230, or 460-volt.

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PACKAGED AIR COM PRESSOR U N IT S

Single-Stage, Water-Cooled

Oil-Lubricated and N onlub ricated

Types

Erection Manhours

 

o

n

 

a

n

u

Motor Horsepower

For

 208-,

 230- or 460-volt units.

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RECIPROCATING

COMPRESSORS

Electric Motor Driven

Equipment Cost

E

p

m

e

n

 

Compressor Horsepower

1 Cast Iron Cylinders 1000 PSI Discharge

2 Nodular Iron Cylinders 1500 PSI Discharge

3 Steel Cylinders 2500 PSI Discharge

4 Steel Cylinders 6000

 PSI

 Discharge

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RECIPROCATING

COMPRESSORS

Electric Motor Driven

1,000 to

 6,000

 psi D ischarge

Erection Manhours

 

o

n

 

a

n

u

Compressor Horsepower

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TWO-STAGE, TWO-CYLINDER,

WATER-COOLED AIR CO M PRE SSOR S

Oil-Lubricated and Nonlubricated

1 5 0 to 350 psi D ischarge

Pressure

Equipment Cost

 

pm

 

n

 

Motor Horsepower

0 Oil-lubricated

© Nonlubricated

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TWO-STAGE, TWO-CYLINDER,

WATER-COOLED AIR CO M PRESSO RS

Oil-Lubricated and Nonlubricated

3 5 0 to 5 0 0 ps ig Discharge

Pressure

Eauimnent Cost

E

pm

e

n

 

Motor Horsepower

  D Oil-Lubricated

  D Nonlubricated

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TWO-STAGE, TWO-CYLINDER,

WATER-COOLED AIR CO M PRESSORS

Oil-Lubricated and Nonlubricated

15 0 to 5 0 0 ps ig Discharge

Pressure

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Motor Horsepower

Next Page

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REFRIGERATED AIR DRYERS

Automatic Type 15 to 1 0 0 0 scfm

Equipment Cost

E

p

m

e

n

 

Capacity SCFM

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REFRIGERATED AIR DRYERS

Au tomatic Type 1 200 to 15 00 0

scfm

Equipment Cost

 

p

m

 

n

 

Capacity scfm

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REFRIGEBATED AIR DRYERS

Au tomatic Type 15 to

 I

 

OOO

 scfm

Erection Manhours

 

r

e

c

t

i

o

n

 

a

n

h

o

u

r

s

Capacity SCFM

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REFRIGERATED AIR DRYERS

Automatic Type 1 200 to IS

9

OOO

scfm

Erection Manhours

E

o

n

M

n

u

Capacity SCFM

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CHILLER AIR DRYERS

Capacity 3 00 0 to 28 000 scfm at

lOOpsig

Equipment Cost

E

p

m

e

n

 

o

C ap acit y SCFM At 100 PSIG

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CHILLER AIR DRYERS

Capacity 3 0 00 to 2 8 0 0 0 scfm at

lOOpsig

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

C a p a c it y SCFM A t 1 00 PSIG

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SURGE ARRESTORS

Hydrocarbon and Water Service

5 0 0 psi D esign O perating Pressu re

ASME Code—Section VIII

Division I

Equipment Cost

E

p

m

n

 

Nominal S iz e G al lons

©Hydrocarbon Service

©Water Service

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SURGE ARRESTORS

Hydrocarbon W ater and S ew ag e Service

275 psi Design Operat ing Pressure

ASME Code—Section VIII

Division I

Equipment Cost

E

p

m

n

 

Nominal Size Gallons

©Hydrocarbon service

©Water service

® Sewage service

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SURGE ABBESTORS

Hydrocarbon W ater and S ew ag e Service

27 5 and 50 0

 psi

 D esign O perating P res su res

ASME Code—Section VIII

Division I

Erection Manhours

 

r

e

c

t

i

o

n

 

a

n

h

o

u

r

s

Nominal Size Gallons

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DRY MATERIAL BL EN DE RS

PACKERS

9

 A N D F E E D E R S

 ug r   Blenders

Rotary Drum Blenders

Equipment Cost

E

p

m

e

n

 

iuaximum M ixin g Cu bic F e e t P e r Hour

(D

 Auger blenders

© Rotary drum blenders

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DRY MATERIAL B LE ND ER S

9

PACKERS

9

 A N D F E E D E R S

Auger Blenders

Rotary Drum Blenders

Erection Manhours

 

o

n

 

a

n

u

Maximum M ixing Cub ic F e e t Per Hour

©Auger blenders

© Rotary drum blenders

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M IX ER S A N D BLEN D ER S

Fixed Side Mounted Mixers with

Top M otors

Equipment Cost

E

pm

n

 

Rat ing  ors epower

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M I XE R S A N D B L E N D E R S

Fixed Side Mounted Mixers

w ith Top M otors

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Rating Horsepower

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M IX ER S A N D B LEN D ER S

Plate M ounted Open Tank M ixers

Equipment Cost

E

p

m

e

n

 

Rating Horsepower

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

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

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M IX ER S A N D B LEN D ER S

Portable Clamp and F lan ged

Mounted Mixers

Equipment Cost

E

pm

e

n

 

o

Rating Horsepower

® Portable clamp mounted mixers—direct drive.

© Portable clamp mounted mixers—gear drive.

© Flanged top tank m ounted mixers—direct drive

® Flanged top tank mounted mixers—gear drive.

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M IX ER S A N D BLEN D ER S

F lange d Top Tank M ounted and

Plate M ounted Open Tank M ixers

Erection Manhours

 

on

 

a

n

u

Rating Horsepower

©Portable clamp mounted mixers—Direct And Gear

Drive.

© Flanged top tank and plate mounted open tank mix-

ers—direct and gear drives.

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M IXER S A N D BL EN D ER S

Gearmotor Mixers

Equipment Cost

E

p

m

e

n

 

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

  ote Motor horsepower range 2-200, shaft length

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

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M IX ERS A N D BLE N D ER S

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

  ote Motor horsepower range 2-200, shaft length

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

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M IX ER S A N D BLEN D ER S

Batch and Pipel ine Homogenizer

Mixers

Equipment Cost

E

p

m

n

 

Horsepower

(D

 Batch homogenizer m ixers

© Pipeline homogenizer mixers

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M IX ER S A N D BL EN D E R S

Batch and Pipel ine Homogenizer

Mixers

Erection Manhours

E

e

o

M

a

n

o

s

Horsepower

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MIXERS

High-Intensity

Equipment Cost

E

p

m

n

 

Working apacity ubic Feet

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MIXERS

High-Intensity

Erection Manhours

 

o

n

M

n

u

Working apacity ubic Feet

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DRY MATERIAL BL EN DE RS

9

PACKERS

9

 A N D F E E D E R S

Bag Vibrating Packers

R igid Container V ibrating

Packers

Equipment Cost

E

p

m

n

 

Maximum Bag Width Or Container Diameter Inches

® Bag vibrating paekers

© Rigid container vibrating packers

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DRY MATERIAL BL EN DE RS

9

PACKERS

9

 A N D F E E D E R S

Bag Vibrating Packers

R igid Container V ibrating

Packers

Erection Manhours

 

o

n

 

a

n

u

Maximum

 Bag

 Width

  Or

 Con tainer Diameter Inches

(D  ag vibrating packers

(2) Rigid container vibrating packers

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BOILERS

Package Type

Equipment Cost

E

p

m

n

 

Pounds Per Hour

  ote Cost is for to tal boiler including forced draft fan

assembly. Boiler capacity pounds per hour-satu-

rated steam at 100 to 235 psig.

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BOILERS

Package Type

Erection Manhours

 

on

 

a

n

u

Pounds Per Hour

  ote

Manhours are for installation of boiler including

forced draft fan. Boiler capacity pounds per

hour-saturated steam a t 100 to 235 psig.

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B O I L E R S T A C K S

1

M-InCh Plate

Equipment Cost

E

p

m

n

 

Linear Feet Of Stack

(D 24-inch

 diameter

  (3) 42

 to 48-inch diam eter

© 30-inch diam eter ©

  54

 to 60-inch diam eter

®  36-inch diameter

  ote Cost includes stack, cable, and clamps.

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BOILER STACKS

5

/ ie-

  and

  3

/s-Inch Plate

Equipment Cost

E

p

m

e

n

 

o

Linear Feet Of Stack

®  >-inch plate 42- to 48-inch d iam eter

© %3-inch pla te

 54-

 to 60-inch diam eter

® %-inch plate

 54-

 to 60-inch d iameter

  ote

Cost includes stack, cable, and clamps.

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BOILEB ST CKS

1

Ai- 5/i6-

3

/8-Inch Plate

Erection Manhours

E

e

o

M

a

n

s

Linear Feet

  Of

  S tack

® 24-inch diameter (D

 42- to

 48-inch diam eter

© 30-inch diameter

  ®  54- to

 60-inch diam eter

©36-inch diameter

Next Page

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CLASSIFICATION EQUIPMENT

Cone Pelletizers

Equipment Cost

E

p

m

n

 

Cone S iz e Fe et

Previous Page

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CLASSIFICATION EQUIPMENT

Cone Pelletizers

Erection Manhours

E

o

n

M

a

n

u

Cone S iz e F ee t

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CLASSIFICATION EQUIPMENT

Turbo-Screen Cyclone and

48 -Pressure Sifter (3-Screens)

Equipment Cost

E

p

m

n

Diameter Inches

® Stainless steel turbo-screen cyclone

© Carbon steel turbo-screen cyclone

® 48-inch pressure sifter 3-screens)

 

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CLASSIFICATION EQUIPMENT

Turbo-Screen Cyclone and

48 -Pressure Sifter (3-Screens)

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Diameter Inches

® Carbon or stainless steel cyclone

©48-inch pressure sifter 3-screens)

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CLASSIFICATION EQUIPMENT

Rotary Screens

Equipment Cost

E

p

m

n

 

Capacity Screen Area Square Feet

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CLASSIFICATION EQUIPMENT

Rotary Screens

Erection Manhours

E

on

M

a

n

u

Capacity Screen Area Square Feet

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VERTICAL TUBE SURFACE

CONDENSERS AN D

RECEIVERS

Equipment Cost

E

pm

n

 

Cooling Surface Square Feet

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VERTICAL TUBE SURFACE

CONDENSERS AND

RECEIVERS

Erection Manhours

E

o

n

M

a

n

u

Cool ing Surface Square Feet

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CONVEYING EQUIPMENT

Conveyors—Open Belt

Equipment Cost

E

p

m

e

n

 

Linear Feet

 D 18-inch belt

  <D

 36-inch belt

©

  24-inch

 belt  ©

 42-inch

 belt

©30-inch belt

  ote See structural steel account for bents.

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CONVEYING EQUIPMENT

Conveyors—Open Belt

Erection Manhours

E

o

n

M

a

n

u

Linear Feet

® 18-inch belt ® 36-inch belt

©

 24-inch

 belt ©

 42-inch

 belt

 S)

 30-inch belt

  ote See structural steel account for bents.

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CONVEYING EQUIPMENT

Conveyors—Belt Enclosed

with Walkway

Equipment Cost

E

p

m

n

 

Linear Feet

 D 18-inch belt ®

 36-inch

 belt

© 24-inch belt © 42-inch belt

<§) 30-inch

 belt

  ote

See structural steel account for bents.

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CONVEYING EQUIPMENT

Conveyors—Belt Enclosed

with Walkway

Erection Manhours

E

e

o

M

a

n

s

L in e a r Fe e t

® 18-inch belt D 36-inch belt

© 24-inch belt © 42-inch belt

 E)

 30-inch belt

  ote See structural steel account for bents.

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CONVEYING EQUIPMENT

Conveyors—Spaced, Bucket

Elevators, Belt-Driven

Equipment Cost

E

p

m

e

n

Linear Feet

® 6-x 4-inch buckets

 2) 12-x 7-inch bu ckets

®

  16-

 x

 8 inch

 buckets

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CONVEYING EQUIPMENT

Conveyors—Spaced, Bucket

Elevators, Chain-Driven

Equipment Cost

E

p

m

e

n

 

o

L in e a r Fe e t

 D 6-x 4-inch buckets

 D 12-x 7-inch bu ckets

 S) 16-x

 8 inch

 buckets

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CONVEYING EQUIPMENT

Conveyors—Spaced, Bucket

Elevators,

Chain- or Belt-Driven

Erection Manhours

E

o

n

M

a

n

u

L in e a r Fe e t

® 6-x 4-inch bu ckets

 2) 12-x

 7 inch

 buckets

®

  16-

 x

 8 inch

 buckets

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CONVEYING EQUIPMENT

Conveyors—Continuous, Bucket

Elevators,

Belt-Driven

Equipment Cost

E

p

m

n

 

L in e a r Fe e t

0 8- x 5-inch buckets

 D 16-x

 8 inch

 buckets

® 20-x

 8 inch

 buckets

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CONVEYING EQUIPMENT

Conveyors—Continuous, Bucket

Elevators,

Chain-Driven

Equipment Cost

E

p

m

n

 

L in e a r Fe e t

 D 8-x 5-inch bu ckets

 2) 16-x 8 inch buckets

® 20-x

 8 inch

 buckets

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CONVEYING EQUIPMENT

Conveyors—Continuous, Bucket

Elevator,

Chain- or Belt-Driven

Erection Manhours

E

on

M

a

n

u

L in e a r Fe e t

® 8-x 5-inch bu ckets

 2) 16-x 8 inch buckets

® 20-x

 8 inch

 buckets

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SCREW CONVEYORS

Equipment Cost

Overa l l Conveyor Length-Linear Feet

Screw Diameter:

 D 6 inch  ©16-inch

©9-inch ©18-inch

 E)

