john s. page, conceptual cost estimating manual

CONCEPTUAL COSTESTIMATING

MANUALS E C O N D E D I T I O N

J O H N S . P A G E

An Imprint ofElsevier

Conceptual CostEstimating

Manual2nd 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 withoutpermission of the publisher.Permissions may be sought directly from Elsevier's Science and Technology Rights Department inOxford, UK. Phone: (44) 1865 843830, Fax: (44) 1865 853333, e-mail: [email protected] may also complete your request on-line via the Elsevier homepage: http://www.elsevier.com byselecting "Customer Support" and then "Obtaining Permissions".

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10 9 8 7 6

Library of Congress Cataloging-in-Publication DataPage, John S.

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

p. cm.ISBN 0-88415-267-71. Chemical plants—Design and construction—

Estimates—Handbooks, manuals, etc. I. Title.TH4524.P34 1996690'.54—dc20 95-52313

CIP

Printed in the United States of America.Printed on acid-free paper (oo).

PREFACE

Long has been the need for a manual on conceptual cost estimating that allowsthe construction industry and the engineering/management staff of chemical, refin-ery, and industrial plants to arrive at a reasonable cost for a specified facility. Sim-ply to rely on past records and say that a certain type plant will cost ten dollars perpound produced, and the product can be sold for fifteen dollars per pound, by nomeans justifies the construction cost of the plant. Management of all organizationsconcerned 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 completedesign and definitive estimate would be, in most cases, too great to justify thedesign and estimate. Therefore, it becomes apparent that a less expensive methodis needed to determine the feasibility of the plant in mind. By using a very moder-ate flow sheet design, specifications, and/or equipment lists, by properly applyingman-hours, dollars, percentage values (as are shown throughout this manual ingraph and table form), and construction indexes, and by considering other itemsoutlined in the Introduction, a total cost very close to the as-built cost of a com-plete plant should be obtainable for any location in the world.

The Human Factor in Estimating

In this high-tech world of sophisticated software packages, including several forlabor and cost estimating, you might wonder what an estimating manual offers thata computer program does not. The answer is the human factor. In preparing a com-plete estimate for a refinery, petrochemical, or other heavy industrial project oneoften 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 seemthat such numerous variables provide the perfect opportunity for computerizedalgorithmic solution, accurate, cost-effective, realistic estimating is still largely afunction of human insight and expertise. Each project has unique aspects that stillrequire the seasoned consideration of an experienced professional, such as gener-al economy, projects supervision, labor relations, job conditions, constructionequipment, and weather, to name a few.

Computers are wonderful tools. They can solve problems as no human can, butI do not believe construction estimating is their forte. I have reviewed several con-struction estimating software packages and have yet to find one that I would com-pletely rely on. Construction estimating is an art, a science, and a craft, and I rec-ommend that it be done by those who understand and appreciate all three of thesefacets. This manual is intended for those individuals.

John S. Page

INTRODUCTION

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

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

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

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

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

Due to the ever-changing economic conditions, the use of what is known throughoutthe 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 valuefor a project to be designed and constructed at some future date. Indices are simplynumbers for a time frame indicating a percentage of change in regard to a relative costof a base time frame. There have been many pro and con discussions as to the use ofindices; however, they are still the only means for achieving an acceptable estimatewhere 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 andGas Journal. The engineer/estimator may wish to use other indices that he is morefamiliar with and has more confidence in. Should this be the case, it is to be recognizedthat 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%. Theengineer/estimator must determine the labor productivity he feels he can achieve foreach project and may acjjust the graph and table manhours as may be required. Majoritems that one should consider in determining productivity are:

1. General Economy2. Project Supervision3. Labor Relations4. Job Conditions5. Construction Equipment6. 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 thelisting by craft of the various personnel required for a crew—such as general foreman,foreman, craftsmen, and apprentices/helpers—and the weighted percentage of theirtime that will be devoted to the crew. The weighted percentage of each classificationmultiplied by the hourly rate for that classification will result in the weighted hourly ratefor each. The sum of all weighted rates will equal the composite crew hourly rate. Thetotal percent of all crew personnel is to equal 100. Using the composite crews and rates,activity crews and rates are to be formed. List the composite crew rates and the weight-ed percent of time each crew will be devoted to the activity. The weighted percent ofeach composite crew multiplied by the weighted composite crew rate will result in theweighted hourly activity rate for that crew. The sum of all weighted crew rates for theactivity will equal the hourly weighted activity rate. The total percent of all compositecrew personnel is to equal 100. See Section One for description of disciplines of workto determine activity crew personnel needed.

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 January1, 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, andvendor or subcontractor.

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

1. Mobilization and demobilization of personnel and equipment2. Foreign differential labor pay3. Permits, licenses, fees, duties4. Load out, tie down and material handling5. Transportation and ocean or air freight6. Camp, family quarters, field office, and storage facilities7. Rest and recreation for personnel

Method One—Accuracy Level of ±10%

A method one, semi-definitive conceptual estimate is defined as one that will producemajor discipline quantities, manhours and labor, material, subcontract and total dollarsfor 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 bethe 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 costwould be achieved. With the overall results of all major disciplines of work the projectcan 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 material2. Total general specifications3. Plant location (site conditions)4. Preliminary soils report with foundation recommendations5. Plot plan and equipment arrangements.6. P. & I.D.'s. (mechanical flow sheets)7. Equipment list8. Buildings listing type, size, and description

This same type estimate can be assembled with far less information than that listedabove 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 knowntotal process equipment material cost and that applies weighted percentages againstthat 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 andmanhours can be achieved by dividing the material dollars by the pre-established unitdollar rate, as outlined in the graphs and tables, and the labor dollars by a pre-estab-lished composite activity rate.

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 material2. Knowledge of general specifications3. 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 becausethe items tend to average each other out.

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

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Contents

Preface .................................................................................... xv The Human Factor in Estimating .................................................. xv

Introduction .............................................................................. xvi

Section 1. Disciplines of Work .......................................... 1 Section Introduction ....................................................................... 1 Direct Cost Items ........................................................................... 1 Construction Equipment ................................................................ 3 Overhead and Indirects ................................................................. 3 Home Office Cost .......................................................................... 10

Section 2. Process Equipment ......................................... 11 Section Introduction ....................................................................... 11 Acid Coolers with Pump and Motor .............................................. 12

Equipment Cost ............................................................... 12 Erection Manhours .......................................................... 13

Activators – Vibrating Bin .............................................................. 14 Equipment Cost ............................................................... 14 Erection Manhours .......................................................... 15

Aerators – Mechanical .................................................................. 16 High-speed – Equipment Cost ......................................... 16 High-speed – Erection Manhours .................................... 17 Low-speed – Equipment Cost .......................................... 18 Low-speed – Erection Manhours ..................................... 19

vi Contents

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

Compressors ................................................................................. 20 Air Power – Synchronous Motor Driven – Equipment

Cost ........................................................................ 20 Air Power – Induction Motor Driven – Equipment

Cost ........................................................................ 21 Air Power – Synchronous and Induction Motor Driven

– Erection Manhours ............................................... 22 Automotive and Industrial Service Air – Equipment

Cost ........................................................................ 23 Automotive and Industrial Service Air – Erection

Manhours ................................................................ 24 Centrifugal Air – Plant and High-pressure –

Equipment Cost ...................................................... 25 Centrifugal Air – Plant and High-pressure – Erection

Manhours ................................................................ 26 Industrial Air – Air-cooled, Two-stage – Equipment

Cost ........................................................................ 27 Industrial Air – Air-cooled, Two-stage – Erection

Manhours ................................................................ 28 Integral Gas Engine – Four Cylinder – Equipment

Cost ........................................................................ 29 Integral Gas Engine – Four Cylinder – Erection

Manhours ................................................................ 30 Packaged Air – Single-stage, Water-cooled –

Equipment Cost ...................................................... 31 Packaged Air – Single-stage, Water-cooled – Erection

Manhours ................................................................ 32 Reciprocating – Electric Motor Driven – Equipment

Cost ........................................................................ 33 Reciprocating – Electric Motor Driven – Erection

Manhours ................................................................ 34

Contents vii


Two-stage, Two-cylinder, Water-cooled – Equipment Cost ........................................................................ 35

Two-stage, Two-cylinder, Water-cooled – Equipment Cost ........................................................................ 36

Two-stage, Two-cylinder, Water-cooled – Erection Manhours ................................................................ 37

Dryers – Air .................................................................................... 38 Automatic, Refrigerated – Equipment Cost ...................... 38 Automatic, Refrigerated – Equipment Cost ...................... 39 Automatic, Refrigerated – Erection Manhours ................. 40 Automatic, Refrigerated – Erection Manhours ................. 41 Chiller – Equipment Cost ................................................. 42 Chiller – Erection Manhours ............................................ 43

Surge Arresters ............................................................................. 44 Hydrocarbon and Water Service – Equipment Cost ......... 44 Hydrocarbon, Water, and Sewage Service –

Equipment Cost ...................................................... 45 Hydrocarbon, Water, and Sewage Service – Erection

Manhours ................................................................ 46 Blenders, Mixers, Packers, and Feeders ...................................... 47

Dry Material Auger and Rotary Drum Blenders – Equipment Cost ...................................................... 47

Dry Material Auger and Rotary Drum Blenders – Erection Manhours .................................................. 48

Fixed Side Mounted Mixers with Top Motors – Equipment Cost ...................................................... 49

Fixed Side Mounted Mixers with Top Motors – Erection Manhours .................................................. 50

Plate Mounted Open Tank Mixers – Equipment Cost ...... 51

viii Contents


Portable Clamp and Flanged Mounted Mixers – Equipment Cost ...................................................... 52

Flanged Top Tank Mounted and Plate Mounted Open Tank Mixers – Erection Manhours ........................... 53

Gearmotor Mixers – Equipment Cost ............................... 54 Gearmotor Mixers – Erection Manhours .......................... 55 Batch and Pipeline Homogenizer Mixers – Equipment

Cost ........................................................................ 56 Batch and Pipeline Homogenizer Mixers – Erection

Manhours ................................................................ 57 High-intensity Mixers – Equipment Cost .......................... 58 High-intensity Mixers – Erection Manhours ...................... 59 Bag and Rigid Container Vibrating Packers –

Equipment Cost ...................................................... 60 Bag and Rigid Container Vibrating Packers – Erection

Manhours ................................................................ 61 Boilers ............................................................................................ 62

Package Type – Equipment Cost .................................... 62 Package Type – Erection Manhours ................................ 63 Boiler Stacks – Equipment Cost ...................................... 64 Boiler Stacks – Erection Manhours .................................. 66

Classification Equipment ............................................................... 67 Cone Pelletizers – Equipment Cost ................................. 67 Cone Pelletizers – Erection Manhours ............................. 68 Turbo-screen Cyclone and Pressure Sifter –

Equipment Cost ...................................................... 69 Turbo-screen Cyclone and Pressure Sifter – Erection

Manhours ................................................................ 70 Rotary Screens – Equipment Cost ................................... 71 Rotary Screens – Erection Manhours .............................. 72

Contents ix


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

x Contents


Dryers – Vacuum ........................................................................... 90 Conical Rotating – Equipment Cost ................................. 90 Double Drum and Rotary – Equipment Cost .................... 91 Conical Rotating and Double Drum – Erection

Manhours ................................................................ 92 Rotary – Carbon and Stainless Steel – Erection

Manhours ................................................................ 93 Dust Collectors .............................................................................. 94

Centrifugal Scrubbers – High Capacity, Hot-rolled Steel – Equipment Cost .......................................... 94

Centrifugal Scrubbers – Medium Capacity, Hot-rolled Steel – Equipment Cost .......................................... 95

Centrifugal Scrubbers – High Capacity, Stainless Steel – Equipment Cost .......................................... 96

Centrifugal Scrubbers – Medium Capacity, Stainless Steel – Equipment Cost .......................................... 97

Centrifugal Scrubbers – High- and Medium-capacity, Hot-rolled and Stainless Steel – Erection Manhours ................................................................ 98

Cyclones – Hot-rolled Steel – Equipment Cost ................ 99 Cyclones – Stainless Steel – Equipment Cost ................. 100 Cyclones – Hot-rolled and Stainless Steel – Erection

Manhours ................................................................ 101 Filter Cartridge or Tube House Filters – Equipment

Cost ........................................................................ 102 Filter Cartridge or Tube House Filters – Erection

Manhours ................................................................ 103 Packaged Motor Operated Blowers – Equipment Cost .... 104 Packaged Motor Operated Blowers – Erection

Manhours ................................................................ 105

Contents xi


Fans and Blowers .......................................................................... 106 Blowers – Rotary – Equipment Cost ................................ 106 Blowers – Rotary – Erection Manhours ........................... 107 Centrifugal Fans – Equipment Cost ................................. 108 Centrifugal Fans – Erection Manhours ............................ 109 Cast Iron Industrial Fans – Equipment Cost .................... 110 Cast Iron Industrial Fans – Erection Manhours ................ 111 Heavy Sheet Steel Industrial Fans – Equipment Cost ...... 112 Heavy Sheet Steel Industrial Fans – Erection

Manhours ................................................................ 113 Feeders ......................................................................................... 114