 12-inch CD 20-inch

014-inch ©24-inch

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SCREW CONVEYORS

Erection Manhours

E

o

n

M

a

n

u

Overall Conveyor Length Linear Feet

Screw Diameter:

®

 6 inch

  ©16-inch

©9-inch ©18-inch

©12-inch ©20-inch

 D 14-inch ©24-inch

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DRYERS—DRUM

Atm ospheric Sing le Drum Type

Equipment Cost

E

p

m

e

n

 

Approximate Weight Pounds

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DRYERS—DRUM

Atmospheric Double and Twin

Drum Types

Equipment Cost

 

p

m

e

n

 

Approximate Weight Pounds

 D Double drum

©Twin drum

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DRYERS—DRUM

A tmo spheric Single, Double,  nd

Twin Drum Types

Erection Manhours

E

o

n

M

a

n

u

Approximate Weight Pounds

 D Single Drum

©Double Drum

©Twin Drum

Next Page

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DRYERS—VACUUM

Conical R otating Type

Equipment Cost

 

p

m

e

n

 

Approximate Weight Pounds

Previous Page

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DRYERS—VACUUM

Double Drum and Rotary Ty pes

Equipment Cost

 

p

m

e

n

 

Approximate Weight Pounds

0 Double drum

© Rotary—stainless steel

(H)

 Rotary—carbon steel

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DRYERS—VACUUM

Conical R otating an d D ouble

Drum Types

Erection Manhours

E

o

n

M

a

n

u

Approximate Weight Pounds

® Conical rotating

©Double drum

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DRYERS—VACUUM

Rotary T yp es Carbon Stee l and

Stainless Steel

Erection Manhours

 

r

e

o

 

a

n

s

Approximate Weight Pounds

©Carbon Steel

©Stainless Steel

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DUST COLLECTORS

CENTRIFUGAL SCRUBBERS

High Capacity, Low Energy

Loss Type

Hot-Rolled Steel Construction

Equipment Cost

 

p

m

e

n

 

C ap ac ity CFM At 4 . 5

V

  Pressure Drop

(D 12-gauge ®

  6-inch

 plate

(2) 10-gauge ® V4-inch plate

Note: Cfin capacity a t

 2.0-inch

 pressu re drop will equal

approxim ately 67 of above cftn.

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DUST COLLECTORS

CENTRIFUGAL SCRUBBERS

Medium Capacity, Medium

Energy Loss

Hot-Rolled Steel

Equipment Cost

 

p

m

e

n

 

C ap ac ity CFM At 4 .5 P re ssu re Drop

® 12-gauge  (E)  6-inch pl at e

<2) 10 -gaug e (D V4-inch p la te

N ote : Cfm capacity at 2.0-inch pr es su re drop will equal

approximately

  71

of above cfm.

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DUST COLLECTORS

CENTRIFUGAL SCRUBBERS

High Capacity, Low Energy

L oss Type

T304-2B Stainless Steel Construction

Equipment Cost

 

p

m

e

n

 

C apa city CFK At 4 .4 Pr essu re Drop

® 12-gauge ® ^16-inch plate

© 10-gauge ® V4-inch plate

Note: Cfm capacity a t

 2.0-inch

 pressure drop will equal

approximately 67 of above cfm.

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DUST COLLECTORS

CENTRIFUGAL SCRUBBERS

Medium Capacity, Medium

En ergy L oss Type

T304-2B Stainless Steel Construction

Equipment Cost

 

p

m

e

n

 

C ap acity CFK At 4 .5 P re ssu re Drop

® 12-gauge © 6-inch plate

(2) 10-gauge (D

 V4-inch

 plate

Note: Cfrn capacity at

 2.0-inch

 pressure drop will equal

approximately

  71

of above cfm.

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DUST COLLECTORS

CENTRIFUGAL SCRUBBERS

H igh- and M edium -Capacity U n its

Hot-Rolled Steel and T304-2B

Stainless Steel

Erection Manhours

E

o

n

M

a

n

u

C apa city CFM At 4 .5 P re ssu re Drop

® Hot-rolled steel—all thicknesses

©T304-2B stainless st ee l- al l thicknesses

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DUST COLLECTORS

Hot-Rolled Steel—Cyclones

Equipment Cost

 

p

m

e

n

 

C ap ac ity CFM At 6 .0 P re ssu re Drop

(D 16-gauge (g) 12-gauge © 6-inch plate

(2) 14-gauge 0 10-gauge

  ote

Cfin capacity at 2.5-inch pressure drop will equal

approximately two-thirds of above cfin.

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D U ST COLLECTORS

304 Stainless Steel Cyclones

Equipment Cost

 

p

m

e

n

 

C a p a c i t y CFM A t 6 , O P r e s s u r e D r o p

® 16-gauge ® 12-gauge © 6-inch plate

© 14-gauge (D 10-gauge

  ote

Cftn capacity at 2.5-inch pressu re drop will equal

approximately two-thirds of above cfin.

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D U ST COLLECTORS

Hot-Rolled Steel and 304

Stainless Steel Cyclones

Erection Manhours

E

o

n

M

a

n

u

C ap ac ity CFM At 6 .0 P re ssu re Drop

® Hot-rolled steel—all thicknesses

©304 stainless steel—all thicknesses

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D U ST COLLECTORS

F ilter Cartridge or Tu be H ou se

Fi l ters

Equipment Cost

E

p

m

n

 

o

t

Filter Cartridge Or Fabric Filter Square Feet Area

(D

 Filter cartridge

© Fabric filter—tube house

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D U ST COLLECTORS

F ilter Cartridge or Tu be H ou se

Fi l ters

Erection Manhours

E

o

n

M

n

Filter Cartridge Or Fabric Filter Square Feet Area

©Filter cartridge

©Fabric filter—tube house

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DUST COLLECTORS

Packaged Motor Operated

Blowers for Filter Cartridge

and Tube Ho us e Du st Col lectors

Equipment Cost

E

p

m

n

 

Motor Horsepower

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D U ST COLLECTORS

Packaged Motor Operated

Blowers for Filter Cartridge

and Tub e H ou se D u st C ollectors

Erection Manhours

E

on

M

a

n

u

Motor Horsepower

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FANS AN D BLOWERS

Blowers—Rotary to 15 psi

Equipment Cost

 

p

o

n

 

Inlet—CFM

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FANS AN D BLOWERS

Blowers—Rotary to 15 psi

Erection Manhours

E

on

M

a

n

u

Inlet—CFM

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FANS AND BLOWERS

Centrifugal Fans with

Backwardly Inclined Blades

Equipment Cost

 

p

m

e

n

 

Maximum Volume - CFM

®

  5-inches @

 2,300 fpm to 2^-inches

 @

 3 200 fpm

(D  8^-inches

 @

 3 000 fpm to 4^-inches

 @

 4,175 fpm

® 13^-inches

 @

 3 780 fpm to 6 -inches

 @ 5 260

 fpm

(D Above Class Three specification

  ote Performance range designations are indicated by

static pressure (inches of water) at fan outlet ve-

locity (feet per minute). Performance range-sin-

gle width-fan class.

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FANS A N D BLOWERS

Centrifugal Fans with

Backwardly Inclined Blades

Erection Manhours

 

r

e

o

 

a

n

s

Maximum Volume - CFM

  ote

Manhours are for all classes

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FANS AN D BLOWERS

Cast Iron Industrial Fans

Equipment Cost

E

p

m

n

 

Maximum Volume-CFM

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FANS AN D BLOWERS

Cast Iron Industrial Fans

Erection Manhours

E

o

n

M

n

Maximum Volume CFM

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FANS AND BLOWERS

Heavy Sheet Steel Industrial Fans

Equipment Cost

E

p

m

n

 

Max imum Vo1ume-CFM

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FANS AN D BLOWERS

Heavy Sheet Steel Industrial Fans

Erection Manhours

E

o

n

M

n

Maximum Volume-CFM

Next Page

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HEAVY DUTY BELT FE E D E R S

Equipment Cost

E

p

m

e

n

 

Capacity Cubic Feet Per Hour

Previous Page

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HEAVY DUTY BELT FE ED ER S

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Capacity Cubic Feet Per Hour

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PRE-WETT ING DRY CHEMICAL

F E E D E R S

Equipment Cost

E

p

m

e

n

 

Hopper Cubic Feet

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PRE-W ETTING DRY CHEMICAL

F E E D E R S

Erection Manhours

E

o

n

M

a

n

u

Hopper Cubic Feet

  ote Manhours are for mounting on drum or tank or

placed on stand or shelf above tank.

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PRJS-WETTING DRY CHEMICAL

Package Uni t s

Equipment Cost

E

p

m

e

n

 

Tank Gallons

 

Single-tank system

©Two-tank system

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PRE-W ETTING DRY CHEMICAL

F E E D E R S

Package Uni t s

Erection Manhours

E

on

M

a

n

u

Tank Gallons

® Single tank system

© Two tank system

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DRY MATERIAL FE ED ER

E Q U I P M E N T

Vibrating Feeders

Equipment Cost

E

p

m

e

n

 

Tons Per Hour

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DRY MATERIAL FE ED ER

E Q U I P M E N T

Vibrating Feeders

Erection Manhours

 

e

o

 

a

n

s

Tons Per Hour

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DRY MATERIAL FE ED ER

E Q U I P M E N T

Volumetric and Gravimetric

Feeders

Equipment Cost

E

p

m

e

n

 

pproximate Weight In  Pounds

©Volumetric feeders

© Gravimetric feeders

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DRY MATERIAL FE ED ER

E Q U I P M E N T

Volumetric and Gravimetric

Feeders

Erection Manhours

E

on

M

a

n

u

 pproximate W eig h t In Pound s

 

Volumetric feeders

© Gravimetric feeders

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DRY MATERIAL FE ED ER S

W ing and Conveyor T ype s

Equipment Cost

E

p

m

e

n

 

Maximum Cubic Feet Per Hour

(D Wing-type feeders-ratchet drive

® Wing-type feeders-micro maste r drive

® Conveyor type feeders

(3) Sanitary wing-type feeders

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DRY MATERIAL FE ED E R S

W ing and Conveyor T yp es

Erection Manhours

E

on

M

a

n

u

Maximum Cu bic F e e t Per Hour

® Wing-type feeders—ratchet drive

©Wing-type feeders—micro master drive

© Conveyor-type feeders

 

Sanitary wing-type feeders

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GRAVITY FILTRATION U N IT S

Total Material Cost

M

e

a

C

U n i t D i a m e t e r - F e e t

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GRAVITY FILTRATION U N IT S

Total Unit Installation Manhours

I

n

t

 

o

n

M

a

n

u

U n i t D ia m e t e r - Fe e t

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FILTERS

Pressure Type

Equipment Cost

E

p

m

n

 

Diameter Feet

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FILTERS

Pressure Type

Erection Manhours

E

on

M

n

Diameter Feet

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FILTERS

Rubber-Lined

Equipment Cost

E

p

m

e

n

 

Flo w R ate G. P . M.

 

Units on casters with rubber-lined filter and pump.

© In addition to above, includes adequate rubber-lined

steel slurry tank, rubber-lined valves, and rubber-

lined steel fittings.

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FILTERS

Rubber-Lined

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Flow Rate G. P, M.

 

Units on caste rs with rubber-lined filter and pum p.

© In addition to above, includes adequate rubber-lined

steel slurry tank, rubber-lined valves, and rubber-

lined steel fittings.

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FILTER EQUIPMENT

Vibrating Screens

Equipment Cost

E

p

m

n

 

Square Feet S ingle Deck Area

® One-deck screen

©Two-deck screen

©Three-deck screen

  ote Costs of all two-and three-deck screens a re based

on square feet of single deck area.

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FILTER EQUIPMENT

Vibrating Screens

Erection Manhours

 

v

v

l

»

1

a

u

v

Q

 

l

H

J

I

I

u

H

4

U

U

Square Feet S ingle Deck Screen Area

(D One-deck screen

©Two-deck screen

© Three-deck screen

  ote

Manhours for two- and three-deck screens are

based on square feet of single deck area.

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F L A K E R S

Cooling Drum Type

Equipment Cost

E

pm

e

n

 

Approximate Weight Pounds

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F L A K E B S

Cooling D rum Type

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

  pproximate Weight Pounds

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INERT GAS GENERATORS

Equipment Cost

E

p

m

e

n

 

Ra ted Out Put - SCFM In e r t s )

® Indoor construction

© Outdoor construction

© Explosion-proof construction

  ote

Add 3 to above for two-point control. Add 5

to above for automatic output control.

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INER T GAS GENERATORS

Erection Manhours

E

o

n

M

a

n

u

Rated Output SCFM I n e r ts )

O

Indoor construction

® Outdoor construction

® Explosion-proof construction

  ote

Add 1 to above for two-point control. Add

1.5 to above for autom atic output control.

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GAS PULSATION DAM PERS

Equipment Cost

E

p

m

e

n

 

Volume Cubic Inches

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GAS PULSATION DAMPERS

Erection Manhours

E

o

n

M

a

n

u

Volume Cubic Inches

Next Page

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HEATERS

Deaerating Feedwater Type

Equipment Cost

E

q

u

i

p

m

e

n

t

 

o

s

t

O ut let C ap acity Pounds Per Hour

Previous Page

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HEATERS

Deaerating Feedwater Type

Erection Manhours

E

o

n

M

n

Outlet apacity Pounds Per Hour

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HEATERS

Gas-

Oil

and Dual-Fired Heaters

Equipment Cost

 

p

m

e

n

 

Approximate Weight Pounds

® Gas fired

©Oil fired

©Dual fired

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HEATERS

Gas-

Oil- and D ual-Fired T ypes

Erection Manhours

E

r

e

c

t

i

o

n

 

a

n

h

o

u

r

s

Approximate Weight Pounds

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HA IRPIN TYPE

HEAT EXCHANGERS

Equipment Cost

 

p

m

e

n

 

Heat T ra nsf er Surface Square F ee t

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HAIRPIN TYPE

HEAT EXCHANG ERS

Erection Manhours

E

o

n

M

a

n

u

Heat Transfer Surface Square Feet

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HEAT EXCHANGERS

Sh ell and Tub e Fixe d Tub e Sheet

and

 U-Tube

Equipment Cost

 

p

m

e

n

 

Heating Surface Square Feet

® 150# R ating ©   300#  Rating ®  600#  Rating

  ote Above is for carbon steel, straight tube

exchangers. Add following percent to the above

for:

Straight

Tub es U-Tubes Tube Sheet

Carbon Steel - 6% 10%

Stainless Steel 20% 26% 30%

Co pper 10% 16% 20%

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HEAT EXCHANGERS

Sh el l and Tube Fixed Tub e Sheet

and U-Tube

Erection Manhours

E

r

e

c

t

i

o

n

 

a

n

h

o

u

r

s

Heating Surface Square Feet

  ote

Above manh ours a re for 150# rating.

Increase above for:

300# Rating-10%

600# Rating-20%

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HEAT EXCH ANG ERS FOR

HEATING WATER

Equipment Cost

 

p

m

e

n

 

Heating Surface Square Feet

 D

 Carbon stee l she lls, copper-lined h eads, % -inch cop-

pe r U tub es 18 BWG, two-pass, 150-pound con-

struction.

© Carbon s teel shells, copper-lined heads, bronze tu be

sheet, two-pass, 150-pound construction.

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HEAT EXCHA NGER S FOR

HEATING WATER

Equipment Cost

 

p

m

e

n

 

H eat ing Surfac e Square F eet

® Carbon steel shell, %-inch O.D. copper U tub es 18

BWG, two-pass, 150-pound construction.

 2

Carbon steel shell, bronze tu be she et, two-pass, 150-

pound construction.

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E

o

n

M

a

n

u

HEAT EXCHANGERS FOR

H E A T I N G W A T ER

Erection Manhours

Heat ing Surface Square Feet

Next Page

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CENTRIFUGAL PUMPS

Single-Stage Vertical Split Case

Equipment Cost

 

p

m

e

n

 

o

Prime Mover Horsepower

 D

 3,500 rpm—specific gravity of 1.0.

 2)

 1,750 rpm—specific gravity of 1.0.

Previous Page

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CENTRIFUGAL PUMPS

Sing le-Stage H orizontal Split

Case

Equipment Cost

 

p

m

e

n

 

o

Prime Mover orsepower

03,600 rpm—specific gravity of 1.0.

© 1,750 rpm—specific gravity of 1.0.

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CENTRIFUGAL PUMPS

Single-Stage A N SI and API 6 1 0

Equipment Cost

E

q

u

i

p

m

e

n

t

 

o

s

t

Prime Mover Horsepower

(D ANSI pumps—3,500 rpm—specific gravity of 1.0.

(2) ANSI pumps—1,750 rpm — specific gravity of 1.0.

® API

 610

 pumps—3,500 rpm— specific gravity of 1.0.

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CENTRIFUGAL PUMPS

Two-Stage and Multi-Stage

Horizontal Split Case

Equipment Cost

 

p

m

e

n

 

o

Prime Mover Horsepower

® Two-stage, 3,550 rpm—specific gravity of 1.0

©Multi-stage, 3,550 rpm—specific gravity of 1.0

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CENTRIFUGAL PUMPS

Single-Stage In-Line

Ductile Iron and Steel Cased

API-610 Standard

Equipment Cost

E

q

u

i

p

m

e

n

t

 

o

s

t

Motor Horsepower

® Ductile iron—3,550 rpm—specific gravity of 1.0

© Steel Cased, API-610 Standard-3,550 r p m -

specific gravity of 1.0

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GEA R PU M PS

Light and H eavy D uty

Equipment Cost

E

p

m

n

 

Motor Horsepower

©Light duty

©Heavy duty

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SEWAGE PUMPS

Horizontal and Vertical—

1 750 rpm

Equipment Cost

E

p

m

n

 

Motor Horsepower

 D

 Horizontal— l inch solids

  D

 Vertical 2-inch—solids

<2>

 Horizontal—2-inch solids © Vertical 3-inch—solids

© Vertical—l inch solids

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SEWAGE PU M PS

Horizontal—1 750 rpm

Equipment Cost

E

p

m

e

n

 

Motor Horsepower

 D

 Horizontal—2 ineh solids

©Horizontal—3-inch solids

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SEWAGE PUMPS

Horizontal and Vertical—

1 150 rpm

Equipment Cost

E

p

m

e

n

 

Motor Horsepower

® Ho rizontal— l ineh solids

© Horizontal—2-inch solids

 S) Ho rizontal— 2 inch solids

(D Horizontal—3-inch solids

© Vertical—2-inch solids

 §) Vertical—3-inch solids

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S U M F A N D P LU N GE R P U M P S

Equipment Cost

 

p

m

 

n

 

Motor Horsepower

® Sump pumps—3,600 rpm—specific gravity of 1.0

© Sump pumps—1,750 rpm—specific gravity of 1.0

© P lu nger pumps—10 to 350 gpm

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VERTICAL TURBINE PUMPS

Single and Multi-Stage

Equipment Cost

 

p

m

 

n

 

Motor Horsepower

 D 3 550

 rpm—specific gravity of 1.0

© 1,750 rpm—specific gravity of 1.0

 2)

 1,170 rpm—specific gravity of 1.0

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CENTRIFUGAL PUMPS

Single- Two- M ulti- and In-Line

Single Stage

Erection Manhours

E

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Prime Mover Or Motor Horsepower

 D

 Single-stage or in-line single-stage

©Two-stage

©Multi-stage

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G E A R P U M P S

Light and H eavy D uty

Erection Manhours

E

o

n

M

a

n

u

Motor Horsepower

©Light duty

©Heavy duty

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SEWAGE FUMPS

H orizontal an d V ertical

Erection Manhours

E

o

n

M

a

n

u

Motor Horsepower

(D  Horizontal

©Vertical

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S U M P A N D P LU N G ER P U M P S

Erection Manhours

E

r

o

n

M

a

n

u

Motor Horsepower

(D  Sump pumps

© Plunger pumps

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VERTICAL TU RB INE PU M PS

Single- and Multi-Stage

Erection Manhours

E

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Motor Horsepower

Next Page

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REACTOBS

Glass Lined Agitated Jacketed

2 5 and 100 psi

Equipment Cost

E

p

m

n

 

Capacity Gallons

(D

 Glass-lined steel—25 psi

©Glass-lined steel-100 psi

Previous Page

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REACTORS

Glass-Lined Agitated Jacketed

25 and 100 ps i

Erection Manhours

 

on

M

a

n

u

C a p a c i t y - Ga l lo n s

® Glass-lined steel—25 psi

©Glass-lined steel-100 psi

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STEAM JE T EJECTORS

Single-Stage Type

Equipment Cost

E

p

m

n

 

Su ct i on And Discharg e S iz e Inches

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STEAM JET EJECTORS

Single-Stage Type

Erection Manhours

 

on

M

n

Suction nd Discharge Size Inches

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GAS SCRUBBERS

High-Energy Venturi TypeEquipment Cost

 

q

p

m

 

n

 

Approximate Weight Pounds

(T) 12-gauge hot-rolled steel material

(D K-inch plate h ot rolled stee l m aterial

® 12-gauge stain less stee l material

(D %-inch 304 stain less steel material

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GAS SCRUBBERS

High-Energy Venturi Type

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Approximate Weight Pounds

® Hot-rolled steel material

(2) 304 stainless steel materia l

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SEPARATORS

Vane Type

Equipment Cost

E

p

m

n

 

Line Size Inches

(D 275-pound rating

<2)

 720-pound rating

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SEPARATORS

Vane Type

Equipment Cost

E

p

m

e

n

 

Unit Diameter Inches

 D Carbon Steel

 2) Stainless Steel

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SEPARATORS

Vane TyP

6

Erection Manhours

 

M

Line S iz e In ches

(D 150 or 300 raised face flanged— without base

© 150 or 300 raised face flanged— with base

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VIBRATING SEPARATORS

Equipment Cost

E

p

m

n

 

Unit Diameter Inches

0 Carbon steel

©

 Stainless

 steel

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VIBRATING SEPABATORS

Carbon or Stainless Steel

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Unit Diameter Inches

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API TYPE OIL/WATER

SEPARATORS

Packaged Equipment Cost

E

p

m

n

 

Gallons  Per  Minute

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A PI TY PE OIL/WATER

SEPARATORS

Packaged Uni ts

Erection Manhours

 

on

M

a

n

u

Gallons Per Minute

Next Page

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SIZE REDUCTION EQ UIPM EN T

Crushers

Equipment Cost

 

p

m

 

n

 

Horsepower

® Gyratory

©Ja w

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SIZE REDUCTION EQUIPMENT

Crushers

Erection Manhours

 

o

n

 

a

n

u

Horsepower

 D Gyratory

©Ja w

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SIZE REDUCTION EQUIPMENT

Impact Breakers

Equipment Cost

E

p

m

n

 

Horsepower

 D Dual ro tary

© Single rotary

(E) Twin ro tary

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SIZE REDUCTION EQUIPMENT

Impact Breakers

Erection Manhours

 

on

 

a

n

u

Horsepower

® Dual rotary

©

 Single

 rotary

©Twin rotary

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SIZE REDUCTION EQUIPMENT

Reversible and Non reversible

Ha mmermi l l s

Equipment Cost

E

p

m

n

 

Horsepower

® Reversible

© Non-reversible

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SIZE REDUCTON EQU IPMEN T

Reversible and Non reversible

Haxnmermills

Erection Manhours

 

on

M

n

Horsepower

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SIZE REDUCTION EQUIPMENT

Ring Type Granulators

Equipment cost

E

p

m

n

 

Horsepower

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SIZE REDUCTION EQ UIPM ENT

Ring Type Granulators

Erection Manhours

 

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Horsepower

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HOT PROCESS

WATER SOFTENER SYSTEM

Total Process Material and Equipment Cost

T

P

r

o

c

e

s

s

 

m

a

t

e

r

i

a

l

 

n

d

 

E

q

u

i

p

m

e

n

t

 

C

o

s

t

S o f t e n e r D i a m e t e r F e e t

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HOT P RO CE SS WATER

SOFTENER SYSTEMSTotal System Installation Manhours

T

o

t

a

l

 

S

y

s

t

e

m

 

I

n

s

t

a

l

l

a

t

i

o

n

 

M

a

n

h

o

u

r

s

S o f t e n e r D i a m e t e r F e e t

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 P CONE ROOF STORAGE

TANKS

Subcontractor Installed Price

on Foundations by Others

S

b

n

r

a

o

 

n

a

e

d

P

c

Capacity arrels

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 P CONE ROOF STORAGE

TANKS

Subcontractor Installed Price

on Foundations by Others

S

b

n

r

a

o

 

n

a

e

d

P

c

Capacity arrels

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A PI FLOATING ROO F STORAGE

TANKS

Subcontractor Installed Price

on Foundations by Others

S

b

o

n

r

o

 

n

a

e

d

P

c

C a p a c i t y B a r r e l s

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STORAGE TANKS—

A S M E S P H E R E S

Subcontractor Installed Price

on Foundations by Others

S

 

P

Capacity Gallons

 S)  -inch pla te

(D V2-inch pla te

 H)  -inch plate

@ -inch pla te

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TANK HEATING COILS

Fintube Type

Equipment Cost

E

p

m

n

 

Heating Surface Square Feet

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TANK HEATING COILS

Fintube Type

Erection Manhours

 

on

 

a

n

u

Heating Surface Square Feet

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FIRED HEATERS FOR TAN KS

Fintube Type

Equipment Cost

E

p

m

n

 

BTU Per Hour

® Gas-fired

©Oil-fired

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FIRED HEATERS FOR TANKS

Fintube Type

Erection Manhours

 

o

n

 

a

n

u

BTU

  er

  Hour

Gas-

  or oil fired.

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TANK SUCTION AND

LINE TYPE FU E L OIL

HEATERS

Equipment Cost

 

p

m

 

n

 

G all on s P er Hour

© T an k suction typ e- he atin g range 60° to 140° F.

© Line type—heating range 80° to 240° F.

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TANK SUCTION AND

LINE TYPE FU E L OIL

HEATERS

Erection Manhours

 

r

e

c

t

i

o

n

 

a

n

h

o

u

r

s

Gallons Per Hour

©Tank suction type—heating range 60° to 140° F.

© Line type -h ea tin g range 80° to 240° F.

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PROFANE STORAGE TANKS

ASM E 2 5 0 psi— 117 Inch I .D.

Equipment Cost

E

p

m

n

 

S h e l l L e n g t h F e e t

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PROPANE STORAGE TANKS

ASM E 2 5 0 psi— 117 Inch I .D.

Erection Manhours

 

o

n

M

n

Shell Length Feet

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SH O P FABRICATED V ES SE LS

24 Inch Throu gh 14 4 Inch

Diameter

Average Weight—Pounds Per Linear Foot

 

v

e

r

a

g

e

 

W

e

i

g

h

t

 

P

o

u

n

d

s

 

P

e

r

 

L

i

n

e

a

r

 

F

o

o

t

V e s s e l D ia m et er I n ch es

0 Horizontal vessels

 2)

 Vertical vessels w ith legs

® Vertical vessels with skirt plates

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SHOP FABRICATED

HORIZONTAL VESSELS

24 Inch Through 144 Inch

Diameter

Fabricated Cost Per Ton

F

b

c

e

d

 

o

P

T

Vessel Diameter Inches

® S potX-Rayed

(2)100%X-Rayed

Note If drip legs are required, w eigh drip legs and

use 2.40 pe r pound for spo t x-rayed and 2.50

per pound for 100 percent

 x-rayed.