Heavy Duty Belt – Equipment Cost .................................. 114 Heavy Duty Belt – Erection Manhours ............................. 115 Pre-wetting Dry Chemical – Equipment Cost ................... 116 Pre-wetting Dry Chemical – Erection Manhours .............. 117 Pre-wetting Dry Chemical, Package Units – Equipment

Cost ........................................................................ 118 Pre-wetting Dry Chemical, Package Units – Erection

Manhours ................................................................ 119 Dry Material, Vibrating – Equipment Cost ........................ 120 Dry Material, Vibrating – Erection Manhours ................... 121 Dry Material, Volumetric and Gravimetric – Equipment

Cost ........................................................................ 122 Dry Material, Volumetric and Gravimetric – Erection

Manhours ................................................................ 123 Dry Material, Wing and Conveyor – Equipment Cost ....... 124 Dry Material, Wing and Conveyor – Erection

Manhours ................................................................ 125 Filters ............................................................................................. 126

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

xii Contents


Gravity Filtration Units – Total Unit Installation Manhours ................................................................ 127

Pressure Type – Equipment Cost .................................... 128 Pressure Type – Erection Manhours ............................... 129 Rubber-lined – Equipment Cost ....................................... 130 Rubber-lined – Erection Manhours .................................. 131 Vibrating Screens – Equipment Cost ............................... 132 Vibrating Screens – Erection Manhours ........................... 133

Flakers ........................................................................................... 134 Cooling Drum – Equipment Cost ..................................... 134 Cooling Drum – Erection Manhours ................................. 135

Generators ..................................................................................... 136 Inert Gas – Equipment Cost ............................................ 136 Inert Gas – Erection Manhours ........................................ 137

Gas Pulsation Dampers ................................................................ 138 Dampers – Equipment Cost ............................................. 138 Dampers – Erection Manhours ........................................ 139

Heaters .......................................................................................... 140 Deaerating Feedwater – Equipment Cost ........................ 140 Deaerating Feedwater – Erection Manhours ................... 141 Gas-, Oil-, and Dual-fired – Equipment Cost .................... 142 Gas-, Oil-, and Dual-fired – Erection Manhours ............... 143

Heat Exchangers ........................................................................... 144 Hairpin Type – Equipment Cost ....................................... 144 Hairpin Type – Erection Manhours .................................. 145 Shell and Tube, Fixed Tube, and U-tube – Equipment

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

Manhours ................................................................ 147

Contents xiii


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

xiv Contents


Reactors ........................................................................................ 167 Glass-lined, Agitated, Jacketed – Equipment Cost .......... 167 Glass-lined, Agitated, Jacketed – Erection Manhours ...... 168

Steam Jet Ejectors ........................................................................ 169 Single-stage – Equipment Cost ....................................... 169 Single-stage – Erection Manhours ................................... 170

Gas Scrubbers .............................................................................. 171 High-energy Venturi Type – Equipment Cost ................... 171 High-energy Venturi Type – Erection Manhours .............. 172

Separators ..................................................................................... 173 Vane Type – Equipment Cost .......................................... 173 Vane Type – Equipment Cost .......................................... 174 Vane Type – Erection Manhours ..................................... 175 Vibrating – Equipment Cost ............................................. 176 Vibrating – Erection Manhours ........................................ 177 API Type Oil/Water – Equipment Cost ............................. 178 API Type Oil/Water– Erection Manhours ......................... 179

Size Reduction Equipment ............................................................ 180 Crushers – Equipment Cost ............................................. 180 Crushers – Erection Manhours ........................................ 181 Impact Breakers – Equipment Cost ................................. 182 Impact Breakers – Erection Manhours ............................. 183 Reversible and Non-reversible Hammermills –

Equipment Cost ...................................................... 184 Reversible and Non-reversible Hammermills – Erection

Manhours ................................................................ 185 Ring Type Granulators – Equipment Cost ....................... 186 Ring Type Granulators – Erection Manhours ................... 187

Contents xv


Water Softener System ................................................................. 188 Hot Process Water – Total Process Material and

Equipment Cost ...................................................... 188 Hot Process Water – Total System Installation

Manhours ................................................................ 189 Tanks ............................................................................................. 190

API Cone Roof Storage – Subcontract Installed Price ..... 190 API Cone Roof Storage – Subcontract Installed Price ..... 191 API Floating Roof Storage – Subcontract Installed

Price ....................................................................... 192 ASME Spheres – Subcontract Installed Price .................. 193 Fintube Heating Coils – Equipment Cost ......................... 194 Fintube Heating Coils – Erection Manhours ..................... 195 Fired Heaters, Fintube Type – Equipment Cost ............... 196 Fired Heaters, Fintube Type – Erection Manhours .......... 197 Suction and Line Type Fuel Oil Heaters – Equipment

Cost ........................................................................ 198 Suction and Line Type Fuel Oil Heaters – Erection

Manhours ................................................................ 199 Propane Storage – Equipment Cost ................................ 200 Propane Storage – Erection Manhours ............................ 201

Vessels .......................................................................................... 202 Shop Fabricated – Average Weight, Pounds per

Linear Foot .............................................................. 202 Horizontal, Shop Fabricated – Cost per Ton .................... 203 Vertical with Angle Legs, Shop Fabricated – Cost per

Ton ......................................................................... 204 Vertical with Anchor Ring and Skirts, Shop Fabricated

– Cost per Ton ........................................................ 205 Tray Rings, Shop Fabricated – Cost Each ....................... 206

xvi Contents


Column Trays, Shop Installation – Cost Each .................. 207 Demisting Pads, Shop Installation – Cost Each ............... 208 Shop Stress Relief – Cost per Ton .................................. 209 Removable Type Trays – Material Cost Each .................. 210 Removable Type Trays – Material Cost Each .................. 211 Demisting Pads – Material Cost Each ............................. 212 Demisting Pads – Material Cost Each ............................. 213 Vessels – Field Erection Manhours per Ton .................... 214 Tray Installation – Field Erection Manhours Each ............ 215 Demisting Pads – Field Erection Manhours Each ............ 216

Section 3. Site Preparation ............................................... 217 Section Introduction ....................................................................... 217 Area Clear and Grub – Manhours per Acre .................................. 217 Area Cuts and Fills – Manhours and Material Cost per Acre ....... 218

Section 4. Site Improvements ........................................... 219 Security Fencing ............................................................................ 219 Railroad and Spurs ........................................................................ 219 Tank Dikes ..................................................................................... 220 Concrete Trenches ........................................................................ 220 Drainage ........................................................................................ 221 Catch Basins and Manholes ......................................................... 221 Road Culverts ................................................................................ 221

Section 5. Concrete ........................................................... 222 Section Introduction ....................................................................... 222 Earth Backfill Materials – Cubic Yards .......................................... 223 Excavation and Backfill – Labor Manhours .................................. 224

Contents xvii


Earthwork for Equipment Structures, Pipe Racks, and Sleepers – Labor Manhours ................................................ 225

Concrete Required for Equipment, Equipment Structures, Pipe Racks and Sleepers – Cubic Yards ............................ 226

Forms, Reinforcing, Embedments and Concrete – Material Cost ...................................................................................... 227

Forms, Reinforcing, Embedments and Concrete – Installation Manhours ............................................................................. 228

Nonshrink, Nonmetallic Grout – Average Square Feet ................ 229 Nonshrink, Nonmetallic Grout – Material Cost ............................. 230 Nonshrink, Nonmetallic Grout – Installation Manhours ................ 231 Fireproofing Structural Steel – Total Material Cost ....................... 232 Fireproofing Structural Steel – Installation Manhours .................. 233 Fireproofing Vessel Skirts – Material Cost .................................... 234 Fireproofing Vessel Skirts – Erection Manhours .......................... 235

Section 6. Structural Steel and Miscellaneous Iron ........ 236 Section Introduction ....................................................................... 236 Structural Steel – Tons Required .................................................. 237 Miscellaneous Iron – Tons Required ........................................... 238 Pipe Rack Steel – Tons Required ................................................. 239 Structural Steel – Equipment Supports and Structures –

Material Cost ........................................................................ 240 Structural Steel for Pipe Racks – Miscellaneous Iron for

Equipment – Material Cost ................................................... 241 Structural Steel and Miscellaneous Iron – Equipment,

Equipment Supports and Structures, and Pipe Racks – Erection Manhours ............................................................... 242

xviii Contents


Section 7. Buildings ........................................................... 243 Section Introduction ....................................................................... 243 Building Types and Descriptions ................................................... 243 Building Materials – Cost per Square Foot ................................... 245 Building Erection – Manhours per Square Foot ............................ 246

Section 8. Piping ................................................................ 247 Section Introduction ....................................................................... 247 Shop Furnish and Fabricate Pipe and Fittings ............................. 248

Quantities Required for Pieces of Equipment .................. 248 Cost for Pieces of Equipment .......................................... 249

Field Furnish, Fabricate and Erect Pipe, Fittings and Valves ...... 251 Quantities Required for Pieces of Equipment .................. 251 Material Cost for Pieces of Equipment ............................. 252

Field Erect Shop Fabricated Spools – Manhours for Pieces of Equipment ............................................................................ 256

Field Furnish, Fabricate and Erect Pipe, Fittings, and Valves – Labor Manhours for Pieces of Equipment ........................ 257

Miscellaneous Pipe Items – Material Cost for Pieces of Equipment ............................................................................ 259

Miscellaneous Pipe Items – Total Manhours for Pieces of Equipment ............................................................................ 260

X-ray and Stress Relieving – Total Subcontract Cost for Pieces of Equipment ............................................................ 261

Section 9. Electrical ........................................................... 262 Section Introduction ....................................................................... 262 Electrical Power – Material Cost ................................................... 263 Electrical Power – Installation Manhours ...................................... 264 Electrical Lighting – Material Cost ................................................. 265

Contents xix


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

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

– Total Material Cost ............................................................ 274 Standards, Tray Supports, Trays, Tubes, and Tube Bundles

– Total Installation Manhours ............................................... 275

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

Manhours ............................................................................. 280

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

Area ...................................................................................... 284 Painting – Equipment – Total Material Cost ................................. 285

xx Contents


Painting – Equipment – Total Manhours ...................................... 286 Painting – Structural Steel – Total Material Cost .......................... 287 Painting – Structural Steel – Total Manhours ............................... 288 Painting – Piping – Total Material Cost ......................................... 289 Painting – Piping – Total Manhours .............................................. 290 Painting – Miscellaneous and Pipe Rack Steel – Total

Material Cost ........................................................................ 291 Painting – Miscellaneous and Pipe Rack Steel – Total

Manhours ............................................................................. 292

Section 13. Paving ............................................................... 293 Section Introduction ....................................................................... 293 Asphalt Pavement – Total Subcontract Price ............................... 294 Concrete and Gravel Pavements – Total Material Cost ............... 295 Concrete and Gravel Pavements – Total Manhours .................... 296

Section 14. Proratables ....................................................... 297 Section Introduction ....................................................................... 297 Proratable Materials – Total Material Cost ................................... 298 Proratable Labor – Total Manhours .............................................. 299

Section 15. Construction Equipment ................................. 300 Section Introduction ....................................................................... 300 Equipment Base Rental or Purchase Cost Fuel, Oil, Grease

and Supplies Cost ................................................................ 301 Equipment Service Labor – Total Manhours ................................ 302

Section 16. Overhead and Indirects ................................... 303 Section Introduction ....................................................................... 303 Engineering and Supervision Personnel – Total Manhours ......... 304

Contents xxi


Office Personnel – Total Manhours .............................................. 305 Other Indirect and Temporary Construction Labor – Total

Manhours ............................................................................. 306 Temporary Construction Materials – Total Cost ........................... 307 Payroll Burdens and Benefits and Other Indirect Materials –

Total Cost ............................................................................. 308

Section 17. Home Office Cost ............................................. 309 Section Introduction ....................................................................... 309 Engineering Design – Manhour Range Allowance per Piece

of Equipment ........................................................................ 310 Engineering Design – Other Cost as a Percent of

Engineering Labor Dollars ................................................... 314 Engineering Design – Manhour Spread Percentages .................. 315

Section 18. Ratio Estimating Factors ................................. 316 Section Introduction ....................................................................... 316 Refinery Process Systems – Direct Cost Percentages ................ 318 Liquid Type Chemical Plant – Direct Cost Percentages .............. 319 Solid Type Chemical Plants – Direct Cost Percentages .............. 320 Liquid/Solid Type Chemical Plants – Direct Cost

Percentages ......................................................................... 321 Liquid High-pressure Chemical Plants – Direct Cost

Percentages ......................................................................... 322 Liquid High-alloy Chemical Plants – Direct Cost

Percentages ......................................................................... 323 Construction Equipment as a Percent of Direct Field Labor ........ 324 Overhead and Indirects as a Percent of Direct Field Labor ......... 324 Home Office Services as a Percent of Total Cost and Indirect

Cost ...................................................................................... 324

xxii Contents


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

Section 1

DISCIPLINES OF WORK

The following is a broad description of the major items included in thevarious 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 specificproject that are not included. Should this occur, the estimator should giveconsideration to these items and add or deduct accordingly.

Direct Cost Items

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

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

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

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

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

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

6. Buildings—AU cost of buildings including earthwork, foundations andother concrete, total superstructure, HVAC, plumbing and utility pip-ing to five feet outside of building, insulation, electrical, painting, andall architectual finishes.

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

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

9. Underground Electrical—All labor and material for undergroundpower and lighting, ducts, conduit, wire, cable, etc. Also includesearthwork and concrete for embedments.

10. Above Ground Electrical—AU items required for the complete aboveground power and lighting systems for the total project, excludingbuildings. Also includes the installation of all electrical instrumentsand their hook-up.

11. Instrumentation—Includes material and labor cost of instrumenta-tion work delineated as follows:

• Material cost includes instruments, control valves, relief valves,control panels, meter runs, orifice fittings and all other instrumentitems plus the tubing, tube bundles, and tray materials required toinstall these items.

• Labor cost includes the installation of the above except as noted.• Labor cost to install relief and control valves and orifice fittings is

included under Above Ground Piping. Labor cost to install electri-cal hook-up is included under "Above Ground Electrical."

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

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

13. Painting—Includes all preparation and protective coating of surfaceswith paint and/or epoxy for the total project excluding buildings.

14. Paving—Includes the furnishing and placing of concrete, asphalt, orgravel used for the final surfacing of roads, sidewalks, parking areas,and process work areas as required.

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

Construction Equipment

1. Rental or Purchase—Cost of rental or purchase of construction equip-ment required to construct the project. Does not include small tools.

2. Service Labor—AU labor required to service and maintain the con-struction equipment. Does not include the operation of the equipmentwhen working. Operators are included in the Direct Account Labor.

3. Fuel, Oil, Grease, Supplies—Includes the cost of all fuels, lubricants,and supplies required to operate and maintain the construction equip-ment.

Overhead and Indirects

The following is a comprehensive list of inclusions, and the scope of theindividual project will dictate the actual item requirements.

Indirect Labor (Except for Temporary Facilities Labor)

AU or part of the items described below are used to establish costs for:

Salaried indirectOffice hourly indirectsField hourly indirects

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

Description

Engineering salaries-estimatingEngineering salaries-field technical support

To Include

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

Watchmen andJanitors—labor

Holiday pay

Salaries—office clerical

Quality assurance—labor

Salaries—subcontractadministrationSalaries—cost engineering

Salaries—scheduling andplanningSalaries—technical clerksMaterial control labor

Move in/out—labor

Non-productive labor

chainmen, rodmen, and laborers tempo-rarily assigned to a field party perform-ing general layout work.Security supervisor, security coordina-tor, guards, watchmen, janitors, laborfor supplying drinking water. Note: Doesnot include contract security personnel.Pay for holidays not worked. Personnelcovered by overhead and indirect esti-mate only.Administrative clerks, office clerks, andsecretaries.Chief construction inspector, construc-tion inspectors, welding inspector, pipinginspector, 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 andplanner/schedulers.Salaries for technical clerical personnel.Material control coordinators and mate-rial control personnel assigned to imple-ment and follow-up the material controlprogram.Job payroll labor for loading, unloading,and transporting from facilities to proj-ect construction area tools and construc-tion equipment, temporary facilities, etc.Move-in is defined as assembly of toolsand construction equipment at jobsite.Move-out is the return of tools and con-struction equipment to other approveddestination, in the immediate area of theproject.Wages paid to hourly employees during atemporary period when work is stopped.Also wages paid to craftsmen for voting

Safety and medicalexpense—laborSalaries—office

Salaries—supervision

Sick pay

Warehouse salaries

in accordance with union or governmentregulations. Welding test labor and jurypay differential. Note: Work stoppagedue to weather and show-up time areconsidered in productivity factors usedelsewhere.Safety supervisor, safety inspectors, andmedics.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 dueto 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 be on job payroll only.

Description

Temporary buildings andutilities—labor

To Include

Labor only for construction or erection,maintenance and dismantling of the tem-porary facilities, in accordance with butnot limited to the following: Roads,ditches, bridges, storage areas, parkinglots, fencing, buildings, water system,sanitary system, power distribution, tel-

Temporary Construction Facilities (Labor and Material)

Labor Burdens and Overhead Personnel Benefits

Temporary buildings andutilities—material andsupplies

ephone and communications systems,and plant air system. Note: Does not in-clude construction camp, quartering orcatering facilities.Material and supplies and maintenancefor construction and dismantling of thetemporary facilities in accordance withbut not limited to the following. Also in-cludes rental of temporary field officesand warehouses, roads, ditches, bridges,storage areas, parking lots, fencing,buildings, water system, sanitary sys-tem, power distribution, telephone andcommunications systems, and plant airsystem. Note: Does not include construc-tion camp, quartering or catering facili-

Description

Retirement and savingsplan (for overhead andindirect personnel only)

Insurance—employees'life and hospitalization (foroverhead and indirectpersonnel only)Insurance—W/C, B/I, andP/D

Taxes—payroll

Vacation pay (foroverhead and indirectpersonnel only)

Tb Include

Actual cost fixed by the appropriate ac-counting office. Note: Does not includeany like or similar item which is a part ofa union fringe benefit.Direct premium charges only. Note: Doesnot include any like or similar itemwhich is a part of a union fringe benefit.

Premium expense based on payrolls.Limits conform to the requirements forthe state as specified in the contract.FICA and Medicare, state unemploy-ment insurance and federal unemploy-ment insurance.Actual cost for overhead and indirectpersonnel only based on gross payroll asbilled by the appropriate Accounting Of-fice. Note: Does not include any like orsimilar item which is a part of a unionfringe benefit.

Small Tool and Consumables

Description

Construction supplies

Small tools (in accordancewith contract limits)

Workmen's supplies

Other Indirects

Description

AdvertisingBond premiums

Communications andpostage

TD Include

This account should include items thatare consumed and, by their use, directlyrelated to construction; for example,sandpaper, rope, chalk, soapstone,emery paper grinding wheels, moilpoints, saw blades, padlocks, threadingdies, drill bits and reamers, rags, broomsand mops, air and water hose for generaluse.Purchase or rental of hand tools, poweroperated hand tools, etc. Rental or re-pair parts for such tools will be includedin this account. This account includes mi-nor equipment such as small pumps to3", vibrators, light plants (800 watt-3,000 watt), chain saws, pipe threaders,tar pots, small, sand blasting machines,air and chain hoists.This cost will include items that are, bytheir use, directly beneficial to and forthe convenience of workmen; for exam-ple, towels, toilet paper, drinking cups,ice drinking water, hard hats, protectiveclothing, gloves, boots, salt tablets, soap,drinking water barrels or containers,safety shoes, and work shoes. Credit isto 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

Containers

Dues

Engineering supplies

Expediting

Heat, light, water, andpower

Insurance—general

Legal

Licenses and permits

Move in/out—supplies andservices

Office supplies

Safety and medicalexpense, material

rented from a third party. Include datalines and couplers.Deposits for returnable containers andreels.Membership dues for clubs and profes-sional organizations, for overhead and in-direct personnel only. Note: Does not in-clude union dues.Surveying instruments (purchase orrental) drafting supplies, surveying sup-plies, blueprint or photostat work,progress photos.Cost for services supplied by expeditorswho are not on the job payroll.Public utility charges and heating fuelsfor job buildings. Cost for water notused for construction purposes.Premiums for builder's risk, fire and ex-tended coverage, equipment floater cov-erage, non-owned automotive liability,independent contractors' liability, con-tractual liability, special risk coverage,such as war risk and heavy lift, hull andP&I, umbrella.Abstracts, lawyers fees, court costs, no-tary fees, sign-up expense.Business permits, construction permits,export/import licenses, government in-spection fees, hauling permits.Transportation of tools, and constructionequipment by others to project construc-tion area, and miscellaneous suppliesconsumed and services used, for move-inand -out purposes.Stationery supplies, printing, officeequipment 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-

Testing and laboratoryanalysis

Traveling

Welding supplies

Unclassified

Data processing services

Consulting services

Trade journals, books,publications, andsubscriptionsContract Guard ServiceQuality Assurance-Material and SuppliesEmployee EducationalAssistance

aid equipment, fire extinguishers, andrefills.Soil surveys, concrete cylinder tests, in-dependent inspectors. Lab charges totest welders.Transportation and subsistence expenseof overhead and indirect employees onbusiness trips (excluding quality assur-ance personnel travel).All material, supplies, and tools requiredby a welder, i.e., acetylene, oxygen, flux,welding rods, lighters, flints, chipping,hammers, wire brushes, stingers, hel-mets, lenses, asbestos gloves, goggles,gauges, welding qualification test mate-rial, etc.Flowers, weather reports and forecasts,and bank service charges.Cost for data processing services for theproject. Terminal rental, supplies, com-puter charges from outside jobsitesources, etc.Cost for outside consulting serviceswhich might be required in connectionwith the projects which are not a part ofengineering.Cost of books or subscriptions.

Cost of subcontract guard serviceNormally includes travel costs for qual-ity control personnel.Cost of employee educational assistance,for overhead and indirect personnel only.

Home Office Cost

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

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

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

Section 2

PROCESS EQUIPMENT

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

Once the production rate has been established and a rough flow sheetpresented, an equipment list can be compiled noting the type, size, capac-ity and material of construction. From the logarithmic graphs that appearon the following pages, an average cost of equipment material and instal-lation manhours can be computed.

Inasmuch as it is not practical within the scope of this manual to ade-quately describe each piece of equipment beyond the very minor descrip-tion as appears on the individual graphs, I rely on the estimator's abilityto realize that the items covered are of a standard nature for chemicalplants, refineries, and industrial plants.

All installation manhours include offloading equipment at job site, haul-ing up to 2,000 feet and rigging, picking, setting, and aligning of theequipment.

The equipment graphs include the total cost of the equipment, but donot include structural steel or miscellaneous iron such as supports, lad-ders, walkways, platforms, or handrails. See other sections for theseitems.

AU shop fabricated equipment graphs, as in the case of vessels, includethe total shop cost, overhead, and profit for fabricating and furnishing ofall material and components required for that piece of equipment.

Packaged unit graphs include the total skid-mounted cost of the equip-ment and piping, electrical components and instrumentation, which maybe an integral part of the package.

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

All equipment graphs include an average allowance for freight costwithin 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.

ACID CCX)LERS WITH PUMPAND MOTOR

Equipment Cost

Eq

uip

men

t C

ost

Heat Exchanger Area Square Feet

ACID COOLERS WITH PUMPAND MOTOR

Erection Manhours

Erec

tion

Manhours

Heat Exchanger Area Square Feet

VIBRATING BIN ACTIVATORSEquipment Cost

Eq

uip

men

t C

ost

Diameter Inches

VIBRATING BIN ACTIVATORSErection Manhours

Ere

ctio

n

Man

hour

s

Diameter Inches

HIGH-SPEED MECHANICALAERATORS

Equipment Cost

Equ

ipm

ent

Co

st

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

HIGH-SPEED MECHANICALAERATORSErection Manhours

Erection

Manhours

Motor Horsepower

LOW-SPEED MECHANICALSURFACE AERATORS

Equipment Cost

Equ

ipm

ent

Cos

t

Motor Horsepower©Fixed low-speed unit© Floating low-speed unit

LOW-SPEED MECHANICALSURFACE AERATORS

Erection Manhours

Erec

tion Manhours

Motor Horsepower

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

Next Page

AIR POWER COMPRESSORSSynchronous Motor Driven

Rated for Sea Level to 3,300 FeetAltitude at 125 psig Maximum

Discharge PressureEquipment Cost

Eq

uip

men

t C

ost

Motor Horsepower0)460,575, or 480 volts©2300 or 4160 volts

Previous Page

AIR POWER COMPRESSORSInduction Motor Driven

Rated for Sea Level to 3,300-FbotAltitude at 125 psig Maximum

Discharge PressureEquipment Cost

Equ

ipm

ent

Co

st

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

AIR POWER COMPRESSORSSynchronous and Induction Motor

Driven Rated for Sea Level to3,300-Foot Altitude at 125 psigMaximum Discharge Pressure

Erection Manhours

Erection

Manhours

Motor Horsepower

AUTOMOTIVE ANDINDUSTRIAL SERVICE AIR

COMPRESSORSEquipment Cost

Equ

ipm

ent

Co

st

Motor Horsepower

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

AUTOMOTIVE ANDINDUSTRIAL SERVICE AIR

COMPRESSORSErection Manhours

Erection

Manhours

Motor Horsepower

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

CENTRIFUGAL AIR COMPRESSORSPlant and High-Pressure

(Soot Blower) Types100 to 350 psig Discharge

PressureEquipment Cost

Eq

uip

men

t C

ost

Nominal Motor Horsepower0 Plant air compressors(2) High-Pressure (soot blower) compressors

CENTRIFUGAL AIB COMPRESSORSPlant and High-Pressure

(Soot Blower) Types100 to 350 psig Discharge

PressureErection Manhours

Ere

ctio

n

Man

hour

s

Nominal Motor Horsepower

INDUSTRIAL AIRCOMPRESSORS

Air-Cooled, Two-Stage—50 to250psig

Equipment Cost

Eq

uip

men

t C

ost

Motor Horsepower

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

INDUSTRIAL AIRCOMPRESSORS

Air-Cooled, Two-Stage—50 to250psig

Erection Manhours

Erection Manhours

Motor Horsepower

INTEGRAL GAS ENGINECOMPRESSOR

Fbur-Cylinder TypeEquipment Cost

Eq

uip

men

t C

ost

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

INTEGRAL GAS ENGINECOMPRESSORS

Fbur-Cylinder Type1,CXX) TO 6,000 psig Discharge

Erection Manhours

Ere

ctio

n

Man

hour

s

Rated Horsepower (BHP)