Baffels, draw-off boxes and vo rtex breakers—

estimate weight and price at 20 perc ent of the

vessel per-ton cost.

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SHOP FABRICATED VERTICAL

VESSE LS W ITH ANGLE LEGS

24 Inch Through 144 Inch

Diameter

Fabricated Cost Per Ton

F

b

c

e

d

 

o

P

T

Vessel Diameter Inches

(DSpotX-Rayed

©100%X-Rayed

Note For conical transm ission piece s use thre e lin-

ear feet of the larger vessel diameter weight a t

35%

 of the cost per ton of tha t diam eter vessel.

See othe r graphs for tray rings, trays, and

demisting pad s if required.

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SHOP FABRICATED VERTICAL

VE SSE LS W ITH ANCHOR RING

AND SKIRTS

24 Inch Through 144 Inch

Diameter

Fabricated Cost Per Ton

F

b

c

ed

 

o

P

T

Vessel Diameter Inches

(DSpotX-Rayed

©100%X-Rayed

Note For con ical transmission pieces use three lin-

ear feet of the larger vessel diam eter weight at

35%

 of the cost per ton of tha t diam eter vessel.

See othe r graphs for tray rings, trays, and

demisting pad s if required.

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SH O P FABRICATED TRAY

RINGS

  o s t E a c h

S

p

F

b

c

a

e

d

 

E

h

V e s s e l D i a m e t e r  I n c h e s

® Tray rings for single-pass removable trays

(D Tray rings for two-pass rem ovab le tray s

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COLUMN TOAYS

Shop Installation Only

36 Inch Through 144 Inch

Diameter

Installation Cost Each

S

p

 

n

a

a

o

n

 

E

h

V es s e l D ia m et er  Inches

©Removable type single downflow valve  or  perfo-

rated type trays

© Removable type double downflow valve  or perfo-

rated type trays

Note

Includes shop installation only. Does not include

cost of tray.

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DEM ISTING PADS

Shop Instal lat ion

36 Inch Through 144 Inch Vessel

Diameter

Shop Installation Cost Each

S

p

 

n

a

a

o

n

 

E

h

Vessel Diameter

 

Inches

®

  2-,

 4-,

 or

 6-inch

 pad

 with bottom grid only

© 2 - ,

  4-,

 or

 6-inch

 pad

 with bottom

 and top

 grid

Note Above cost includes furnishing and installing bar

support

 and

 installation only

 of

 pad

 as

 outlined.

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SHOP STRE SS RELIEF OP

V ESSEL

Cost Pter Ton

S

p

 

P

T

n

Total Vessel Weight Tons

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REMOVABLE TYPE TRAYS

14 Gauge Stainless Steel Valve

Trays With Stainless Steel Valve

Discs 24 Inch Tray Spacing

Material Cost Each

M

e

a

 

E

h

Tray Diameter Feet

©Single downflow—410 stainless steel

©  Single  downflow—304 stainless steel

®

  Single

  downflow—316 stainless steel

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REMOVABLE TYPE TRAYS

14 Gauge Stainless Steel Valve

Trays With Stainless Steel Valve

Discs 24 Inch Tray Spacing

Material Cost Each

M

a

e

a

 

E

h

Tray Diameter Feet

(D Double downflow—410 stainless s teel

© Double downflow—304 stainless steel

(S) Double downflow— 316 stainless steel

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DEMISTING FADS

Four Inch Thickness

Material Cost Each

M

a

e

a

 

E

h

Vessel Diameter Inches

 D Carbon steel

 2) 410, 304, or 316 stainless steel

® Monel

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DEMISTING PADS

Pour-Inch Thickness

Top or Bottom Grids only

Material Cost Each

 

e

 

o

E

V es se l D iameter Inches

0 Carbon Steel

(D 410 or 304 Stainless Steel

® 316 Stainless Steel

(D Monel

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V E S S E L S

24 Inch Through 144 Inch

Diameter

Field Erection Manhours Per Ton

E

e

o

M

a

n

o

P

T

V es se l Weight Tons

® Horizontal vessels

© Vertical vessels

Add for following if required:

Remove and replace manway cover—1.3 manhours per tray.

Check tray and tighten retaining bolts—1.8 man- hours pe r tray.

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VESSEL TRAY INSTALLATION

36 Inch Through 144 Inch Vessel

Diameter

Field Erection Manhours Each

E

r

e

c

t

i

o

n

 

a

n

h

o

u

r

s

 

E

a

c

h

V e s s e l D i a m e t e r I n c h e s

® Single downflow valve or perforated tray types

 

Double downflow valve or perforated tray types

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DEMISTING PADS

36 Inch Through 144 Inch Vessel

Diameter

Field Erection Manhours Each

E

e

o

M

a

n

o

 

V es s e l D ia m et er I n ch es

(D 2-, 4-, or 6-inch pad with bottom grid only

©  2-, 4-, or 6-inch pad w ith bo ttom and top grid

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Section 3

SITE PREPARATION

General preparatio n of the plan t site for construction is included in this

section.

Items include, but are not necessarily limited to, clearing, rough grad-

ing, cut, fill, borrow, disposal, soil stabilization, and finish grading.

Soil tests are not considered a part of site preparation and are not in-

cluded. If this is to form a part of the estimate, it must be determined

from other sources.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

A R E A C L E A R A N D G R U B

M anhours Per Acre

Manhours Per Acre

On Site Off Site

Si te Description Disposal Disposal

Light 30.0 40.0

Medium 40.0 50.0

Medium Heavy 50.0 60.0

Heavy 60.0 70.0

Light—Light brush and grass no tree s .

Medium—Considerable brush of larger size.

Medium Heavy—Large brush and small trees .

Heavy—M uch small brush man y small tre es and occasional large tree s.

All manh ours include cutting stacking or piling.

On site disposal manhours include hauling to on site disposal area or on site burning.

Off site disposal manhours include hauling to off site disposal area within five mile radius of

s i te.

Cost of all small tools and construction equipment is included under their respective ac-

counts .

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  RE CUTS ND FILLS

Manhours and Material Cost Per cre

Lan d Av erage C.Y./AC. Av erage M.H. /AC. Pu rcha se

Descript ion

  Cut

  Fil l

  Cut

  Fil l Fi l l /AC.

Leve l

  1,080 532 40.0 5.0

9,400

Slightly Rolling

  1,613 1,080 60.0 10.0

  18,900

Rolling 2,420

  1,613 85.0 15.0

  28,200

Rough 2,952

  1,888 105.0 17.0

  33,100

Ve ry Ro ug h 3,870 2,420

  135.0 22.0

  42,400

Level—Smooth and level no hills.

Slightly Rolling—Level with minor contour changes and small hills.

Rolling—Constant contour changes and small hills.

Rough—Partially level with minor contour changes, slues and valleys.

Very Rough—Constant changes, major hills, slues and valleys.

If ample fill material is available on the site delete above purchase fill cost.

Manhours include removal and on site stock piling top soil and spoil, area cuts and fills to

grade and minor site drainage.

Cost of all small tools and construction equipment is included under their respective ac-

counts.

Fine Grading: Use 1.3 manhours per 100 square yards.

Soil Stabilization:

Material—Use 1.30 pe r square yard.

Labor—Use 0.05 manhours p er square yard.

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Section

SITE IMPROVEMENTS

This section includes items of work that provide permanent improve-

m en ts to the plan t site, such as security fencing, railroad s or spu rs includ-

ing ballast, tank dikes and all sub-base materials for roads, parking areas,

paved areas and railroads, concrete trenches, drainage piping, catch ba-

sins,  manholes and road culverts.

Pavem ents for road s, park ing a reas and process a reas a re included un-

de r Discipline, Pav ing

Site improvem ents will va ry depending on site location, conditions, and

project requirements. For these reasons I have listed unit costs for vari-

ous items that may be required.

The scope of work or plot plan will dictate the items required for site

improvements.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction of this manual before applying this information.

Security Fencing

Fencing is usually listed as a subcontract price in the estimate and as

such includes his overhead and profit.

A six-foot-high chain link fence with three stran ds of barbw ire, line and

corner post em bedded in concrete, top rail and traffic and personnel gates

will cost an average of  15.50 per linear foot. Included in this price is instal-

lation labo r at an average of

 0 35

 manhours per linear foot.

Railroad and Sp urs

Railroads including ballast, ties, tracks, switches, stops, etc., are usu-

ally carried in the e stimate as a subcontract item . The sub-base m aterial

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is usually furnished in place by the earth subcontractor or the general

contractor.

1.  Sub-base material will average 0.75 cubic yards per linear foot of

track (2-rails) at:

Material—$22.00 pe r cubic yard

Labor—0.60 manhours per cubic yard

2.  Railroad and appurtenan ces subco ntracted price including overhead

and profit will average:

Labor and Material—$88.00 pe r linear foot of track (2-rails).

Included in this subco ntract price is the cost of 1.06 m anhours per lin-

ear foot of track.

Tank Dikes

Earth type dikes include the furnishing, placing, and compaction of all

ea rth m aterials. Concrete typ e dikes include all operations for t he form-

ing and placing of concrete.

1.  Earth type dikes material will average 1.60 cubic yards per linear

foot of dike at the average cost of:

Material—$22.00 per cub ic yard

Labor—0.60 m anhours per cubic yard

2.  Concrete type dikes material will averag e 1.4 cubic ya rds of concrete

per linear foot of dike at the average cost of:

Material—$180.00 per cub ic yard

Labor—10.00 manho urs per cubic yard

Concrete Trenches

Concrete trench es two feet wide by two feet d eep, with stan dard sumps

and basins and gra ted cover including all earthw ork , concrete and related

items will average:

Material—$35.00 pe r linear foot

Labor—2.50 manhours per linear foot

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Drainage

Drainage item s such as raw wa ter, oily wa ter, and pressurized system s

will va ry depend ing on pipe size, elevations, etc . The following repr es en ts

an average cost of all items involved:

Material—$30.00 pe r linear foot

Labor—3.00 manho urs pe r linear foot

Catch Basins and Manholes

Catch basins and m anhole size and leng th will va ry depending on capac-

ity and bo ttom elevation. The following a re average for th is type installa-

tion and include all costs for earthw ork , concrete, concrete related item s,

frames and solid or grated covers:

Material—$700.00 each

Labor—25.00 manhours each

Road Culverts

Road cu lverts will vary in size depending on volume requirem ents. T he

following costs are based on using 24-inch reinforced concrete pipe which

seems to be predominant for this item:

Material—$18.00 pe r linear foot

Labor—0.60 manho urs pe r linear foot

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Section 5

CONCRETE

Logarithmic graphs in this section indicate the value of labor in man-

hours and materials in dollars of earthwork, concrete, fireproofing and

grout for equipment foundations and equipment structure foundations.

Earthwork and concrete for buildings are included with the buildings

and are not to be considered here.

The earth and concrete graphs are average and are based on the total

equipment count, even though some pieces of equipm ent m ay not re qu ire

foundations.

Earthwork graphs include labor in manhours for all hand and machine

excavation and backfill. There is also a graph show ing averag e quan tities

of required backfill in the event special fill material is required. Should

special fill materia l be required i t should be priced a t the cur rent m ateria l

value for that particular type of fill.

Concrete graphs include the furnishing, fabricating, and placing of

forms,

 reinforcing steel; miscellaneous embedments; concrete and curing;

protecting and finishing concrete. There is also a graph showing esti-

mated cubic yards of concrete for cost control and reporting purpose.

Piling as such has been excluded. The graphs represent the use of

spread type footings and reflect enough manhour and material values to

include this item if required.

Graphs are included for fireproofing vessel skirts and s truc tura l steel.

Should this not be required, simply disregard these graphs.

The graphs for grouting show average square feet required, for labor

manhours and material value based on total equipment count for equip-

ment support and total tons of steel for base plates.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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CONCRETE FOUNDATIONS

Earth Backfi l l Materials

Cubic Yards

 

c

Y

d

O

 

k

Pieces Of Equipment

©Equipment foundations

©Equipment structure foundations

© Pipe rack or sleeper foundations

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CONCRETE FOUNDATIONS

Excavation and Backfi l l

for Equipment Foundations

Labor Manhours

L

M

a

n

u

Pieces Of quipment

 D Hand excavation

©Machine excavation

 H)

 Hand backfill

®  Machine backfill

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CONCRETE FOUNDATIONS

For Equipment Structures

and Pipe Rack and Sleepers

Labor Manhours

L

b

M

a

n

u

Pieces Of Equipment

Equipment Structures Pipe Rack And Sleepers

 D Hand Excavation © Hand Excavation

© Machine Excavation ©

 Machine

 Excavation

© Hand Backf ll

  CD

 Hand Backfill

 D Machine

 Backfill ®

 Machine

 Backfill

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CONCRETE FOUNDATIONS

Concrete Quantities

Cubic Yards

 

Y

O

P i e c e s  f  Equipment

 D Equipm ent foundations

© Equipment structure foundations

®  Pipe rack and sleeper foundations

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CONCRETE FOUNDATIONS

Forms Reinforcing Embedments

Concrete

Material Cost

T

Pieces Of quipment

0 Equipment foundations

 D Equipment structure foundations

® Pipe rack and sleeper foundations

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CONCRETE FOUNDATIONS

Forms Reinforcing Embedments

Concrete

Installation Manhours

I

n

a

a

o

n

M

a

n

u

Pieces

  f

  quipment

® Equipment foundations

© Equipment structure foundations

©Pipe rack and sleeper foundations

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CONCRETE FOUNDATIONS

Nonshrink—Nonmetal l ic Grout

Average Square Feet

S

F

P ie c e s Of Equipment Or Tons Of S t e e l

© quipment

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CONCRETE FOUNDATIONS

Nonshrink—Nonmetal l ic Grout

Material Cost

M

e

a

C

P ie c e s Of Equipment Or Tons Of S t e e l

©Equipment

©Steel

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CONCRETE FOUNDATIONS

Nonshrink—Nonmetal l ic Grout

Installation Manhours

 

n

s

t

a

l

l

a

t

i

o

n

 

M

a

n

h

o

u

r

s

P i e c e s  f Equipment  r Tons  f  S t e e l

®  quipment

©Steel

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CONCRETE FOUNDATIONS

Fireproof in g Stru ctural S tee l

Total Material Cost

T

a

 

e

a

 

o

Tons  f S t e e l

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CONCRETE FOUNDATIONS

Fireproof in g Stru ctura l Ste el

Installation Manhours

 

n

s

t

a

l

l

a

t

i

o

n

 

a

n

h

o

u

r

s

Tons Of Steel

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CONCRETE FOUNDATIONS

Fireproof in g V essel Sk irts

Material Cost

T

a

 

e

a

 

o

P i e c e s  f Equipment With S k ir ts

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CONCRETE FOUNDATIONS

Fireproof in g V essel Skir ts

Erection Manhours

E

c

on

M

n

u

Pieces Of quipment With Skirts

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Section 6

STRUCTURAL STEEL AND

MISCELLANEOUS IRON

The curve s in this section rep res en t th e m aterial cost in dollars and the

erection manhours requ ired for equipm ent supports equipment struc-

tu re s and piperacks and miscellaneous steel and iron for equipm ent plat-

forms walkways and ladd ers.