PACKAGED AIR COMPRESSORUNITS

Single-Stage, Water-CooledOil-Lubricated and Nonlubricated

TypesEquipment Cost

Eq

uip

men

t C

ost

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

PACKAGED AIR COMPRESSOR UNITSSingle-Stage, Water-Cooled

Oil-Lubricated and NonlubricatedTypes

Erection Manhours

Ere

ctio

n

Man

hour

s

Motor Horsepower

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

RECIPROCATINGCOMPRESSORS

Electric Motor DrivenEquipment Cost

Eq

uip

men

t C

ost

Compressor Horsepower

1) Cast Iron Cylinders 1000 PSI Discharge2) Nodular Iron Cylinders 1500 PSI Discharge3) Steel Cylinders 2500 PSI Discharge4) Steel Cylinders 6000 PSI Discharge

RECIPROCATINGCOMPRESSORS

Electric Motor Driven1,000 to 6,000 psi Discharge

Erection Manhours

Ere

ctio

n M

anho

urs

Compressor Horsepower

TWO-STAGE, TWO-CYLINDER,WATER-COOLED AIR COMPRESSORS

Oil-Lubricated and Nonlubricated150 to 350 psi Discharge

PressureEquipment Cost

Equ

ipm

ent

Co

st

Motor Horsepower0 Oil-lubricated© Nonlubricated


Oil-Lubricated and Nonlubricated350 to 500 psig Discharge

PressureEauimnent Cost

Eq

uip

men

t C

ost

Motor Horsepower(D Oil-Lubricated(D Nonlubricated


Oil-Lubricated and Nonlubricated150 to 500 psig Discharge

PressureErection Manhours

Erec

tion

Manhours

Motor Horsepower

Next Page

REFRIGERATED AIR DRYERSAutomatic Type 15 to 1000 scfm

Equipment Cost

Eq

uip

men

t C

ost

Capacity SCFM

Previous Page

REFRIGERATED AIR DRYERSAutomatic Type 1,200 to 15,000

scfmEquipment Cost

Equ

ipm

ent

Cos

t

Capacity scfm

REFRIGEBATED AIR DRYERSAutomatic Type 15 to I9OOO scfm

Erection Manhours

Erection Manhours

Capacity SCFM

REFRIGERATED AIR DRYERSAutomatic Type 1,200 to IS9OOO

scfmErection Manhours

Ere

ctio

n M

anho

urs

Capacity SCFM

CHILLER AIR DRYERSCapacity 3,000 to 28,000 scfm at

lOOpsigEquipment Cost

Equ

ipm

ent

Cos

t

Capacity SCFM At 100 PSIG

CHILLER AIR DRYERSCapacity 3,000 to 28,000 scfm at

lOOpsigErection Manhours

Erection Manhours

Capacity SCFM At 100 PSIG

Next Page

SURGE ARRESTORSHydrocarbon and Water Service

500 psi Design Operating PressureASME Code—Section VIII

Division IEquipment Cost

Eq

uip

men

t C

ost

Nominal Size Gallons©Hydrocarbon Service©Water Service

Previous Page

SURGE ARRESTORSHydrocarbon, Water and Sewage Service

275 psi Design Operating PressureASME Code—Section VIII

Division IEquipment Cost

Eq

uip

men

t C

ost

Nominal Size Gallons

©Hydrocarbon service©Water service® Sewage service

SURGE ABBESTORSHydrocarbon, Water and Sewage Service

275 and 500 psi Design Operating PressuresASME Code—Section VIII

Division IErection Manhours

Erection Manhours

Nominal Size Gallons

DRY MATERIAL BLENDERS,PACKERS9 AND FEEDERS

Auger BlendersRotary Drum Blenders

Equipment Cost

Equ

ipm

ent

Cos

t

iuaximum Mixing Cubic Feet Per Hour(D Auger blenders© Rotary drum blenders

DRY MATERIAL BLENDERS9PACKERS9 AND FEEDERS

Auger BlendersRotary Drum Blenders

Erection Manhours

Ere

ctio

n M

anho

urs

Maximum Mixing Cubic Feet Per Hour

©Auger blenders© Rotary drum blenders

MIXERS AND BLENDERSFixed Side Mounted Mixers with

Top MotorsEquipment Cost

Eq

uip

men

t C

ost

Rating Hors epower

MIXERS AND BLENDERSFixed Side Mounted Mixers

with Top MotorsErection Manhours

Erection Manhours

Rating Horsepower

MIXERS AND BLENDERSPlate Mounted Open Tank Mixers

Equipment Cost

Equ

ipm

ent

Co

st

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

MIXERS AND BLENDERSPortable Clamp and Flanged

Mounted MixersEquipment Cost

Equ

ipm

ent

Cos

t

Rating Horsepower® Portable clamp mounted mixers—direct drive.© Portable clamp mounted mixers—gear drive.© Flanged top tank mounted mixers—direct drive® Flanged top tank mounted mixers—gear drive.

MIXERS AND BLENDERSFlanged Top Tank Mounted and

Plate Mounted Open Tank MixersErection Manhours

Ere

ctio

n

Man

hour

s

Rating Horsepower

©Portable clamp mounted mixers—Direct And GearDrive.

© Flanged top tank and plate mounted open tank mix-ers—direct and gear drives.

MIXERS AND BLENDERSGearmotor Mixers

Equipment Cost

Equ

ipm

ent

Co

st

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 sealsNote: Motor horsepower range 2-200, shaft length

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

MIXERS AND BLENDERSGearmotor Mixers

Erection Manhours

Approximate Weight - Pounds

(D For mounting on structural steel support aboveopen tank

© For mounting on closed tank with stuffing box/shaftseals or end face mechanical seals

Note: Motor horsepower range 2-200, shaft lengthrange 100"-23O*, impeller range 29"-75".

MIXERS AND BLENDERSBatch and Pipeline Homogenizer

MixersEquipment Cost

Eq

uip

men

t C

ost

Horsepower

(D Batch homogenizer mixers© Pipeline homogenizer mixers

MIXERS AND BLENDERSBatch and Pipeline Homogenizer

MixersErection Manhours

Ere

ctio

n M

anho

urs

Horsepower

MIXERSHigh-Intensity

Equipment Cost

Eq

uip

men

t C

ost

Working Capacity Cubic Feet

MIXERSHigh-Intensity

Erection Manhours

Ere

ctio

n

Man

hour

s

Working Capacity Cubic Feet


Bag Vibrating PackersRigid Container Vibrating

PackersEquipment Cost

Eq

uip

men

t C

ost

Maximum Bag Width Or Container Diameter Inches

® Bag vibrating paekers© Rigid container vibrating packers


Bag Vibrating PackersRigid Container Vibrating

PackersErection Manhours

Ere

ctio

n

Man

hour

s

Maximum Bag Width Or Container Diameter Inches

(D Bag vibrating packers(2) Rigid container vibrating packers

BOILERSPackage Type

Equipment Cost

Eq

uip

men

t C

ost

Pounds Per Hour

Note: Cost is for total boiler including forced draft fanassembly. Boiler capacity pounds per hour-satu-rated steam at 100 to 235 psig.

BOILERSPackage Type

Erection Manhours

Ere

ctio

n

Man

hour

s

Pounds Per Hour

Note: Manhours are for installation of boiler includingforced draft fan. Boiler capacity pounds perhour-saturated steam at 100 to 235 psig.

BOILER STACKS1M-InCh Plate

Equipment Cost

Eq

uip

men

t C

ost

Linear Feet Of Stack

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

BOILER STACKS5/ie- and 3/s-Inch Plate

Equipment Cost

Equ

ipm

ent

Cos

t


® %>-inch plate 42- to 48-inch diameter© %3-inch plate 54- to 60-inch diameter® %-inch plate 54- to 60-inch diameterNote: Cost includes stack, cable, and clamps.

BOILEB STACKS1Ai-, 5/i6-, 3/8-Inch Plate

Erection Manhours

Ere

cti

on

M

anho

urs


® 24-inch diameter (D 42- to 48-inch diameter© 30-inch diameter ® 54- to 60-inch diameter©36-inch diameter

Next Page

CLASSIFICATION EQUIPMENTCone Pelletizers

Equipment Cost

Eq

uip

men

t C

ost

Cone Size Feet

Previous Page

CLASSIFICATION EQUIPMENTCone Pelletizers

Erection Manhours

Ere

ctio

n

Man

hour

s

Cone Size Feet

CLASSIFICATION EQUIPMENTTurbo-Screen Cyclone and

48"-Pressure Sifter (3-Screens)Equipment Cost

Equ

ipm

ent

Diameter Inches

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

Co

st

CLASSIFICATION EQUIPMENTTurbo-Screen Cyclone and

48"-Pressure Sifter (3-Screens)Erection Manhours

Erec

tion

Manhours

Diameter Inches

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

CLASSIFICATION EQUIPMENTRotary Screens

Equipment Cost

Eq

uip

men

t C

ost

Capacity Screen Area Square Feet

CLASSIFICATION EQUIPMENTRotary Screens

Erection Manhours

Ere

ctio

n

Man

hour

s

Capacity Screen Area Square Feet

VERTICAL TUBE SURFACECONDENSERS AND

RECEIVERSEquipment Cost

Eq

uip

men

t C

ost

Cooling Surface Square Feet

VERTICAL TUBE SURFACECONDENSERS AND

RECEIVERSErection Manhours

Ere

ctio

n M

anho

urs

Cooling Surface Square Feet

CONVEYING EQUIPMENTConveyors—Open Belt

Equipment Cost

Equ

ipm

ent

Cos

t

Linear Feet(D 18-inch belt <D 36-inch belt© 24-inch belt © 42-inch belt©30-inch beltNote: See structural steel account for bents.

CONVEYING EQUIPMENTConveyors—Open Belt

Erection Manhours

Ere

ctio

n M

anho

urs

Linear Feet® 18-inch belt ® 36-inch belt© 24-inch belt © 42-inch belt(S) 30-inch beltNote: See structural steel account for bents.

CONVEYING EQUIPMENTConveyors—Belt Enclosed

with WalkwayEquipment Cost

Eq

uip

men

t C

ost

Linear Feet(D 18-inch belt ® 36-inch belt© 24-inch belt © 42-inch belt<§) 30-inch beltNote: See structural steel account for bents.

CONVEYING EQUIPMENTConveyors—Belt Enclosed

with WalkwayErection Manhours

Ere

ctio

n M

anho

urs

Linear Feet

® 18-inch belt (D 36-inch belt© 24-inch belt © 42-inch belt(E) 30-inch beltNote: See structural steel account for bents.

CONVEYING EQUIPMENTConveyors—Spaced, Bucket

Elevators, Belt-DrivenEquipment Cost

Equ

ipm

ent

Linear Feet

® 6-x 4-inch buckets(2) 12-x 7-inch buckets® 16- x 8-inch buckets


Elevators, Chain-DrivenEquipment Cost

Equ

ipm

ent

Cos

t

Linear Feet(D 6-x 4-inch buckets(D 12-x 7-inch buckets(S) 16-x 8-inch buckets


Elevators,Chain- or Belt-Driven

Erection Manhours

Ere

ctio

n

Man

hour

s

Linear Feet

® 6-x 4-inch buckets(2) 12-x 7-inch buckets® 16- x 8-inch buckets

CONVEYING EQUIPMENTConveyors—Continuous, Bucket

Elevators,Belt-Driven

Equipment Cost

Eq

uip

men

t C

ost

Linear Feet

0 8- x 5-inch buckets(D 16-x 8-inch buckets® 20-x 8-inch buckets


Elevators,Chain-Driven

Equipment Cost

Eq

uip

men

t C

ost

Linear Feet(D 8-x 5-inch buckets(2) 16-x 8-inch buckets® 20-x 8-inch buckets


Elevator,Chain- or Belt-Driven

Erection Manhours

Ere

ctio

n

Man

hour

s

Linear Feet

® 8-x 5-inch buckets(2) 16-x 8-inch buckets® 20-x 8-inch buckets

SCREW CONVEYORSEquipment Cost

Overall Conveyor Length-Linear Feet

Screw Diameter:(D 6-inch ©16-inch©9-inch ©18-inch(E) 12-inch CD 20-inch014-inch ©24-inch

SCREW CONVEYORSErection Manhours

Ere

ctio

n M

anho

urs

Overall Conveyor Length-Linear Feet

Screw Diameter:® 6-inch ©16-inch©9-inch ©18-inch©12-inch ©20-inch(D 14-inch ©24-inch

DRYERS—DRUMAtmospheric Single Drum Type

Equipment Cost

Equ

ipm

ent

Cos

t

Approximate Weight Pounds

DRYERS—DRUMAtmospheric Double and Twin

Drum TypesEquipment Cost

Equ

ipm

ent

Cos

t

Approximate Weight Pounds(D Double drum©Twin drum

DRYERS—DRUMAtmospheric Single, Double, and

Twin Drum TypesErection Manhours

Ere

ctio

n M

anho

urs


(D Single Drum©Double Drum©Twin Drum

Next Page

DRYERS—VACUUMConical Rotating Type

Equipment Cost

Equ

ipm

ent

Cos

t


Previous Page

DRYERS—VACUUMDouble Drum and Rotary Types

Equipment Cost

Equ

ipm

ent

Cos

t

Approximate Weight Pounds0 Double drum© Rotary—stainless steel(H) Rotary—carbon steel

DRYERS—VACUUMConical Rotating and Double

Drum TypesErection Manhours

Ere

ctio

n M

anho

urs


® Conical rotating©Double drum

DRYERS—VACUUMRotary Types Carbon Steel and

Stainless SteelErection Manhours

Ere

ctio

n M

anho

urs

Approximate Weight Pounds©Carbon Steel©Stainless Steel

DUST COLLECTORSCENTRIFUGAL SCRUBBERS

High Capacity, Low EnergyLoss Type

Hot-Rolled Steel ConstructionEquipment Cost

Equ

ipm

ent

Cos

t

Capacity CFM At 4.5V Pressure Drop(D 12-gauge ® %6-inch plate(2) 10-gauge ® V4-inch plateNote: Cfin capacity at 2.0-inch pressure drop will equal

approximately 67% of above cftn.