All steel items are based on the total pieces of equipm ent even though

some pieces will require no steel.

If pipe racks are not requ ired delete these curve s from the estim ate.

All building steel is included w ith th e bu ildings and is not a pa rt of this

section.

I caution the engine er/estimator to be thoroughly familiar with th e in-

troduction to this manual before applying this information.

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STRUCTURAL STEEL

Tons Required

T

o

 

e

q

r

e

d

Pieces Of quipment

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MISCELLANEOUS IRON

Tons Required

T

n

R

q

r

d

Pieces

  f

  quipment

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PIPE RACK STEE L

Tons Required

T

n

R

q

r

d

P ie c e s Of Equipment

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STRUCTURAL STEEL

Equipment Supports and

Structures

Material Cost

M

e

a

 

Pieces Of quipment

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STRUCTURAL STEEL FOR

PIPE RACKS

Miscellaneous Iron

 for

 Equipment

Material Cost

M

e

a

 

P i e c e s  f  Equipment

© iscellaneous iron

© Pipe racks

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STRUCTURAL STEEL AND

MISCELLANEOUS IRON

Equipment Equipment Supports

and Structures and Pipe R acks

Erection Manhours

E

o

n

M

a

n

u

Pieces Of Equipment

® Structural steel

  Miscellaneous iron

© Pipe racks

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Section

BUILDINGS

The scope of work, for a proposed p roject should include information as

to type and size of buildings required.

The logarithmic graphs included in this section show average labor in

manhours and material dollar cost per square foot of floor area for vari-

ous types of one-story buildings that are more or less standard.

All buildings listed include building earthwork, concrete foundations,

concrete ground floor slabs, structural framing, exterior and interior

finishes, sprinkler system, plumbing, HVAC, and electrical power and

lighting. AU utilities extend five feet outside of building.

Following is a listing of buildings w ith a brief description of the ir typ es

and inclusions.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

Bu ilding Types and D escriptions

Office Building

Structure—Clear span steel framing.

Exterior Walls—Masonry and curtain wall with aluminum entrance.

Interior Walls—Metal studs and drywall with hollow metal doors and

frames.

Ceilings—Suspended and insulated.

Roof—Metal deck with built-up

 roof

roof ventilators, gutters and drains.

Dining Facilities—Coffee bar and dining area.

Plumbing—Water, utility lines, toilets, drains and sprinklers.

HYkC-Ample for size of structure.

Electrical—Lighting and power.

Note No furniture is included.

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Laboratory Building:

Same type construction as office building with additional plumbing and

electrical outlets for laboratory equipment.

Note No laboratory equipment or furniture is included.

Control Building

Structure—Structural steel framing.

Exter io r Walls—Concrete block, hollow meta l frames and doors and steel

sash.

Interior Walls—Office and toilet with metal studs and drywall, hollow

metal frames and doors.

Roof—Pre-cast concrete slabs with insulation and built up

 roof.

Ceilings—Exposed.

Plumbing—Toilet utilities and drinking fountain.

HVAC—Ample for size of structure.

Electrical—Lighting and power.

Note No instrumentation included.

W arehouse B uilding:

Structure—Structural steel framing.

Exterior Walls—Corrugated asbestos or insulated metal siding with hol-

low metal doors and frames, truck doors and steel sash.

Interior Walls—Office and toilet room partitions of metal studs and dry-

wall with hollow metal doors and frames, storage shelv-

ing and bins included.

Roof—Same as exterior wall siding.

Ceilings—Exposed except office and toilet area with same type construc-

tion as interior partitions.

Plumbing—Toilet utilities and drinking fountains.

HVAC-Office area only.

Electrical—Power and lighting.

M aintenance Shop B uilding

Same type construction as warehouse with additional foundations for

shop equipment and including an overhead crane.

Note No shop equipm ent is included.

Change H ouse Bui lding

Same type construction as control building with concrete locker bases,

lockers and additional toilet and shower facilities for men and women.

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BUILDING MATERIALS

Cost Per Square Foot

Materials Only

M

a

t

e

r

i

a

l

 

o

s

t

 

P

e

r

 

S

q

u

a

r

e

 

F

o

o

t

Square Feet Of Floor Area

 D

 Office building ® Warehouse building

 D Laboratory building © Maintenance shop building

 E

Control building ® Change house building

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BUILDING ERECTION

Manhours Per Square Foot

M

a

n

h

o

u

r

s

 

P

e

r

 

S

q

u

a

r

e

 

F

o

o

t

Square Feet Of Floor Area

 D Office building D Warehouse building

© Laboratory building © Maintenance shop building

®

  Control building

  ©

 Change house building

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Section 8

PIPING

In th e absence of plot plans, piping and in strum ent diagram s, and flow

sheets the cost of process piping can be determined from the following

logarithmic graphs.

The graphs are based on total equipment count.

All dollar costs on the m aterial grap hs are avera ge and include the costs

of all pipe, valves, and fittings that should be req uired . C ontrol valve ma-

terial cost is included in the instrumentation section.

Labor manhour graphs are average and include all necessary installa-

tion operations. Installation of control valves furnished under the instru-

mentation section is included here.

The offsite fabrication grap hs include all labor, m ateria l, and shop costs

for furnishing and fabricating pipe spools and delivery within reasonable

distance of job site.

Graphs for und erground potable wa ter, fire loops, etc., include all mate-

rial and labor operations to five feet outside of buildings.

The field x-ray and stress relief graphs are to be considered as subcon-

tract work.

Building piping for plumbing, etc., to five feet outside the building, is

included under the building section and is not to be considered here.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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S H O P F U R N I S H A N D

FABRICATE PIPE AND

FITTINGS

Linear Feet of Pipe For Pieces Of Equipment

 

n

 

O

P

p

P i e c e s  Of  Equipment

©Alloy

  2V2

and over

©Carbon s teel 2V2 and over

© Alloy 2 and under

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S H O P F U R N I S H A N D

FABRICATE PIPE AND

FITTINGS

Cost For Pieces Of Equipment

S

h

o

p

 

F

u

r

n

i

s

h

 

n

d

 

F

a

b

r

i

c

a

t

e

 

T

o

t

a

l

 

C

o

s

t

Pieces Of quipment

O Alloy 2J/2 and over

© Carbon steel 2Vz and over

© A lloy 2 and under

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S H O P F U R N I S H A N D

FABRICATE PIPE AND

FITTINGS

  ost For Pieces of Equipment

S

 

d

t

 

o

s

t

Pieces

  f

  quipment

©Alloy 2^ and over

© Carbon steel 2te and over

©Alloy 2 and under

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FIEL D FU R N ISH FABRICATE

9

A N D ERECT PIPE FITTINGS

A N D VALVES

Linear Feet Of Pipe For Pieces Of Equipment

L

i

n

e

a

r

 

P

e

e

t

 

O

f

 

P

i

p

e

Pieces Of Equipment

 D Carbon steel 2

1

^ and over

 E)

 Carbon steel 2 and under

 S) Steam tracing

 D

 U nderground

© Alloy 2 and under

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FIELD FURNISH

9

  FABRICATE

9

AN D ERECT PIPE

9

  FITTINGS

9

A N D VALVES

Material Cost For Pieces Of Equipment

M

a

e

a

 

a

Pieces Of Equipment

® Carbon steel

  W

  and over

© Carbon steel 2 and under

© Carbon steel underground

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FIEL D FU R N ISH FABRICATE

9

AN D ERECT PIPE FITTINGS

A N D VALVES

Material Cost For Pieces Of Equipment

P ie c e s Of Equipment

© C arb on steel 2% and over

© Carbon steel 2 and under

© Carbon steel underground

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FIELD FU R N ISH FABRICATE

AND ERECT STEAM TRACING

PIPE

FTTTINGS A N D VALVES

Material Cost For Pieces Of Equipment

P ie c e s Of Equipment

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FIELD FUBNISH

9

  FABRICATE

9

A N D ERECT PIPE

9

 FITTINGS

9

A N D VALVES

Material Cost For Pieces Of Equipment

M

a

t

e

r

i

a

l

 

C

o

s

t

Pieces Of Equipment

0  Alloy 2 and under

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FIELD ERECT SHOP

FABRICATED SPOOLS

PIPE

FITT ING S A N D VALVES

Labor Manhours For Pieces Of Equipment

E

r

e

c

t

i

o

n

 

M

a

n

h

o

u

r

s

Pieces Of Equipment

Note: All items include installation of control valves.

©Alloy

 2Mz

and Over

© C arb on Steel 2t e And Over

© Alloy 2 And Under

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FIEL D FU R N ISH FABRICATE

AN D ERECT PIPE FITTINGS

A N D VALVES

Labor Manhours For Pieces Of Equipment

E

r

e

c

t

i

o

n

 

a

n

h

o

u

r

s

P ie c e s Of Equipment

Note: All items include installation of control valves.

® Carbon steel 2

1

^ and over

® Carbon steel 2 and under

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FIELD FU R N ISH FABRICATE

A N D ER EC T

PIPE

FITTING S A N D VALVES

Labor Manhours For Pieces Of Equipment

 

o

n

M

a

n

u

Pieces Of quipment

Note: All items include installation of control valves.

 D Carbon steel underground

© Steam tracing

© Alloy 2 and under

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FIELD FU RNISH

9

  FABRICATE

9

AND ERECT

MISCELLANEOUS PIPING

ITEMS

Material Cost For Pieces Of Equipment

 

a

e

a

 

Pieces Of quipment

 D

 Hangers and supports

© Testing pipe and fittings

© Testing welders

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FIELD FU R N ISH FABRICATE

9

AND ERECT

MISCELLANEOUS PIPING

ITEMS

Total Manhours For Pieces Of Equipment

T

a

M

a

n

u

Pieces Of Equipment

 D Hangers and supports

 2)

 Testing pipe and fittings

© Testing welders

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FIELD FU R N ISH FABRICATE

A N D ER ECT

X-RAY A N D ST RE SS

RELIEVING

Total Subcontract Cost For Pieces Of Equipment

T

o

t

a

l

 

S

u

b

c

o

n

t

r

a

c

t

 

o

s

t

P ie c e s Of Equipment

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Section

ELECTRICAL

Logarithmic graphs in this section reflect the average cost of project

power and lighting excluding building electrical that is included with the

building section.

Power and lighting graph s for m aterial in dollars and labor in m anhours

are included for the battery limit requirements and are based on total

pieces of equipment.

Ins trum entation g raph s are included for the cost of miscellaneous hook-

up materials in dollars and installation of this material in manhours. In-

struments, instrument standards, tray supports, trays, tubes and tube

bundles are discussed in Section 10, Instru m enta tion.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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ELECTRICAL POWER

Power Material Cost

E

Pieces Of Equipment

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ELECTRICAL POWER

Installation Manhours

 

n

 

o

 

a

n

s

P i e c e s

  f

 Equipment

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ELECTRICAL LIGHTING

Lighting Material Cost

L

i

g

h

t

i

n

g

 

M

a

t

e

r

i

a

l

 

o

s

t

Pieces Of Equipment

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ELECTRICAL LIGHTING

Installation Manhours

 

n

 

o

n

 

n

u

Pieces Of quipment

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ELECTRICAL

INSTRUMENTATION

Total Miscellaneous Instrumentation Material Cost

M

i

s

c

e

l

l

a

n

e

o

u

s

 

E

l

e

c

t

r

i

c

a

l

 

I

n

s

t

r

u

m

e

n

t

 

M

a

t

e

r

i

a

l

 

o

s

t

Pieces Of Equipment

  ote Pneumatic instruments and other instrument

materials are included under Instruments.

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ELECTRICAL

INSTRUMENTATION

Miscellaneous Electrical Instrument Manhours

 

a

n

h

o

u

r

s

Pieces Of quipment

  ote Manhours for installation of electrical instrument

materials only. All other instrument manhours

included under In stru m en ts

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Section 10

INSTRUMENTATION

The following graphs represent the average number of instruments re-

quired, their material value in dollars and installation in manhours based

on total pieces of equipment.

Included with the instrument graphs are dollars and manhours for the

furnishing and installation of panel boards.

Other graphs are included for the cost and installation of standards,

tray supports, trays, tubes, and tube bundles.

Material value of control valves is included under this section. The in-

stallation of these valves is discussed in Section 8, Piping.

Furnishing and installation of miscellaneous electrical hook-up materi-

als is discussed in Section 9, Electrica l .