Medium Capacity, MediumEnergy Loss

Hot-Rolled SteelEquipment Cost

Equ

ipm

ent

Cos

t

Capacity CFM At 4.5" Pressure Drop® 12-gauge (E) %6-inch plate<2) 10-gauge (D V4-inch plateNote: Cfm capacity at 2.0-inch pressure drop will equal

approximately 71% of above cfm.


High Capacity, Low EnergyLoss Type

T304-2B Stainless Steel ConstructionEquipment Cost

Equ

ipm

ent

Cos

t

Capacity CFK At 4.4" Pressure Drop® 12-gauge ® ^16-inch plate© 10-gauge ® V4-inch plateNote: Cfm capacity at 2.0-inch pressure drop will equal



Medium Capacity, MediumEnergy Loss Type

T304-2B Stainless Steel ConstructionEquipment Cost

Equ

ipm

ent

Cos

t

Capacity CFK At 4.5" Pressure Drop® 12-gauge © %6-inch plate(2) 10-gauge (D V4-inch plateNote: Cfrn capacity at 2.0-inch pressure drop will equal



High- and Medium-Capacity UnitsHot-Rolled Steel and T304-2B

Stainless SteelErection Manhours

Ere

ctio

n

Man

hour

s

Capacity CFM At 4.5" Pressure Drop

® Hot-rolled steel—all thicknesses©T304-2B stainless steel-all thicknesses

DUST COLLECTORSHot-Rolled Steel—Cyclones

Equipment Cost

Equ

ipm

ent

Cos

t

Capacity CFM At 6.0" Pressure Drop(D 16-gauge (g) 12-gauge ©%6-inch plate(2) 14-gauge 0 10-gaugeNote: Cfin capacity at 2.5-inch pressure drop will equal

approximately two-thirds of above cfin.

DUST COLLECTORS304 Stainless Steel Cyclones

Equipment Cost

Equ

ipm

ent

Cos

t

Capacity CFM At 6,O" Pressure Drop

® 16-gauge ® 12-gauge ©%6-inch plate© 14-gauge (D 10-gaugeNote: Cftn capacity at 2.5-inch pressure drop will equal

approximately two-thirds of above cfin.

DUST COLLECTORSHot-Rolled Steel and 304Stainless Steel Cyclones

Erection Manhours

Ere

ctio

n

Man

hour

s

Capacity CFM At 6.0" Pressure Drop

® Hot-rolled steel—all thicknesses©304 stainless steel—all thicknesses

DUST COLLECTORSFilter Cartridge or Tube House

FiltersEquipment Cost

Equ

ipm

ent

C os

t

Filter Cartridge Or Fabric Filter Square Feet Area

(D Filter cartridge© Fabric filter—tube house

DUST COLLECTORSFilter Cartridge or Tube House

FiltersErection Manhours

Ere

ctio

n

Man

hour

s

Filter Cartridge Or Fabric Filter Square Feet Area

©Filter cartridge©Fabric filter—tube house

DUST COLLECTORSPackaged Motor Operated

Blowers for Filter Cartridgeand Tube House Dust Collectors

Equipment Cost

Equ

ipm

ent

Cos

t

Motor Horsepower

DUST COLLECTORSPackaged Motor Operated

Blowers for Filter Cartridgeand Tube House Dust Collectors

Erection Manhours

Ere

ctio

n

Man

hour

s

Motor Horsepower

FANS AND BLOWERSBlowers—Rotary to 15 psi

Equipment Cost

Equ

ipro

e nt

Cos

t

Inlet—CFM

FANS AND BLOWERSBlowers—Rotary to 15 psi

Erection Manhours

Ere

ctio

n

Man

hour

s

Inlet—CFM

FANS AND BLOWERSCentrifugal Fans with

Backwardly Inclined BladesEquipment Cost

Equ

ipm

ent

Cos

t

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 specificationNote: 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.

FANS AND BLOWERSCentrifugal Fans with

Backwardly Inclined BladesErection Manhours

Ere

ctio

n M

anho

urs

Maximum Volume - CFM

Note: Manhours are for all classes

FANS AND BLOWERSCast Iron Industrial Fans

Equipment Cost

Eq

uip

men

t C

ost

Maximum Volume-CFM

FANS AND BLOWERSCast Iron Industrial Fans

Erection Manhours

Ere

ctio

n

Man

hour

s

Maximum Volume-CFM

FANS AND BLOWERSHeavy Sheet Steel Industrial Fans

Equipment Cost

Eq

uip

men

t C

ost

Max imum Vo1ume-CFM

FANS AND BLOWERSHeavy Sheet Steel Industrial Fans

Erection Manhours

Erecti

on

Man

hour

s

Maximum Volume-CFM

Next Page

HEAVY DUTY BELT FEEDERSEquipment Cost

Equ

ipm

ent

Cos

t

Capacity Cubic Feet Per Hour

Previous Page

HEAVY DUTY BELT FEEDERSErection Manhours

Erection

Manhours

Capacity Cubic Feet Per Hour

PRE-WETTING DRY CHEMICALFEEDERSEquipment Cost

Equ

ipm

ent

Cos

t

Hopper Cubic Feet

PRE-WETTING DRY CHEMICALFEEDERS

Erection Manhours

Ere

ctio

n

Man

hour

s

Hopper Cubic Feet

Note: Manhours are for mounting on drum or tank orplaced on stand or shelf above tank.

PRJS-WETTING DRY CHEMICAL

Package UnitsEquipment Cost

Equ

ipm

ent

Cos

t

Tank Gallons(D Single-tank system©Two-tank system

PRE-WETTING DRY CHEMICALFEEDERS

Package UnitsErection Manhours

Ere

ctio

n

Man

hour

s

Tank Gallons

® Single-tank system© Two-tank system

DRY MATERIAL FEEDEREQUIPMENT

Vibrating FeedersEquipment Cost

Equ

ipm

ent

Cos

t

Tons Per Hour


Vibrating FeedersErection Manhours

Ere

ctio

n M

anho

urs

Tons Per Hour


Volumetric and GravimetricFeeders

Equipment Cost

Equ

ipm

ent

Cos

t

Approximate Weight In Pounds

©Volumetric feeders© Gravimetric feeders


Volumetric and GravimetricFeeders

Erection Manhours

Ere

ctio

n

Man

hour

s

Approximate Weight In Pounds

(D Volumetric feeders© Gravimetric feeders

DRY MATERIAL FEEDERSWing and Conveyor Types

Equipment Cost

Equ

ipm

ent

Cos

t

Maximum Cubic Feet Per Hour

(D Wing-type feeders-ratchet drive® Wing-type feeders-micro master drive® Conveyor type feeders(3) Sanitary wing-type feeders

DRY MATERIAL FEEDERSWing and Conveyor Types

Erection Manhours

Ere

ctio

n

Man

hour

s

Maximum Cubic Feet Per Hour

® Wing-type feeders—ratchet drive©Wing-type feeders—micro master drive© Conveyor-type feeders(D Sanitary wing-type feeders

GRAVITY FILTRATION UNITSTotal Material Cost

Mat

eria

l C

ost

Unit Diameter-Feet

GRAVITY FILTRATION UNITSTotal Unit Installation Manhours

Ins t

all

ati

on

M

anho

urs

Unit Diameter-Feet

FILTERSPressure Type

Equipment Cost

Equ

ipm

ent

Cos

t

Diameter Feet

FILTERSPressure Type

Erection Manhours

Ere

ctio

n

Man

hour

s

Diameter Feet

FILTERSRubber-Lined

Equipment Cost

Equ

ipm

ent

Cos

t

Flow Rate G. P. M.

(D 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.

FILTERSRubber-Lined

Erection Manhours

Erection Manhours

Flow Rate G. P, M.

(D 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.

FILTER EQUIPMENTVibrating Screens

Equipment Cost

Equ

ipm

ent

Cos

t

Square Feet Single Deck Area

® One-deck screen©Two-deck screen©Three-deck screenNote: Costs of all two-and three-deck screens are based

on square feet of single deck area.

FILTER EQUIPMENTVibrating Screens

Erection Manhours

* v

jiv

ii

l-»

1'i

aiu

ivQ

HlIlI

H J

lIlI

f ilu

illlH

II44

4144

44-4

UuU

III

Square Feet Single Deck Screen Area

(D One-deck screen©Two-deck screen© Three-deck screenNote: Manhours for two- and three-deck screens are

based on square feet of single deck area.

FLAKERSCooling Drum Type

Equipment Cost

Equ

ipm

ent

Cos

t


FLAKEBSCooling Drum Type

Erection Manhours

Erection

Manhours


INERT GAS GENERATORSEquipment Cost

Equ

ipm

ent

Cos

t

Rated Out Put - (SCFM Inerts)

® Indoor construction© Outdoor construction© Explosion-proof constructionNote: Add 3% to above for two-point control. Add 5%

to above for automatic output control.

INERT GAS GENERATORSErection Manhours

Ere

ctio

n

Man

hour

s

Rated Output (SCFM Inerts)

OD Indoor construction® Outdoor construction® Explosion-proof constructionNote: Add 1% to above for two-point control. Add

1.5% to above for automatic output control.

GAS PULSATION DAMPERSEquipment Cost

Equ

ipm

ent

Cos

t

Volume Cubic Inches

GAS PULSATION DAMPERSErection Manhours

Ere

ctio

n M

anho

urs

Volume Cubic Inches

Next Page

HEATERSDeaerating Feedwater Type

Equipment Cost

Equipment

Cost

Outlet Capacity Pounds Per Hour

Previous Page

HEATERSDeaerating Feedwater Type

Erection Manhours

Ere

ctio

n M

anho

urs

Outlet Capacity Pounds Per Hour

HEATERSGas-, Oil, and Dual-Fired Heaters

Equipment Cost

Equ

ipm

ent

Cos

t


® Gas-fired©Oil-fired©Dual-fired

HEATERSGas-, Oil-, and Dual-Fired Types

Erection Manhours

Erec

tion Manhours


HAIRPIN TYPEHEAT EXCHANGERS

Equipment Cost

Equ

ipm

ent

Cos

t

Heat Transfer Surface Square Feet

HAIRPIN TYPEHEAT EXCHANGERS

Erection Manhours

Ere

ctio

n

Man

hour

s

Heat Transfer Surface Square Feet

HEAT EXCHANGERSShell and Tube, Fixed Tube Sheet,

and U-TubeEquipment Cost

Equ

ipm

ent

Cos

t

Heating Surface Square Feet® 150# Rating © 300# Rating ® 600# RatingNote: Above is for carbon steel, straight tube

exchangers. Add following percent to the abovefor:

StraightTubes U-Tubes Tube Sheet

Carbon Steel - 6% 10%Stainless Steel 20% 26% 30%Copper 10% 16% 20%

HEAT EXCHANGERSShell and Tube, Fixed Tube Sheet,

and U-TubeErection Manhours

Erec

tion Manhours

Heating Surface Square FeetNote: Above manhours are for 150# rating.

Increase above for:300# Rating-10%600# Rating-20%

HEAT EXCHANGERS FORHEATING WATER

Equipment Cost

Equ

ipm

ent

Cos

t

Heating Surface Square Feet(D Carbon steel shells, copper-lined heads, %-inch cop-

per "U" tubes 18 BWG, two-pass, 150-pound con-struction.

© Carbon steel shells, copper-lined heads, bronze tubesheet, two-pass, 150-pound construction.


Equipment Cost

Equ

ipm

ent

Cos

t

Heating Surface Square Feet

® Carbon steel shell, %-inch O.D. copper "U" tubes 18BWG, two-pass, 150-pound construction.

(2) Carbon steel shell, bronze tube sheet, two-pass, 150-pound construction.

Ere

ctio

n M

anho

urs


Erection Manhours


Next Page

CENTRIFUGAL PUMPSSingle-Stage, Vertical Split Case

Equipment Cost

Equ

ipm

ent

Cos

t

Prime Mover Horsepower

(D 3,500 rpm—specific gravity of 1.0.(2) 1,750 rpm—specific gravity of 1.0.

Previous Page

CENTRIFUGAL PUMPSSingle-Stage, Horizontal Split

CaseEquipment Cost

Equ

ipm

ent

Cos

t


03,600 rpm—specific gravity of 1.0.© 1,750 rpm—specific gravity of 1.0.