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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I N S T R U M E N T S

Total Number  f  Instruments Required

N

m

b

O

I

n

r

u

m

n

s

P i e c e s

  f

  Equipment

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I N STR U M EN TS

Total Material Cost

 

o

O

f

 

n

r

u

m

e

n

s

Pieces Of quipment

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I N S T R U M E N T S

Total Instrument Installation Manhours

 

n

s

t

a

l

l

a

t

i

o

n

 

a

n

h

o

u

r

s

Pieces Of Equipment

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C O N T R O L V A L V E S

Total Material Cost

 

a

l

v

e

s

 

M

Pieces Of Equipment

  ote

Installation manhours included under Piping.

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STANDA RDS TRAY SUPP OR TS

TRAYS TUB ES A N D TU BE

B U N D L E S

Total Material Cost

T

a

M

e

a

 

Pieces

  f

  quipment

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STANDAR DS TRAY SUPPO RTS

TRA YS TU BE S A N D TU B E

B U N D L E S

Total Installation Manhours

I

n

a

a

o

 

a

n

u

Pieces

  f

  quipment

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Section

INSULATION

The following piping and equipment insulation graphs are based on to-

tal pieces of equipment for a project and are average for various types

and thickness tha t are m ore or less stand ard for refinery and petrochemi-

cal work.

All building insulation is discussed in Section 7, Bu ildings.

Refractories and linings are considered a minor operation for this type

construction and can be estimated on the same basis as insulation.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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INSULATING MATERIAL

Total Square Feet

T

a

 

q

u

a

r

 

P ie c e s Of Equipment

©Pipe

© Equipment

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INSULATING MATERIAL

FOR EQUIPMENT

Total Material Cost

T

a

M

e

a

 

Pieces

  f

  quipment

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INSULATING MATERIAL

FOR PIPING

Total Material Cost

T

o

t

a

l

 

M

a

t

e

r

i

a

l

 

o

s

t

Pieces Of quipment

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INSULATING LABOR FOB

PIPING A ND EQU IPM ENT

Total Manhours

 

Pieces

  f

  quipment

©Pipe

© Equipment

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Section 2

PAINTING

Based on total pieces of equipment the following graphs are average

cost of materials in dollars and labor in manhours for painting.

Material cost includes sandblasting materials as required and protec-

tive coating materials of paint and/or epoxy.

Labor manhours include time required for sandblasting and painting.

Building pain ting is discussed in Section 7, Buildings.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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PAINTING—EQUIPMENT

Square Feet Area

S

F

 

a

Pieces Of Equipment

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PAINTING—STRUCTURAL

STEE L AN D PIPING

Square Feet Area

S

F

 

a

P i e c e s  f  Equipment

(D

 Structural steel

©Piping

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PAINTING—MISCELLANEOUS

A ND PIPE RACK STEE L

Square Feet Area

S

q

u

a

r

e

 

F

e

e

t

 

r

e

a

Pieces Of Equipment

0 Miscellaneous iron

© Pipe rack steel

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PAINTING—EQUIPMENT

Total Material Cost

T

a

M

a

e

a

 

Pieces Of Equipment

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PAINTING—EQUIPMENT

Total Manhours

 

n

n

M

n

Pieces Of quipment

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PAINTING—STRUCTURAL

STEEL

Total Material Cost

T

a

M

a

e

a

 

P i e c e s  f  Equipment

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PAINTING—STRUCTURAL

STEEL

Total Manhours

P

n

n

M

a

u

Pieces Of Equipment

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PAINTING—PIPING

Total Material Cost

T

a

M

a

e

a

 

Pieces

  f

  quipment

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PAINTING—PIPING

Total Manhours

P

n

n

M

n

Pieces Of quipment

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PAINTING—MISCELLANEOUS

AND PIPE RACK STEEL

Total Material Cost

T

a

M

a

e

a

C

P i e c e s  f  Equipment

© iscellaneous iron

© Pipe rack steel

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PAINTING—MISCELLANEOUS

AN D PIPE RACK STEEL

Total Manhours

 

n

n

 

a

n

s

Pieces Of Equipment

©Miscellaneous iron

© Pipe rack steel

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Section 3

PAVING

This section includes items of work for the installation of road, parking

area and yard pavements.

The placement of sub-base materia ls for these item s is described in Sec-

tion 4, Site improvem ent. The furnishing and placing of finish base and

asphalt, concrete or gravel pavement is included.

The scope of work or other proposal documents should indicate the

pav em ent re qu irem en ts. In th e absence of this information, the following

allowances can be added based on the total equipment count.

1.  Asphalt Pavement—40.0 square yards per piece of equipment.

2.  Concrete Pavement—4.5 square yards per piece of equipment.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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ASPHALT PAVEMENT

  Inch

 Base— 2 Inches Asph alt

Total Subcontract Price

T

o

t

a

l

 

S

u

b

c

o

n

t

r

a

c

t

 

r

i

c

e

Square Yards

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CONCRETE AND GRAVEL

PAVEMENTS

Total Material Cost

T

a

M

e

a

 

quare Yards

01 2 -in ch base material and 6 inch reinforced concrete

®

  6 inch

 gravel pavem ent

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CONCRETE AND GRAVEL

PAVEMENTS

Total Manhours

T

a

 

a

n

u

Square Yards

(D 12-inch base material and

 6 inch

 reinforced concrete

©  6 inch gravel pavement

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Section 4

PRORATABLES

M aterials costs in dollars and labor in manhou rs on the following grap hs

reflect the avera ge cost and tim e req uire d for daily area clean-up all

 proj-

ect scaffolding and final te st sta rt-u p and pre-comm issioning assistance.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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P R O R A T A B L E M A T E R I A L

Total Material Cost

T

a

 

a

e

a

 

Pieces Of Equipment

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PROR T BLE L BOR

Total M a n h o u r s

T

a

M

a

n

P i e c e s Of  q u i p m e n t

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Section 15

CONSTRUCTION EQUIPMENT

The average cost of equipment to construct a project can be estimated

from the following logarithmic graphs.

The rental or purchase curve represents the average cost of rental or

purchase of construction equipment to construct the project. This does

not include small tools.

The fuel oil grease and supply curve includes the cost of these items

to operate and maintain the equipment.

The equipment service labor curve represents all labor required to ser-

vice and maintain the construction equipment. This does not include the

operating labor of the equipment when working. Operators are included

in the direct account labor.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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CONSTRUCTION EQUIPMENT

BASE RENTAL OR PURCHASE COST

FU EL OIL GR EA SE A N D

SUPPLIES COST

 

o

Total Direct Field Labor ost In Million Dollars

 D Rental or puchase cost

© F u e l, oil, grease and supplies cost

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CONSTRUCTION EQUIPMENT

SERVICE LABOR

Total Manhours

T

o

t

a

l

 

a

n

h

o

u

r

s

Equipment Rental Or Purchase ost

In Hundred Thousand Dollars

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Section 6

OVERHEADS AND INDIRECTS

Included in this section are logarithmic grap hs reflecting averag e cost

of

 labor

materials, temporary facilities, small tools, consumable supplies,

burdens and benefits, etc., required to supervise and construct a project.

Various items have been grouped together on the following graphs for

ease of listing and application. F or a com prehensive listing of total cover-

age of items un der th is section refer to the overhead and indirect listings

un de r Section 1 Disciplines of Work.

I caution the engineer/estimator to be thoroughly familiar with the in-

troducton to this manual before applying this information.

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INDIRECT LABOR

Engineering and Supervision

Personnel

Total Manhours

 

a

n

u

Tota l D irect Labor  n  Hundred Thousand D o ll a r s

(D

 Engineering personnel

© Supervision personnel

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INDIRECT LABOR

Office Personnel

Total Manhours

T

o

t

a

l

 

a

n

h

o

u

r

s

Total irect Labor In Hundred Thousand ollars

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OTHER INDIRECT A N D

TEMPORARY CONSTRUCTION

LABOR

Total Manhours

T

o

t

a

l

 

a

n

h

o

u

r

s

Total Direct Labor In Hundred Thousand Dollars

® Other Indirect Labor

(D Temporary Construction Labor

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PAYROLL B U R D E N S A N D

B E N E F I T S

Other Indirect and

Temporary Construction

Materials

Total Cost

 

o

T ot al D ir ec t Labor In Hundred Thousand D ol la rs

©Payroll burdens and benefits

 2 Other indirect materials

(H) Temporary construction materials

  ote See next page for continuation of these items.

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PAYROLL B U R D E N S A N D

B E N E F I T S

OTHER INDIRECT MATERIALS

Total Cost

 

o

T o t a l D irec t Lab or In M i l l i o n D o l la r s

 D Payroll burdens and benefits

 E

Other indirect materials

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Section 7

HOM E OFFICE COST

Total engineering design, including construction services such as esti-

m ating, scheduling, expediting, etc., project general m anagem ent, design

allowance, and fee are included as a part of home office cost and as such

are considered under this section.

Manhour range tables listing manhour ranges for single and duplicate

pieces of equipment are included to establish the total home office man-

hours required.

After total manhours are established they are to be spread, on a per-

centage basis, to the various personnel disciplines, as outlined in the fol-

lowing manhour spread percentage table.

Simply by multiplying the established discipline manhours by your es-

tablished discipline rates a total labor manhour and dollar cost is ob-

tained.

Other cost such as bluep rints, reproductions, com puter u se, miscellane-

ous expenses, travel expenses, telephone, telex, postage, and burdens

and benefits a re to be established as a pe rce nt of the total labor dollars in

accordance with the following percentage spread table for these items.

After the total labor and material dollars are established, the estimator

need only apply a cost for design allowance and fee for a complete home

office engineering design cost.

See Section 19, Definition of E stim ate Ad justm ents, for design allow-

ance and fee definitions.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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E N G I N E E R I N G D E S I G N

Manhour Range Allowance

  r   Piece of Equipment

Equipment Classification

Boilers And Heaters

Packaged Steam Boilers

Packaged Electric Hydronic Boilers

Cast Iron Gas Fired Boilers

Steel Boiler Stacks

Fired Heaters

Deaerating Heaters

Classification Equipment

Cone Type Pelletizers

Pressure Sifters

Rotary Screens

Turbo-Screen Classifiers

Compressors And Air Dryers

Reciprocating Gas Engine Compressors

Reciprocating Electric Compressors

Centrifugal Package Unit Compressors

Air Cooled Service Compressors

Air Dryer—Refrigerated Type

Air Dryer—Chiller Type

Conveyors And Bucket Elevators

Conveyor—Open Belt

Conveyor—Belt Enclosed With Walkway

Conveyor—Steel Screw

Conveyor—Reciprocating

Conveyor—Scroll

Conveyor—Spaced Bucket Elevator

Conveyor—Continuous Bucket Elevator

Crystallizers

Batch Vacuum

Mechanical

Dow Therm Units

Manhour Allowance For

Single

Unit Range

800-1,000

800-1,000

650-850

400-500

600-800

600-800

400-600

450-650

400-600

500-700

1 000 1 200

1 000 1 200

850-1,000

600-800

650-850

650-850

800-1,000

1 000 1 200

850-1,000

800-1,000

800-1,000

800-1,000

800-1,000

650-850

700-900

750-850

Duplicate

Unit Range

400-500

400-500

350-450

200-250

300-400

300-400

200-400

225-325

200-400

250-350

600-700

600-700

425-500

300-400

325-425

325-425

400-500

500-600

400-500

400-500

400-500

400-500

400-500

325-425

350-450

300-400

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E N G I N E E R I N G D E S I G N

Manhour Rang e A llowance

Per Piece of Equipment

Equipment Classification

Dry Material Blenders And Feeders

Blenders

Vibrating Packers

Electric Vibrating Feeders

Gravimetric Feeders

Volumetric Feeders

Wing-Type Feeders

Conveyor Type Feeders

Sanitary Type Feeders

Dry Polymer Feeders

Dryers And Flakers

Atmospheric Drum Dryer

Vacuum Drum Dryer

Twin Drum Dryer

Tray Atmospheric Dryer

Tray Vacuum Dryer

Rotary Dryer

Spray Dryer

Cooling Drum Flakers

Dust Collectors

Cyclone

Multi Cyclones

Washers

Automatic Cloth Filters

Centrifugal Precipitators

Electrical Precipitators

Feeder Valves

Ejectors

Single-Stage Noncondensing

Two-Stage Barometric Intercondenser

Extractors

Continuous Centrifugal

Manhour Allowance For

Single

Unit Range

50-100

50-100

50-100

50-100

50-100

50-100

80-150

80-150

70-120

700-900

700-900

800-1,000

800-1,000

800-1,000

800-900

800-900

700-900

700-900

800-1,000

800-1,000

800-1,000

1 000 1 200

1 000 1 200

300-400

200-400

200-400

200-500

Duplicate

Unit Range

20-40

20-40

20-40

20-40

20-40

20-40

30-70

30-70

30-50

350-450

350-400

400-500

400-500

400-500

400-450

400-450

350-450

350-450

400-500

400-500

400-500

500-600

500-600

150-200

100-200

100-200

100-200

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E N G I N E E R I N G D E S I G N