CENTRIFUGAL PUMPSSingle-Stage ANSI and API 610

Equipment Cost

Equipment Cost


(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.

CENTRIFUGAL PUMPSTwo-Stage and Multi-Stage

Horizontal Split CaseEquipment Cost

Equ

ipm

ent

Cos

t

Prime Mover Horsepower® Two-stage, 3,550 rpm—specific gravity of 1.0©Multi-stage, 3,550 rpm—specific gravity of 1.0

CENTRIFUGAL PUMPSSingle-Stage, In-Line

Ductile Iron and Steel CasedAPI-610 Standard

Equipment Cost

Equipment Cost

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

GEAR PUMPSLight and Heavy Duty

Equipment Cost

Eq

uip

men

t C

ost

Motor Horsepower©Light duty©Heavy duty

SEWAGE PUMPSHorizontal and Vertical—

1,750 rpmEquipment Cost

Eq

uip

men

t C

ost

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

SEWAGE PUMPSHorizontal—1,750 rpm

Equipment Cost

Eq

uip

men

t C

ost

Motor Horsepower(D Horizontal—2%ineh solids©Horizontal—3-inch solids

SEWAGE PUMPSHorizontal and Vertical—

1,150 rpmEquipment Cost

Eq

uip

men

t C

ost

Motor Horsepower® Horizontal—l%ineh solids© Horizontal—2-inch solids(S) Horizontal—2%inch solids(D Horizontal—3-inch solids© Vertical—2-inch solids(§) Vertical—3-inch solids

SUMF AND PLUNGER PUMPSEquipment Cost

Equ

ipm

ent

Co

st

Motor Horsepower® Sump pumps—3,600 rpm—specific gravity of 1.0© Sump pumps—1,750 rpm—specific gravity of 1.0©Plunger pumps—10 to 350 gpm

VERTICAL TURBINE PUMPSSingle and Multi-Stage

Equipment Cost

Equ

ipm

ent

Co

st

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

CENTRIFUGAL PUMPSSingle-, Two-, Multi- and In-Line

Single StageErection Manhours

Erection Manhours

Prime Mover Or Motor Horsepower(D Single-stage or in-line single-stage©Two-stage©Multi-stage

GEARPUMPSLight and Heavy Duty

Erection Manhours

Ere

ctio

n

Man

hour

s

Motor Horsepower

©Light duty©Heavy duty

SEWAGE FUMPSHorizontal and Vertical

Erection Manhours

Ere

ctio

n

Man

hour

s

Motor Horsepower(D Horizontal©Vertical

SUMP AND PLUNGER PUMPSErection Manhours

Ere

ctio

n M

anho

urs

Motor Horsepower

(D Sump pumps© Plunger pumps

VERTICAL TURBINE PUMPSSingle- and Multi-Stage

Erection Manhours

Erection Manhours

Motor Horsepower

Next Page

REACTOBSGlass Lined, Agitated, Jacketed

25 and 100 psiEquipment Cost

Eq

uip

men

t C

ost

Capacity-Gallons

(D Glass-lined steel—25 psi©Glass-lined steel-100 psi

Previous Page

REACTORSGlass-Lined, Agitated, Jacketed

25 and 100 psiErection Manhours

Ere

ctio

n

Man

hour

s

Capacity-Gallons

® Glass-lined steel—25 psi©Glass-lined steel-100 psi

STEAM JET EJECTORSSingle-Stage Type

Equipment Cost

Eq

uip

men

t C

ost

Suction And Discharge Size Inches

STEAM JET EJECTORSSingle-Stage Type

Erection Manhours

Ere

ctio

n

Man

hour

s

Suction And Discharge Size Inches

GAS SCRUBBERSHigh-Energy Venturi Type

Equipment Cost

Equ

ipm

ent

Co

st

Approximate Weight Pounds(T) 12-gauge hot-rolled steel material(D K-inch plate hot rolled steel material® 12-gauge stainless steel material(D %-inch 304 stainless steel material

GAS SCRUBBERSHigh-Energy Venturi Type

Erection Manhours

Erection Manhours

Approximate Weight Pounds® Hot-rolled steel material(2) 304 stainless steel material

SEPARATORSVane TypeEquipment Cost

Eq

uip

men

t C

ost

Line Size Inches

(D 275-pound rating<2) 720-pound rating

SEPARATORSVane TypeEquipment Cost

Equ

ipm

ent

Cos

t

Unit Diameter Inches

(D Carbon Steel(2) Stainless Steel

SEPARATORSVane TyP6

Erection Manhours

Erection

Manhours

Line Size Inches

(D 150# or 300# raised face flanged—without base© 150# or 300# raised face flanged—with base

VIBRATING SEPARATORSEquipment Cost

Eq

uip

men

t C

ost


0 Carbon steel© Stainless steel

VIBRATING SEPABATORSCarbon or Stainless Steel

Erection Manhours

Erection

Manhours


API TYPE OIL/WATERSEPARATORS

Packaged Equipment Cost

Eq

uip

men

t C

ost

Gallons Per Minute

API TYPE OIL/WATERSEPARATORS

Packaged UnitsErection Manhours

Ere

ctio

n

Man

hour

s

Gallons Per Minute

Next Page

SIZE REDUCTION EQUIPMENTCrushersEquipment Cost

Equ

ipm

ent

Cos

t

Horsepower® Gyratory©Jaw

Previous Page

SIZE REDUCTION EQUIPMENTCrushers

Erection Manhours

Ere

ctio

n M

anho

urs

Horsepower

(D Gyratory©Jaw

SIZE REDUCTION EQUIPMENTImpact Breakers

Equipment Cost

Eq

uip

men

t C

ost

Horsepower

(D Dual rotary© Single rotary(E) Twin rotary

SIZE REDUCTION EQUIPMENTImpact Breakers

Erection Manhours

Ere

ctio

n

Man

hour

s

Horsepower® Dual rotary© Single rotary©Twin rotary

SIZE REDUCTION EQUIPMENTReversible and Non-reversible

HammermillsEquipment Cost

Eq

uip

men

t C

ost

Horsepower® Reversible© Non-reversible

SIZE REDUCTON EQUIPMENTReversible and Non-reversible

HaxnmermillsErection Manhours

Ere

ctio

n

Man

hour

s

Horsepower

SIZE REDUCTION EQUIPMENTRing-Type Granulators

Equipment cost

Eq

uip

men

t C

ost

Horsepower

SIZE REDUCTION EQUIPMENTRing-Type Granulators

Erection Manhours

Erection Manhours

Horsepower

HOT PROCESSWATER SOFTENER SYSTEM

Total Process Material and Equipment Cost

Total Process material

And Equipment Cost

Softener Diameter-Feet

HOT PROCESS WATERSOFTENER SYSTEMS

Total System Installation Manhours

Total System

Installation Manhours

Softener Diameter-Feet

API CONE ROOF STORAGETANKS

Subcontractor Installed Priceon Foundations by Others

Su

bc

on

tra

cto

r In

sta

lled

P

rice

Capacity-Barrels

API CONE ROOF STORAGETANKS


Su

bco

ntr

acto

r In

sta

lled

P

rice

Capacity-Barrels

API FLOATING ROOF STORAGETANKS


Su

bco

ntr

act

or

Inst

all

ed

P

ric

e

Capacity-Barrels

STORAGE TANKS—ASME SPHERESSubcontractor Installed Price

on Foundations by Others

Subcontractor Installed Price

Capacity-Gallons

(S) %-inch plate(D V2-inch plate(H) %-inch plate@ %-inch plate

TANK HEATING COILSFintube Type

Equipment Cost

Eq

uip

men

t C

ost


TANK HEATING COILSFintube Type

Erection Manhours

Ere

ctio

n

Man

hour

s


FIRED HEATERS FOR TANKSFintube Type

Equipment Cost

Eq

uip

men

t C

ost

BTU Per Hour® Gas-fired©Oil-fired

FIRED HEATERS FOR TANKSFintube Type

Erection Manhours

Ere

ctio

n

Man

hour

s

BTU Per Hour

Gas- or oil-fired.

TANK SUCTION ANDLINE TYPE FUEL OIL

HEATERSEquipment Cost

Equ

ipm

ent

Co

st

Gallons Per Hour©Tank suction type-heating range 60° to 140° F.© Line type—heating range 80° to 240° F.

TANK SUCTION ANDLINE TYPE FUEL OIL

HEATERSErection Manhours

Erection Manhours

Gallons Per Hour

©Tank suction type—heating range 60° to 140° F.© Line type-heating range 80° to 240° F.

PROFANE STORAGE TANKSASME 250 psi—117-Inch I.D.

Equipment Cost

Eq

uip

men

t C

ost

Shel l Length-Feet

PROPANE STORAGE TANKSASME 250 psi—117-Inch I.D.

Erection Manhours

Ere

ctio

n

Man

hour

s

Shell Length-Feet

Next Page

SHOP FABRICATED VESSELS24-Inch Through 144 Inch

DiameterAverage Weight—Pounds Per Linear Foot

Average Weight Pounds Per Linear Foot

Vessel Diameter-Inches

0 Horizontal vessels(2) Vertical vessels with legs® Vertical vessels with skirt plates

Previous Page

SHOP FABRICATEDHORIZONTAL VESSELS24-Inch Through 144-Inch

DiameterFabricated Cost Per Ton

Fab

ricate

d

Co

st

Per

T

on

Vessel Diameter - Inches

®SpotX-Rayed(2)100%X-RayedNote: If drip legs are required, weigh drip legs and

use $2.40 per pound for spot x-rayed and $2.50per pound for 100 percent x-rayed.Baffels, draw-off boxes and vortex breakers—estimate weight and price at 20 percent of thevessel per-ton cost.

SHOP FABRICATED VERTICALVESSELS WITH ANGLE LEGS

24-Inch Through 144-InchDiameter

Fabricated Cost Per Ton

Fab

ricate

d

Co

st

Per

T

on


(DSpotX-Rayed©100%X-RayedNote: For conical transmission pieces use three lin-

ear feet of the larger vessel diameter weight at35% of the cost per ton of that diameter vessel.See other graphs for tray rings, trays, anddemisting pads if required.

SHOP FABRICATED VERTICALVESSELS WITH ANCHOR RING

AND SKIRTS24-Inch Through 144-Inch

DiameterFabricated Cost Per Ton

Fab

ricate

d

Co

st

Per

T

on

Vessel Diameter - Inches(DSpotX-Rayed©100%X-RayedNote: For conical transmission pieces use three lin-

ear feet of the larger vessel diameter weight at35% of the cost per ton of that diameter vessel.See other graphs for tray rings, trays, anddemisting pads if required.

SHOP FABRICATED TRAYRINGSCost Each

Shop

Fab

rica

ted

Cos

t E

ach


® Tray rings for single-pass removable trays(D Tray rings for two-pass removable trays

COLUMN TOAYSShop Installation Only

36-Inch Through 144-InchDiameter

Installation Cost Each

Sh

op In

sta

lla

tio

n C

ost

E

ach


©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 includecost of tray.

DEMISTING PADSShop Installation

36-Inch Through 144-Inch VesselDiameter

Shop Installation Cost Each

Sh

op In

sta

lla

tio

n C

ost

E

ach


® 2-, 4-, or 6-inch pad with bottom grid only©2-, 4-, or 6-inch pad with bottom and top gridNote: Above cost includes furnishing and installing bar

support and installation only of pad as outlined.

SHOP STRESS RELIEF OPVESSELCost Pter Ton

Shop

Cos

t P

er T

on

Total Vessel Weight Tons

REMOVABLE TYPE TRAYS14 Gauge Stainless Steel Valve

Trays With Stainless Steel ValveDiscs 24-Inch Tray Spacing

Material Cost Each

Mat

eria

l C

ost

Eac

h

Tray Diameter Feet©Single downflow—410 stainless steel© Single downflow—304 stainless steel® Single downflow—316 stainless steel

REMOVABLE TYPE TRAYS14 Gauge Stainless Steel Valve

Trays With Stainless Steel ValveDiscs 24-Inch Tray Spacing

Material Cost Each

Mat

eria

l C

ost

Eac

h

Tray Diameter Feet

(D Double downflow—410 stainless steel© Double downflow—304 stainless steel(S) Double downflow—316 stainless steel

DEMISTING FADSFour-Inch Thickness

Material Cost Each

Ma

teri

al

Cos

t E

ach


(D Carbon steel(2) 410, 304, or 316 stainless steel® Monel

DEMISTING PADSPour-Inch Thickness

Top or Bottom Grids onlyMaterial Cost Each

Mate

rial

Co

st

Eac

h


0 Carbon Steel(D 410 or 304 Stainless Steel® 316 Stainless Steel(D Monel

VESSELS24-Inch Through 144-Inch

DiameterField Erection Manhours Per Ton

Ere

ctio

n M

anho

urs

Per

Ton

Vessel Weight-Tons

® Horizontal vessels© Vertical vesselsAdd for following if required:

Remove and replace manway cover—1.3 manhours per tray.Check tray and tighten retaining bolts—1.8 manhours per tray.