Manhour Range Allowance

Per Piece of Equipment

Equipment Classification

Fans And Blowers

Heavy Gauge Centrifugal Fans

Motors And V-BeIt Drive For Fans

Rotary Blowers

Centrifugal Turbo Blowers

Filters

Pressure Type

Oil Mist Collectors

Plate And Frame Type

Sparkler

Leaf

Sewage And Rotary

Screen Vibrating

Flotation Machines

Gas Holders

Generators

Steam Turbine Units

Inert Gas Generators

Skid Mounted—Diesel Engine Driven

Heat Exchangers, Evaporators And Condensers

Shell And Tube, Floating Head Excha ngers

Shell And Tube, Fixed-Tube Sheet, U-Tube

Exchangers

Steel Fin Tubes, Steel ReBoilers And

Jacketed Pipe

Long Tube Vertical Evaporators

Horizontal Tube Evaporators

Jacketed, Glass Lined Steel Vessel Evaporators

Condensers—Barometric

Manhour Allowance For

Single

Unit Range

600-800

100-150

400-600

600-800

200-300

200-300

200-400

200-300

200-300

300-400

400-600

400-600

150-200

5 000 8 000

2 000 4 000

1 000 2 000

600-800

600-800

600-800

800-900

800-1,000

850-1,050

650-850

Duplicate

Unit Range

300-400

50-60

200-300

300-400

100-150

100-150

100-200

100-150

100-150

150-200

200-300

200-250

50-70

2 000 3 500

800-1,500

300-500

300-400

300-400

300-400

400-450

400-500

425-525

325-425

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E N G I N E E R I N G D E S I G N

Manhour Ran ge Allowance

Per Piece of Equipment

Equipment Classification

Mixers And Blenders For Liquid And Liquid Solids

Propeller Mixers

Blender Type Mixers

Pan And Sigma Mixers

Homogenizers

High Intensity Mixers

Pumps

Centrifugal

Vertical Turbine And Sump

Power And Internal Gear Rotary

Vacuum

Sewage Nonclog

Scales And Weighing Equipment

Mechanical Lever Truck Scales

Electronic Load Cell Truck Scales

Built In Industrial Scales

Automatic Bagging Scales

Bulk Weighing Scales

Separators

Centrifugal Batch Top Suspended

Centrifugal Batch Bottom Driven

Centrifugal Batch Automatic

Centrifugal High Speed

Size Reduction Equipment

Size Reduction Crushers

Size Reduction Mills, Cutters, Pulverizers

Ball Mills

Thickeners

Continuous Type

Manhour Allowance For

Single

Unit Range

50-150

50-150

50-150

60-150

60-150

700-900

850-1,100

700-900

400-600

700-900

1 000 1 200

1 000 1 200

200-300

200-300

300-400

600-800

600-800

700-900

700-900

400-600

400-600

500-700

400-600

Duplicate

Unit Range

20-60

20-60

20-60

25-60

25-60

350-450

425-550

350-450

200-300

350-450

500-600

500-600

100-150

100-150

150-200

300-400

300-400

350-450

350-450

200-300

200-300

250-350

200-300

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E N G I N E E R I N G D E S I G N

Manhour Range Allowance

Per Piece of Equipment

Equipment Classification

Vessels, Reactors And Tanks

Horizontal Pressure Vessels

Vertical Pressure Vessels (Towers)

Agitated, Jacketed Reactors

Vacuum Receiver Tanks

Agitated Tanks

Storage Tanks

Waste Treatment Equipment

Sewage Treatment Plant Package

Incinerators—Liquid Waste

Incinerators—Solid Waste

Solid Waste Shredders

Wastewater Treatment Package System

Water Treating Equipment

Mechanical Surface Aerators

Ion Exchanger Demineralizers

Water Stills

Manhour Allowance For

Single

Unit Range

800-1,000

1 000 1 200

1 000 1 200

800-1,000

700-900

600-1,000

600-800

500-800

500-800

400-600

600-800

850-1,000

600-800

200-300

Duplicate

Unit Range

400-500

500-600

500-600

400-500

350-450

300-500

300-400

250-400

250-400

200-300

300-400

425-500

300-400

100-200

E N G I N E E R I N G D E S I G N

Other Cost as a Percent of

Total Engineering Design Labor Dollars

Item Percent

Blue Pr in ts And Reproduction 14.0

Comp uter Use 12.0

Miscellaneous Exp en se 10.0

Travel Ex pen se 3.0

Telephone, Telex And Postage 4.0

Burdens And Benefits 32.0

Total 75.0

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E N G I N E E R I N G D E S I G N

Manhour Spread Percentages

P e r C e n t

D iscipline 1 2 3__

Op era t ions M ana gem ent 0 .1 0 .1 0 .1

Pr oje ct M an ag em en t 1.5 1.6 1.9

Pro ject E ng in ee r 5 .5 6 .1 7.0

De sign Su pe rv iso r 0.9 1.0 1.0

C ivil /St ru ctu ral 5.2 8.7 6.3

Ve ssels 2.6 2.8 3.1

E lec tric al 5.9 6.5 7.2

P la nt D esign 19.7 17.0 23.8

Pip ing 3.0 2.3 3.8

A dm inis t ra t io n 4.3 4.7 5.0

P & Fs Flow D iag ram s 2.1 2.0 2.7

M echanical Su per visio n 0.4 0.4 0.4

In s t r um en t En gin eer in g 3 .6 5 .0 4 .4

In st r um en t D raf t ing 4.9 6.4 5.8

Ro ta t ing Eq uip m en t 0 .8 0 .8 0 .9

Sp ecial E q u ip m e n t 1.2 1.3 1.4

H ea t T ran sfer 0 .5 0 .5 0.6

Pr oc es s 4.2 4.6 5.1

E st im a ti n g 1.0 1.0 1.1

C os t E ng in ee rin g 1.7 1.3 1.4

C om pu ter 2 .5 2 .5 2.8

Init ial O pe ratio ns 0.1 0.2 0.2

Technical Info rm ation 0.1 0.1 0.1

S ch ed ul in g 2.2 1.5 1.4

Pu rc ha sin g 3.9 3.8 0.0

Insp ect io n/E xp edi t in g 3.9 3.8 0.0

Ste no grap hic 3 .8 4.1 4.6

A cco un ting 8.8 5.8 5.8

Office S er v ic es 1.5 1.6 1.7

C on tra ct Le gal 0 .1 0 .1 0.1

H om e Office C on stru ctio n 2.0 LO OO

To tal 100.0 100.0 100.0

Code:

1—Engineering Procurement And Construction Contract

2—Engineering And Procurement Contract

3—Engineering

  Only Contract

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Section 18

RATIO ESTIMATING FACTORS

Ratio estimating factors are simply the relationship, in percentage

range s, between two or more things and are the transformation of statis-

tical data into combinations of variables that are usually not correlated.

The minimum basic information required to assemble an estimate of

this type is:

1.

  Information regarding plant capacity, product form, basic process

and raw material.

2.  A complete process equipment list with individual shipping dates

and total material dollar cost.

3.

  The general plant location.

The accuracy of this type estimate should fall in the range of + 30% to

- 30%.

Accuracy Definition

+ % = Add to total cost

  excluding contingency

  for highest cost.

- % = Deduct from total cost

  excluding contingency

  for lowest cost.

The direct cost percent ranges in the following tables are to be applied

against th e total m aterial dollar value of the process equipm ent. The con-

struction equipm ent and overhead and indirects perc ent ra ng es are a per-

cent of the direct field labor dollar value. The home office p erc en t rang e is

applied against the total direct and indirect cost of the project.

The percentages for the various disciplines of work are averages of

many projects located in the Gulf Coast Area. When determining a per-

centage to be applied for a specific project from the percentage range ta-

bles consideration should be given to this fact.

The percentages for labor are for open or me rit shop typ e operations. If

closed shop methods are to be employed additional consideration should

be given and applied against the labor dollar value.

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Manhours for the various disciplines of work can be obtained by divid-

ing the labor percentage dollars by the established hourly activity rate.

A construction schedule can be executed utilizing the discipline man-

hours coupled with equipment shipping dates.

Fo r a description of item s included unde r th e va rious disciplines of work

see Section 1, Disciplines of Work.

Ratio Estimating Factors

The Refinery Process Systems table is based on any one or all of the

following process systems and includes all discipline requirements.

1.

  Atmosphere and vacuum crude distillation

2.

  Saturates gas plant

3.  Naphtha hydrodesulphurization

4.  Distillate hydrotreater

5.

  Flexicoker

6. Heavy oil hydrodesulphurization

7.

  Fluid catalytic cracker

8. Unsaturates gas plant

9. Cycle oils hydrodesulphurization

10.

  C

5

, C

6

  isomerization

11.

  Catalytic reformer

12.

  Aromatics extractions

13.

  Steam reforming hydrogen plant

14.

  Butane alkylation

15.

  Olifin poly plant

16.  H

2

S recovery and sulphur manufacturing

Tables on Chemical Plants are self-explanatory.

I caution the engineer/estimator to be thoroughly familiar with the in-

troduction to this manual before applying this information.

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R E F I N E R Y P R O C E S S S Y S T E M S

Ratio Percentages

Direct Cost

Average

Percent

Percentage Ratio Ranges of Totals

Discipline I II HI IV V VI VII

1.

  Process Equipment 100.00 44.30-44.60 7.70-7.80 55.83 92.82 10.03 49.97

2.

  Site Preparation 0.02-0.05 0.25-0.30 2.75-2.85 0.01 0.55 3.59 1.01

3.  Site Improvements 0.95-1.10 * 1.10-1.12 0.55 * 1.43 0.69

4.  Concrete 4.25-4.75 0.10-0.12 12.70-12.90 2.41 0.22 16.42 5.63

5. Structural Steel 8.00-8.30 * 3.70-3.75 4.53 * 4.82 3.90

6. Buildings 1.10-1.25 2.20-2.40 1.70-1.75 0.66 4.81 2.21 1.71

7. Underground Piping 1.10-1.20 * 1.40-1.48 0.62 * 1.84 0.83

8. Above-ground Piping 32.00-35.00 0.75-0.80 21.30-22.40 18.59 1.60 27.51 18.19

9. Underground Electric 0.30-0.50 * 0.65-0 .70 0.16 * 0.87 0.32

10.

  Above-ground Electric 11.50-12.00 * 6.10-6.25 6.47 * 7.90 5.81

11.  Instrumentation 10.30-10.70 * 3.20-3.50 5.82 * 4.16 4.48

12.  Insulation 4.50-5.00 * 7.40-7.50 2.55 * 9.57 3.94

13.  Painting 1.50-1.70 * 3.90-4.00 0.93 * 5.06 1.84

14.

  Paving 0.40-0.60 * 0.60-0.70 0.27 * 0.81 0.36

15.

  Proratables 1.00-1.10 * 2.80-2 .95 0.60 * 3.79 1.32

** lbta l Direct Cost 176.9-183.3 47.6-48.2 77.0-79.7 100.0 100.0 100.0 100.0

* Not applicable or no significant trend data available.

Roman Numeral Codes:

I. Discipline, Other Materials as a percent of Process Equipment costs. 1,1)

II.  Discipline, Subcontracts as a percent of Process Equipment costs. 1,1)

III.

  Discipline, Direct Labor as a percent of Process Equipment costs. 1,1)

IV. Discipline, Material cost as a percent of Total Material costs . IV**)

V. Discipline, Subcontract cost as a percent of Total Subcontract costs. V**)

VI.

  Discipline, Labor cost as a percent of Total Labor cost. VI**)

VII.

 Discipline, Total cost as a percent of Total Direct cost. VII**)

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L I Q U ID T Y P E CH E M IC A L P L A N T

Ratio Percentages

Direct Cost

Average

Percent

Percentag e Ratio Ranges of Totals

Discipline I II H I IV V VI VI I

1.

  Pro cess Eq uipment 100.00 24.00-25.50 3 .75-5.50 43.50 61.30 5.44 37.60

2.

  Site Preparation

  1.75 2.50

  0.01-0.01 0.50-1.00 1.00 0.01 0.72 0.82

3 .

  Site Imp rovem ents 2.75-3.50 0.60-0.75

  1.50 2.25

  1.30 1.74 2.95 1.70

4.

  Co ncre te 7.50-8.75 2.00-3.00 9.00-12.00 3.58 6.30 15.04 6.39

5.

  St ructu ral Stee l 11.50-12.50 * 4.00-6.00 5.20 * 6.51 4.89

6. Buildings 4.00-5.00 3.00-3 .50 3.50-4.50 1.90 8.23 6.08 3.55

7.

  Un derg roun d Piping 4.00-5.00 0.01-0.02 2.75-3 .25 2.00 0.02 4.04 2.17

8. Above-ground Piping 37.00-43 .00 2.75-3 .25 24.00-27.00 18.30 7.35 34.54 20.40

9. Undergrou nd Elec tric 0.40-0.60 * 0.20-0.40 0.20 * 0.39 0.25

10.

  Above-ground Electric 15.00-17.00 * 6.50-7.75 7.20 * 9.50 6.85

11.

  Instru menta tion 22.00-25.00 * 3.25-4.50 10.90 * 4.59 8.24

12.

  Insula tion 7.50-8.50 * 4.50-5.25 3.60 * 6.44 3.74

13.  Painting 2.50-3 .25 * 2.75-2.90 6.30 * 3.93 1.70

14.

  Paving  1.00 1.50  0.30-0.40 0.50-1.00 0.50 0.85 1.05 0.66

15.

  Proratables

  1.00 1.50

  * 2.00-2 .40 0.60 * 3.09 1.04

** Total Direc t Cost 217.9-23 7.5 32 .57-36.43 68.7-85.7 100.0 100.0 100.0 100.0

* Not applicable or no significant trend data available.

Roman Numeral Codes:

I. Discipline, O ther Materials as a perc ent of Process Equ ipment costs. (1,1)

II .

  Discipline, Sub contrac ts as a pe rcen t of Process Equipm ent costs. (1,1)

I I I .

  Discipline, Direct Labo r as a percen t of Process Equ ipm ent costs. (1,1)

IV. Discipline, M aterial cost as a pe rce nt of Total Material costs. (IV**)

V. Discipline, Subcontract cost as a perc ent of Total Subcontract co sts. (V**)

V I.

  Discipline, Labor cost as a perce nt of Total Labor cost. (VI**)

VII .