VESSEL TRAY INSTALLATION36-Inch Through 144-Inch Vessel

DiameterField Erection Manhours Each

Erection Manhours Each


® Single downflow valve or perforated tray types0 Double downflow valve or perforated tray types

DEMISTING PADS36-Inch Through 144-Inch Vessel

DiameterField Erection Manhours Each

Ere

ctio

n M

anho

urs

Eac

h

Vessel Diameter-Inches(D 2-, 4-, or 6-inch pad with bottom grid only© 2-, 4-, or 6-inch pad with bottom and top grid

Section 3

SITE PREPARATION

General preparation of the plant site for construction is included in thissection.

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 determinedfrom other sources.


AREA CLEAR AND GRUB

Manhours Per Acre

Manhours Per Acre

On Site Off SiteSite Description Disposal Disposal

Light 30.0 40.0Medium 40.0 50.0Medium Heavy 50.0 60.0Heavy 60.0 70.0

Light—Light brush and grass, no trees.Medium—Considerable brush of larger size.Medium Heavy—Large brush and small trees.Heavy—Much small brush, many small trees and occasional large trees.

All manhours 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 ofsite.

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

AREA CUTS AND FILLS

Manhours and Material Cost Per Acre

Land Average C.Y./AC. Average M.H./AC. Purchase

Description Cut Fill Cut Fill Fill/AC.

Level 1,080 532 40.0 5.0 $ 9,400Slightly Rolling 1,613 1,080 60.0 10.0 18,900Rolling 2,420 1,613 85.0 15.0 28,200Rough 2,952 1,888 105.0 17.0 33,100Very Rough 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 tograde 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 per square yard.Labor—Use 0.05 manhours per square yard.

Section 4

SITE IMPROVEMENTS

This section includes items of work that provide permanent improve-ments to the plant site, such as security fencing, railroads or spurs 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.

Pavements for roads, parking areas and process areas are included un-der "Discipline, Paving "

Site improvements will vary depending on site location, conditions, andproject 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 siteimprovements.

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 assuch includes his overhead and profit.

A six-foot-high chain link fence with three strands of barbwire, line andcorner post embedded in concrete, top rail and traffic and personnel gateswill cost an average of $15.50 per linear foot. Included in this price is instal-lation labor at an average of 0.35 manhours per linear foot.

Railroad and Spurs

Railroads including ballast, ties, tracks, switches, stops, etc., are usu-ally carried in the estimate as a subcontract item. The sub-base material

is usually furnished in place by the earth subcontractor or the generalcontractor.

1. Sub-base material will average 0.75 cubic yards per linear foot oftrack (2-rails) at:

Material—$22.00 per cubic yardLabor—0.60 manhours per cubic yard

2. Railroad and appurtenances subcontracted price including overheadand profit will average:

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

Included in this subcontract price is the cost of 1.06 manhours per lin-ear foot of track.

Tank Dikes

Earth type dikes include the furnishing, placing, and compaction of allearth materials. Concrete type dikes include all operations for the form-ing and placing of concrete.

1. Earth type dikes material will average 1.60 cubic yards per linearfoot of dike at the average cost of:


2. Concrete type dikes material will average 1.4 cubic yards of concreteper linear foot of dike at the average cost of:


Concrete Trenches

Concrete trenches two feet wide by two feet deep, with standard sumpsand basins and grated cover including all earthwork, concrete and relateditems will average:

Material—$35.00 per linear footLabor—2.50 manhours per linear foot

Drainage

Drainage items such as raw water, oily water, and pressurized systemswill vary depending on pipe size, elevations, etc. The following representsan average cost of all items involved:


Catch Basins and Manholes

Catch basins and manhole size and length will vary depending on capac-ity and bottom elevation. The following are average for this type installa-tion and include all costs for earthwork, concrete, concrete related items,frames and solid or grated covers:

Material—$700.00 eachLabor—25.00 manhours each

Road Culverts

Road culverts will vary in size depending on volume requirements. Thefollowing costs are based on using 24-inch reinforced concrete pipe whichseems to be predominant for this item:


Section 5

CONCRETE

Logarithmic graphs in this section indicate the value of labor in man-hours and materials in dollars of earthwork, concrete, fireproofing andgrout for equipment foundations and equipment structure foundations.

Earthwork and concrete for buildings are included with the buildingsand are not to be considered here.

The earth and concrete graphs are average and are based on the totalequipment count, even though some pieces of equipment may not requirefoundations.

Earthwork graphs include labor in manhours for all hand and machineexcavation and backfill. There is also a graph showing average quantitiesof required backfill in the event special fill material is required. Shouldspecial fill material be required it should be priced at the current materialvalue for that particular type of fill.

Concrete graphs include the furnishing, fabricating, and placing offorms, 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 ofspread type footings and reflect enough manhour and material values toinclude this item if required.

Graphs are included for fireproofing vessel skirts and structural steel.Should this not be required, simply disregard these graphs.

The graphs for grouting show average square feet required, for labormanhours and material value based on total equipment count for equip-ment support and total tons of steel for base plates.


CONCRETE FOUNDATIONSEarth Backfill Materials

Cubic Yards

Cub

ic

Yar

ds

Of

Ba

ckfi

ll

Pieces Of Equipment

©Equipment foundations©Equipment structure foundations© Pipe rack or sleeper foundations

CONCRETE FOUNDATIONSExcavation and Backfill

for Equipment FoundationsLabor Manhours

Lab

or M

anho

urs

Pieces Of Equipment

(D Hand excavation©Machine excavation(H) Hand backfill® Machine backfill

CONCRETE FOUNDATIONSFor Equipment Structures

and Pipe Rack and SleepersLabor Manhours

Lab

or M

anho

urs

Pieces Of Equipment

Equipment Structures Pipe Rack And Sleepers

(D Hand Excavation © Hand Excavation© Machine Excavation © Machine Excavation© Hand Backf ill CD Hand Backfill(D Machine Backfill ® Machine Backfill

CONCRETE FOUNDATIONSConcrete Quantities

Cubic Yards

Cubic Yards Of Concrete

Pieces Of Equipment

(D Equipment foundations© Equipment structure foundations® Pipe rack and sleeper foundations

CONCRETE FOUNDATIONSForms, Reinforcing, Embedments,

ConcreteMaterial Cost

Total Material Cost

Pieces Of Equipment

0 Equipment foundations(D Equipment structure foundations® Pipe rack and sleeper foundations

CONCRETE FOUNDATIONSForms, Reinforcing, Embedments,

ConcreteInstallation Manhours

Inst

all

ati

on

Man

hour

s

Pieces Of Equipment

® Equipment foundations© Equipment structure foundations©Pipe rack and sleeper foundations

CONCRETE FOUNDATIONSNonshrink—Nonmetallic Grout

Average Square Feet

Squa

re

Fee

t

Pieces Of Equipment Or Tons Of Steel

©Equipment

CONCRETE FOUNDATIONSFireproof ing Structural Steel

Total Material Cost

To

tal

Mate

rial

Co

st

Tons Of Stee l

CONCRETE FOUNDATIONSFireproof ing Structural Steel



Tons Of Stee l

CONCRETE FOUNDATIONSFireproof ing Vessel Skirts

Material Cost

To

tal

Mate

rial

Co

st

Pieces Of Equipment With Skirts

CONCRETE FOUNDATIONSFireproof ing Vessel Skirts

Erection Manhours

Ere

ctio

n

Man

hour

s

Pieces Of Equipment With Skirts

Section 6

STRUCTURAL STEEL ANDMISCELLANEOUS IRON

The curves in this section represent the material cost in dollars and theerection manhours required for equipment supports, equipment struc-tures and piperacks, and miscellaneous steel and iron for equipment plat-forms, walkways, and ladders.

All steel items are based on the total pieces of equipment even thoughsome pieces will require no steel.

If pipe racks are not required, delete these curves from the estimate.All building steel is included with the buildings and is not a part of this

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

troduction to this manual before applying this information.

STRUCTURAL STEELTons Required

Tons

R

equi

red

Pieces Of Equipment

MISCELLANEOUS IRONTons Required

Ton

s R

equ

ired

Pieces Of Equipment

PIPE RACK STEELTons Required

Ton

s R

equi

red

Pieces Of Equipment

STRUCTURAL STEELEquipment Supports and

StructuresMaterial Cost

Ma

teri

al

Co

st

Pieces Of Equipment

STRUCTURAL STEEL FORPIPE RACKS

Miscellaneous Iron for EquipmentMaterial Cost

Mat

eria

l C

ost

Pieces Of Equipment©Miscellaneous iron© Pipe racks

STRUCTURAL STEEL ANDMISCELLANEOUS IRON

Equipment, Equipment Supportsand Structures, and Pipe Racks

Erection Manhours

Ere

ctio

n M

anho

urs

Pieces Of Equipment

® Structural steel® Miscellaneous iron© Pipe racks

Section 7

BUILDINGS

The scope of work, for a proposed project should include information asto type and size of buildings required.

The logarithmic graphs included in this section show average labor inmanhours 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 interiorfinishes, sprinkler system, plumbing, HVAC, and electrical power andlighting. AU utilities extend five feet outside of building.

Following is a listing of buildings with a brief description of their typesand inclusions.


Building Types and Descriptions

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.

Laboratory Building:

Same type construction as office building with additional plumbing andelectrical outlets for laboratory equipment.Note: No laboratory equipment or furniture is included.

Control Building

Structure—Structural steel framing.Exterior Walls—Concrete block, hollow metal 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.

Warehouse Building:

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.

Maintenance Shop BuildingSame type construction as warehouse with additional foundations forshop equipment and including an overhead crane.Note: No shop equipment is included.

Change House Building

Same type construction as control building with concrete locker bases,lockers and additional toilet and shower facilities for men and women.

BUILDING MATERIALSCost Per Square Foot

Materials Only

Material Cost Per Square Foot

Square Feet Of Floor Area

(D Office building ® Warehouse building(D Laboratory building © Maintenance shop building(E) Control building ® Change house building

BUILDING ERECTIONManhours Per Square Foot

Manhours Per Square Foot

Square Feet Of Floor Area

(D Office building (D Warehouse building© Laboratory building © Maintenance shop building® Control building © Change house building

Section 8

PIPING

In the absence of plot plans, piping and instrument diagrams, and flowsheets the cost of process piping can be determined from the followinglogarithmic graphs.

The graphs are based on total equipment count.All dollar costs on the material graphs are average and include the costs

of all pipe, valves, and fittings that should be required. Control 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 graphs include all labor, material, and shop costsfor furnishing and fabricating pipe spools and delivery within reasonabledistance of job site.

Graphs for underground potable water, 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, isincluded under the building section and is not to be considered here.


SHOP FURNISH ANDFABRICATE PIPE AND

FITTINGSLinear Feet of Pipe For Pieces Of Equipment

Lin

ear

Feet

Of

Pip

e

Pieces Of Equipment

©Alloy 2V2" and over©Carbon steel 2V2" and over©Alloy 2" and under


FITTINGSCost For Pieces Of Equipment

Shop Furnish And Fabricate Total Cost

Pieces Of Equipment

OAlloy2J/2" and over© Carbon steel 2Vz" and over©Alloy 2" and under


FITTINGSCost For Pieces of Equipment

Shop Furnish And Fabricate Total Cost

Pieces Of Equipment

©Alloy 2 ^ " and over© Carbon steel 2te" and over©Alloy 2" and under

FIELD FURNISH, FABRICATE9AND ERECT PIPE, FITTINGS,

AND VALVESLinear Feet Of Pipe For Pieces Of Equipment

Linear Peet Of Pipe

Pieces Of Equipment

(D Carbon steel 21^" and over(E) Carbon steel 2" and under(S) Steam tracing(D Underground©Alloy 2" and under

FIELD FURNISH9 FABRICATE9AND ERECT PIPE9 FITTINGS9

AND VALVESMaterial Cost For Pieces Of Equipment

Mat

eria

l C

ast

Pieces Of Equipment

® Carbon steel 2W and over© Carbon steel 2" and under© Carbon steel underground

FIELD FURNISH, FABRICATE9AND ERECT PIPE, FITTINGS,


Pieces Of Equipment©Carbon steel 2%" and over© Carbon steel 2" and under© Carbon steel underground

FIELD FURNISH, FABRICATE,AND ERECT STEAM TRACINGPIPE, FTTTINGS, AND VALVES

Material Cost For Pieces Of Equipment

Pieces Of Equipment

FIELD FUBNISH9 FABRICATE9AND ERECT PIPE9 FITTINGS9


Material Cost

Pieces Of Equipment

0 Alloy 2" and under

FIELD ERECT SHOPFABRICATED SPOOLS

PIPE, FITTINGS, AND VALVESLabor Manhours For Pieces Of Equipment

Erection Manhours

Pieces Of Equipment

Note: All items include installation of control valves.©Alloy 2Mz" and Over©Carbon Steel 2te" And Over©Alloy 2" And Under

FIELD FURNISH, FABRICATE,AND ERECT PIPE, FITTINGS,

AND VALVESLabor Manhours For Pieces Of Equipment

Erection Manhours

Pieces Of EquipmentNote: All items include installation of control valves.® Carbon steel 21^" and over® Carbon steel 2" and under

FIELD FURNISH, FABRICATE,AND ERECT

PIPE, FITTINGS, AND VALVESLabor Manhours For Pieces Of Equipment

Ere

ctio

n M

anho

urs

Pieces Of Equipment

Note: All items include installation of control valves.(D Carbon steel underground© Steam tracing©Alloy 2" and under

FIELD FURNISH9 FABRICATE9AND ERECT

MISCELLANEOUS PIPINGITEMS

Material Cost For Pieces Of Equipment

Mat

eria

l C

ost

Pieces Of Equipment

(D Hangers and supports© Testing pipe and fittings© Testing welders

FIELD FURNISH, FABRICATE9AND ERECT

MISCELLANEOUS PIPINGITEMS

Total Manhours For Pieces Of Equipment

Tot

al M

anho

urs

Pieces Of Equipment

(D Hangers and supports(2) Testing pipe and fittings© Testing welders

FIELD FURNISH, FABRICATE,AND ERECT

X-RAY AND STRESSRELIEVING

Total Subcontract Cost For Pieces Of Equipment

Total Subcontract Cost

Pieces Of Equipment

Section 9

ELECTRICAL

Logarithmic graphs in this section reflect the average cost of projectpower and lighting excluding building electrical that is included with thebuilding section.