 Discipline, Total cost as a percent of Total Direct cost. (VII**)

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SOLID TYPE CHEMICAL PL AN TS

Ratio Percentages

Direct Cost

Average

Percent

Percentage Ratio Ranges of Totals

Discipline I II IH IV V VI V l T

1.  Process Equipment 100.00 25.00-26.00 3.75-4.75 44.16 69.24 4.99 37.80

2.  Site Preparation 2.50-3.00 0.01-0.01 0.50-1.00 1.19 0.02 0.78 0.97

3.  Site Improvements 3.50-3.75 0.80-0.90 2.25-3.00 1.57 2.32 3.20 2.02

4.  Concrete 8.75-10.25 2.50-3.00 12.00-13.75 4.33 7.37 17.08 7.59

5. Structural Steel 12.50-14.30 * 5.50-6.25 6.30 * 7.06 5.81

6. Buildings 5.00-5.50 3.75-4.25 4.00-5.25 2.34 10.99 6.51 4.22

7. Underground Piping 4.75-5.50 0.01-0.01 3.00-3.25 2.18 0.02 4.05 2.38

8. Above-ground Piping 45.50-46.00 3.25-3.50 27.00-28.25 20.27 9.06 34.59 22.37

9. Underground Electric 0.50-0.70 * 0.30-0.50 0.25 * 0.35 0.25

10.

  Above-ground Electric 15.50-17.00 * 6.75-7.25 7.35 * 8.72 6.89

11.

  Instrumentation 12.25-14.00 * 1.50-2.50 5.51 * 2.11 4.14

12.  Insulation 5.50-6.50 * 3.00-4.00 2.47 * 4.03 2.56

13.  Painting 2.00-2.75 * 1.75-2.25 0.91 * 2.46 1.17

14.

  Paving 1.10-1.80 0.30-0.40 0.75-1.00 0.52 0.98 0.98 0.68

15.

  Proratables 1.40-1.75 * 2.25-2 .50 0.65 * 3.09 1.15

  Tbtal Direct Cost 220.8-232.8 36.12-38.07 74.30-85.50 100.0 100.0 100.0 100.0

* Not applicable or no significant trend data available.

Roman Numeral Codes:

I. Discipline, Other Materials as a percent of Process Equipment costs. 1,1)

II.  Discipline, Subcontracts as a percent of Process Equipment costs. 1,1)

III.

  Discipline, Direct Labor as a percent of Process Equipment costs. 1,1)

IV. Discipline, Material cost as a percent of Total Material costs. IV**)

V. Discipline, Subcontract cost as a percent of Total Subcontract costs. V**)

VI.  Discipline, Labor cost as a percent of Total Labor cost. VI**)

VII.

 Discipline, Total cost as a percent of Total Direct cost. VII**)

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L I Q U I D / S O L I D T Y P E C H E M I C A L P L A N T S

Ratio Percentages

Direct Cost

Average

Percent

Percentage Ratio Ranges of Totals

Discipline I II HI IV V VI VII

1.  Process Equipment 100.00 25.00-26.50 4.00-6.00 42.00 70.31 4.93 36.52

2.  Site Preparation 2.25-3.00 0.01-0.01 0.60-1.25 1.08 0.02 0.74 0.90

3.  Site Improvements 3.30-3.80 0.75-0.85 2.25-3.00 1.43 2.25 3.02 1.87

4.  Concrete 9.25-10.50 2.75-3.50 12.50-14.00 3.94 7.16 16.15 7.01

5. Structural Steel 13.50-14.50 * 5.50-6.50 5.73 * 6.68 5.37

6. Buildings 5.00-5.50 3.75-4.25 4.75-5.25 2.13 10.67 6.16 3.90

7. Underground Piping 4.50-5.25 0.01-0.01 3.00-3.50 1.94 0.01 3.75 2.15

8. Above-ground Piping 43.00-45.00 3.00-3.50 25.50-28.00 18.06 8.62 32.03 20.25

9. Underground Electric 0.60-0.90 * 0.30-0.50 0.25 * 0.36 0.25

10.

  Above-ground Electric 17.00-18.00 * 7.15-8.00 7.30 * 9.00 6.94

11.  Instrumentation 24.00-27.00 * 3.30-4.60 10.48 * 4.17 8.00

12.  Insulation 8.00-9.00 * 4.50-5.50 3.37 * 5.72 3.55

13.  Painting 3.00-3.50 * 2.80-3 .10 2.14 * 3.49 1.62

14.

  Paving 1.25-1.75 0.30-0.50 0.75-1.25 0.47 0.96 0.94 0.63

15.

  Proratables 1.50-2.00 * 2.25-2.50 0.58 * 2.86 1.04

** Total Direct Cost 237.2-249.7 35.57-39.12 79.15-92.95 100.0 100.0 100.0 100.0

* Not applicable or no significant trend data available.

Roman Numeral Codes:

I. Discipline, Other Materials as a percent of Process Equipment costs. 1,1)

II.  Discipline, Subcontracts as a percent of Process Equipment costs. 1,1)

III.

  Discipline, Direct Labor as a percent of Process Equipment costs. 1,1)

IV. Discipline, Material cost as a percent of Total Material costs. IV**)

V. Discipline, Subcontract cost as a percent of Total Subcontract costs. V**)

VI.

  Discipline, Labor cost as a percent of Total Labor cost. VI**)

VII.

 Discipline, Total cost as a percent of Total Direct cost. VII**)

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CHEMICAL PLANT—LIQUID HIGH PRESSURE TYPE

4 TO 5 PSI

Ratio Percentages

Direct Cost

Average

Percent

Percentage Ratio Ranges of Totals

Discipline

  I II III IV V VI VII

1.

  Process Equipment 100.00 25.00-26.00 3.75-5.00

  43.16

 74.86

  5.34 38.1

2.

  Site Preparation

  1.70 2.25

  0.01-0.01 0.25-0.50

  0.75 0.01 0.54 0.63

3.  Site Improvements 2.30-3.00 0.50-0.75  1.50 1.75  0.99 1.62 2.21 1.31

4.

  Concrete 6.50-7.25

  1.75 2.00

  9.25-10.00

  2.92 5.30 12.62 5.26

5.

  Structural Steel 9.00-10.00

 

3.50-4.00

  3.98 4.88 3.78

6. Buildings 3.25-4.00 2.50-3.00 3.25-3.75

  1.48 7.67 4.50 2.75

7.  Underground Piping 4.75-5.25 0.01-0.01 3.00-3.25  2.12 0.02 4.30 2.38

8. Above-ground Piping 45.25-47.00 3.25-3.50 27.00-28.00  19.66 9.72  36.75 22.38

9.  Underground Electric 0.50-1.00

 

0.25-0.40

  0.25 0.38 0.25

10.

  Above-ground Electric 16.50-17.25

 

6.75-7.25

  7.19 9.34 6.94

11.

  Instrumentation 26.50-27.50

 

3.50-4.00

  11.66 4.88 9.04

12.  Insulation 8.00-8.50  4.50-5.00  3.54 6.33 3.79

13.  Painting 2.75-3.25  2.75-3.00  1.30 3.86 1.73

14.

  Paving 0.75-1.25 0.02-0.04 0.50-0.70

  0.37 0.80 0.79 0.51

15.

  Proratables

  1.25 1.50 

2.00-2.50

  0.63 3.28 1.15

** Total Direct Cost 229.0-239.0 33.04-35.31 71.75-79.10 100.0

  100.0 100.0 100.0

* Not applicable or no significant trend data available.

Roman Numeral Codes:

I. Discipline, Other Materials as a percent of Process Equipment costs. 1,1)

II.

  Discipline, Subcontracts as a percent of Process Equipment costs. 1,1)

III .  Discipline, Direct Labor as a percent of Process Equipment costs. 1,1)

IV.  Discipline, Material cost as a percent of Total Material costs. IV**)

V. Discipline, Subcontract cost as a percent of Total Subcontract costs. V**)

V I.  Discipline, Labor cost as a percent of Total Labor cost. VI**)

VII. Discipline, Total cost as a percent of Total Direct cost. VII**)

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C H E M I C A L P L A N T — L I Q U I D H I G H A L L O Y T Y P E

Ratio Percentages

Direct Cost

Average

Percent

Percentage Ratio Rang es of Totals

Discipline I II H I IV V VI V l T

1.  Process Equipment 100.00 25.00-25.50 3.75-4.25 45.58 75.07 5.74 40.18

2.

  Site Preparation  1.50 2.00  0.01-0 .01 0.25-0.50 0.81 0.01 0.59 0.68

3 .

  Site Improvem ents 2.25-3.00 0.50-0.75

  1.50 1.75

  1.07 1.65 2.42 1.42

4.  Concrete 6.25-7.00  1.50 2.00  8.75-10.00 2.95 5.09 12.97 5.31

5.

  Stru ctura l Steel 9.25-9.75 * 3.50-3.75 4.28 * 5.35 4.06

6. Buildings 3.25-4.00 2.50-3.00 3.25-3 .50 1.59 7.84 4.93 2.95

7.

  Un derground Piping 4.50-5.00 0.01-0.01 3.00-3 .50 2.18 0.02 4.51 2.45

8. Above-ground Piping 44.25-45.00 3.00-3 .25 26.00-27.50 20.24 9.51 38.51 23.01

9. Undergroun d Electric 0.25-0.50 * 0.01-0.02 0.17 * 0.27 0.18

10.

  Above-ground Electric 11.00-12.00 * 4.50-5.25 5.06 * 6.69 4.88

11.  Instrumentatio n 23.50-25.00 * 3.00-4.00 10.75 * 4.58 8.31

12.

  Insulation 6.75-7.25 * 3.50-4.00 3.11 * 5.67 3.33

13.  Painting 2.50-3 .00 * 2.25-2.50 1.14 * 3.46 1.52

14.

  Paving 0.75-1.00 0.25-0.50 0.50-0.70 0.42 0.81 0.87 0.54

15.

  Proratables

  1.25 1.50

  * 2.00-2 .50 0.65 *• 3.44 1.18

** Total Direct Cost 217.3-226.0 32 .77-35 .02 65.76-73 .72 100.0 100.0 100.0 100.0

* Not applicable or no significant trend data available.

Roman Numeral Codes:

I. Discipline, Other Materials as a perc ent of Process Equ ipment costs. (1,1)

II.

  Discipline, Subcontracts as a perc ent of Process Eq uipm ent costs. (1,1)

I I I .

  Discipline, Direct L abor as a percent of Process Equipm ent costs. (1,1)

IV. Discipline, Material cost as a pe rcent of Total Material costs. (IV**)

V. Discipline, Subcontract cost as a percent of Total Sub contract costs. (V**)

V I.

  Discipline, Labor cost as a percent of Total Labor cost. (VI**)

VII .

 Discipline, Total cost as a percent of Total Direct cost. (VII**)

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C O N S T R U C T I O N E Q U I P M E N T

Ratio Percentages

A s A Percent Of Direct Field Labor

Percent of

Direct Field Labor

Description Range Average

16.

  Rental or Purchase 12.0-18.0 15.0

17.

  Service Labor 2.0-6.0 4.0

18.

  Fu el, Oil, Grease, Supplies 7.0-15.0 1^0

Tbtal 21.0-3 9.0 31.0

Note Fuel percentage based on diesel cost of $1.25 per gallon.

O V E R H E A D A N D I N D I R E C T S

Ratio Percentages

As A Percent Of Direct Field Labor

Percent of

Direct Field Labor

Description Range Average

19.  Salaried Ind irec t 8.0-12.0 10.0

Office Hourly Ind irec ts 4.0-8.0 16.0

Field Hourly Indirects 3.0-7.0 5.0

20.

  Tem porary Construction 10.0-20.0 15.0

Facilities*

21.

  Burdens and Benefits 25.0-28.0 27.0

22 .

  Small Tools and Consumables 5.0-10.0 7.0

23.  Othe r Ind irects 10.0-20.0 1^0

Tbtal 65.0-105.0 85.0

* Includes Labor for Constructing.

H O M E O F F I C E S E R V I C E S

Ratio P ercentages

As A Percent Of Tbtal Direct And Indirect Cost

Percent of Total

Direct and Indirect

Description Range Average

24.

  Engineering/Design Services 8.0-16.0 12.0

25.

  Construction Services 0.1-0.4 0.2

26.

  Project General Management  1.0 1.5  U

Tbtal 9.1-17.9 13.3

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Section 19

ESTIMATE ADJUSTMENTS

Ea ch estim ate , in all probab ility, will need some or all of the following

adjustments dependent upon the scope of work, amount of pre-bid infor-

mation available, and th e ty pe of estima te to be p rep are d. T he following

are definitions of these adjustments:

D e s i g n A l lo w a n c e The design allowance is an adjus tment to the es-

timated mechanical equipment cost to provide for nominal and routine

changes in equ ipm ent design. The design allowance is included in the de-

tails of the estim ate and is considered as pa rt of the

  direct b se cost

The

magnitude of the design allowance is a function of the amount of design

information available to the estimator, and it decreases as the accuracy

level of the estimate increases. An example of a design allowance is the

addition of money for routin e nozzle and clip changes on a fabricated ves-

sel. It is expected that all design allowance money will be expended dur-

ing the project.

Q u a n t i t y A l l o w a n c e The quantity allowance is an adjustment to

the estimated construction activity take-off quantities to provide for (1)

the difference between neat take-off quantities and in-place quantities

and for (2) consideration of fabrication waste. The quantity allowance is

included in the details of the estimate and is considered as a part of the

direc t base cost. The m agn itude of the q uantity allowance is a function of

the amount of design information available to the estimator and de-

creases as the accuracy level of the estimate increases. An example of a

qu an tity allowance is adding to the piping take-off an allowed quantity of

small diameter pipe and valves for vents and drains not shown on esti-

mate drawings. It is expected that all quantity allowance money will be

expended during the project.

E s c a l a t i o n The escalation is the amount of dollars or percentage of