Power and lighting graphs for material in dollars and labor in manhoursare included for the battery limit requirements and are based on totalpieces of equipment.

Instrumentation graphs 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 tubebundles are discussed in Section 10, "Instrumentation."


ELECTRICAL POWERPower Material Cost

Electrical Power Material Cost

Pieces Of Equipment

ELECTRICAL POWERInstallation Manhours

Inst

all

ati

on

Man

hour

s

Pieces Of Equipment

ELECTRICAL LIGHTINGLighting Material Cost

Lighting Material Cost

Pieces Of Equipment

ELECTRICAL LIGHTINGInstallation Manhours

Inst

all

ati

on

Man

hour

s

Pieces Of Equipment

ELECTRICALINSTRUMENTATION

Total Miscellaneous Instrumentation Material Cost

Miscellaneous Electrical Instrument Material Cost

Pieces Of Equipment

Note: Pneumatic instruments and other instrumentmaterials are included under "Instruments."

ELECTRICALINSTRUMENTATION

Miscellaneous Electrical Instrument Manhours


Pieces Of Equipment

Note: Manhours for installation of electrical instrumentmaterials only. All other instrument manhoursincluded under "Instruments"

Section 10

INSTRUMENTATION

The following graphs represent the average number of instruments re-quired, their material value in dollars and installation in manhours basedon total pieces of equipment.

Included with the instrument graphs are dollars and manhours for thefurnishing 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, "Electrical".


INSTRUMENTSTotal Number Of Instruments Required

Num

ber

Of

Inst

rum

ents

Pieces Of Equipment

INSTRUMENTSTotal Material Cost

Cos

t O

f In

stru

men

ts

Pieces Of Equipment

INSTRUMENTSTotal Instrument Installation Manhours


Pieces Of Equipment

CONTROL VALVESTotal Material Cost

Control Valves Material Cost

Pieces Of EquipmentNote: Installation manhours included under "Piping."

STANDARDS, TRAY SUPPORTS,TRAYS, TUBES, AND TUBE

BUNDLESTotal Material Cost

Tot

al M

ater

ial

Cos

t

Pieces Of Equipment

STANDARDS, TRAY SUPPORTS,TRAYS, TUBES, AND TUBE

BUNDLESTotal Installation Manhours

Inst

all

ati

on

Man

hour

s

Pieces Of Equipment

Section 11

INSULATION

The following piping and equipment insulation graphs are based on to-tal pieces of equipment for a project and are average for various typesand thickness that are more or less standard for refinery and petrochemi-cal work.

All building insulation is discussed in Section 7, "Buildings."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-


INSULATING MATERIALFOR EQUIPMENT

Total Material Cost

To

tal

Mate

rial

Co

st

Pieces Of Equipment

INSULATING MATERIALFOR PIPING

Total Material Cost

Total Material Cost

Pieces Of Equipment

Section 12

PAINTING

Based on total pieces of equipment the following graphs are averagecost 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 painting is discussed in Section 7, "Buildings."I caution the engineer/estimator to be thoroughly familiar with the in-


PAINTING—EQUIPMENTSquare Feet Area

Squa

re F

eet

Are

a

Pieces Of Equipment

PAINTING—STRUCTURALSTEEL AND PIPING

Square Feet Area

Squa

re

Fee

t A

rea

Pieces Of Equipment

(D Structural steel©Piping

PAINTING—MISCELLANEOUSAND PIPE RACK STEEL

Square Feet Area

Square Feet Area

Pieces Of Equipment

0 Miscellaneous iron©Pipe rack steel

PAINTING—EQUIPMENTTotal Material Cost

Tot

al M

ater

ial

Cos

t

Pieces Of Equipment

PAINTING—EQUIPMENTTotal Manhours

Pain

tin

g M

anho

urs

Pieces Of Equipment

PAINTING—STRUCTURALSTEEL

Total Material Cost

Tot

al M

ater

ial

Cos

t

Pieces Of Equipment

PAINTING—STRUCTURALSTEEL

Total Manhours

Pain

tin

g M

anho

urs

Pieces Of Equipment

PAINTING—PIPINGTotal Material Cost

To

tal

Ma

teri

al

Co

st

Pieces Of Equipment

PAINTING—PIPINGTotal Manhours

Pain

tin

g M

anho

urs

Pieces Of Equipment

Section 13

PAVING

This section includes items of work for the installation of road, parkingarea and yard pavements.

The placement of sub-base materials for these items is described in Sec-tion 4, "Site improvement." The furnishing and placing of finish base andasphalt, concrete or gravel pavement is included.

The scope of work or other proposal documents should indicate thepavement requirements. In the absence of this information, the followingallowances 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.


ASPHALT PAVEMENT6-Inch Base—2 Inches Asphalt

Total Subcontract Price

Total Subcontract Price

Square Yards

CONCRETE AND GRAVELPAVEMENTS

Total Material Cost

Tot

al M

ater

ial

Cos

t

Square Yards

012-inch base material and 6-inch reinforced concrete® 6-inch gravel pavement

CONCRETE AND GRAVELPAVEMENTS

Total Manhours

Tot

al M

anho

urs

Square Yards

(D 12-inch base material and 6-inch reinforced concrete© 6-inch gravel pavement

Section 14

PRORATABLES

Materials costs in dollars and labor in manhours on the following graphsreflect the average cost and time required for daily area clean-up, all proj-ect scaffolding and final test, start-up, and pre-commissioning assistance.


PRORATABLE MATERIALTotal Material Cost

Tot

al M

ater

ial

Cos

t

Pieces Of Equipment

PRORATABLE LABORTotal Manhours

Tot

al

Man

hour

s

Pieces Of Equipment

Section 15

CONSTRUCTION EQUIPMENT

The average cost of equipment to construct a project can be estimatedfrom the following logarithmic graphs.

The rental or purchase curve represents the average cost of rental orpurchase of construction equipment to construct the project. This doesnot include small tools.

The fuel, oil, grease, and supply curve includes the cost of these itemsto 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 theoperating labor of the equipment when working. Operators are includedin the direct account labor.


CONSTRUCTION EQUIPMENTBASE RENTAL OR PURCHASE COST

FUEL, OIL, GREASE, ANDSUPPLIES COST

To

tal

Co

st

Total Direct Field Labor Cost In Million Dollars

(D Rental or puchase cost©Fuel, oil, grease and supplies cost

CONSTRUCTION EQUIPMENTSERVICE LABOR

Total Manhours

Total Manhours

Equipment Rental Or Purchase CostIn Hundred Thousand Dollars

Section 16

OVERHEADS AND INDIRECTS

Included in this section are logarithmic graphs reflecting average costof 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 forease of listing and application. For a comprehensive listing of total cover-age of items under this section refer to the overhead and indirect listingsunder 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.

INDIRECT LABOREngineering and Supervision

PersonnelTotal Manhours

Tot

al M

anho

urs

Total Direct Labor In Hundred Thousand Dollars

(D Engineering personnel© Supervision personnel

INDIRECT LABOROffice Personnel

Total Manhours

Total Manhours


OTHER INDIRECT ANDTEMPORARY CONSTRUCTION

LABORTotal Manhours

Total Manhours


® Other Indirect Labor(D Temporary Construction Labor

PAYROLL BURDENS ANDBENEFITS

Other Indirect andTemporary Construction

MaterialsTotal Cost

To

tal

Co

st

Total Direct Labor In Hundred Thousand Dollars©Payroll burdens and benefits(2) Other indirect materials(H) Temporary construction materialsNote: See next page for continuation of these items.

PAYROLL BURDENS ANDBENEFITS

OTHER INDIRECT MATERIALSTotal Cost

To

tal

Co

st

Total Direct Labor In Million Dollars(D Payroll burdens and benefits(E) Other indirect materials

Section 17

HOME OFFICE COST

Total engineering design, including construction services such as esti-mating, scheduling, expediting, etc., project general management, designallowance, and fee are included as a part of home office cost and as suchare considered under this section.

Manhour range tables listing manhour ranges for single and duplicatepieces 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 blueprints, reproductions, computer use, miscellane-ous expenses, travel expenses, telephone, telex, postage, and burdensand benefits are to be established as a percent of the total labor dollars inaccordance with the following percentage spread table for these items.

After the total labor and material dollars are established, the estimatorneed only apply a cost for design allowance and fee for a complete homeoffice engineering design cost.

See Section 19, "Definition of Estimate Adjustments," for design allow-ance and fee definitions.


ENGINEERING DESIGN

Manhour Range AllowancePer Piece of Equipment

Equipment Classification

Boilers And HeatersPackaged Steam BoilersPackaged Electric Hydronic BoilersCast Iron Gas Fired BoilersSteel Boiler StacksFired HeatersDeaerating Heaters

Classification Equipment

Cone Type PelletizersPressure SiftersRotary ScreensTurbo-Screen Classifiers

Compressors And Air Dryers

Reciprocating Gas Engine CompressorsReciprocating Electric CompressorsCentrifugal Package Unit CompressorsAir Cooled Service CompressorsAir Dryer—Refrigerated TypeAir Dryer—Chiller Type

Conveyors And Bucket Elevators

Conveyor—Open BeltConveyor—Belt Enclosed With WalkwayConveyor—Steel ScrewConveyor—ReciprocatingConveyor—ScrollConveyor—Spaced Bucket ElevatorConveyor—Continuous Bucket Elevator

CrystallizersBatch VacuumMechanical

Dow Therm Units

Manhour Allowance For

SingleUnit Range

800-1,000800-1,000650-850400-500600-800600-800

400-600450-650400-600500-700

1,000-1,2001,000-1,200

850-1,000600-800650-850650-850

800-1,0001,000-1,200

850-1,000800-1,000800-1,000800-1,000800-1,000

650-850700-900750-850

DuplicateUnit Range

400-500400-500350-450200-250300-400300-400

200-400225-325200-400250-350

600-700600-700425-500300-400325-425325-425

400-500500-600400-500400-500400-500400-500400-500

325-425350-450300-400

ENGINEERING DESIGN



Dry Material Blenders And FeedersBlendersVibrating PackersElectric Vibrating FeedersGravimetric FeedersVolumetric FeedersWing-Type FeedersConveyor Type FeedersSanitary Type FeedersDry Polymer Feeders

Dryers And FlakersAtmospheric Drum DryerVacuum Drum DryerTwin Drum DryerTray Atmospheric DryerTray Vacuum DryerRotary DryerSpray DryerCooling Drum Flakers

Dust Collectors

CycloneMulti CyclonesWashersAutomatic Cloth FiltersCentrifugal PrecipitatorsElectrical PrecipitatorsFeeder Valves

Ejectors

Single-Stage NoncondensingTwo-Stage Barometric Intercondenser

ExtractorsContinuous Centrifugal


SingleUnit Range

50-10050-10050-10050-10050-10050-10080-15080-15070-120

700-900700-900800-1,000800-1,000800-1,000800-900800-900700-900

700-900800-1,000800-1,000800-1,000

1,000-1,2001,000-1,200

300-400

200-400200-400

200-500

DuplicateUnit Range

20-4020-4020-4020-4020-4020-4030-7030-7030-50

350-450350-400400-500400-500400-500400-450400-450350-450

350-450400-500400-500400-500500-600500-600150-200

100-200100-200

100-200

ENGINEERING DESIGN



Fans And BlowersHeavy Gauge Centrifugal FansMotors And V-BeIt Drive For FansRotary BlowersCentrifugal Turbo Blowers

Filters

Pressure TypeOil Mist CollectorsPlate And Frame TypeSparklerLeafSewage And RotaryScreen Vibrating

Flotation MachinesGas HoldersGenerators

Steam Turbine UnitsInert Gas GeneratorsSkid Mounted—Diesel Engine Driven

Heat Exchangers, Evaporators And Condensers

Shell And Tube, Floating Head ExchangersShell And Tube, Fixed-Tube Sheet, U-Tube

ExchangersSteel Fin Tubes, Steel ReBoilers And

Jacketed PipeLong Tube Vertical EvaporatorsHorizontal Tube EvaporatorsJacketed, Glass Lined Steel Vessel EvaporatorsCondensers—Barometric


SingleUnit Range

600-800100-150400-600600-800

200-300200-300200-400200-300200-300300-400400-600400-600150-200

5,000-8,0002,000-4,0001,000-2,000

600-800

600-800

600-800800-900800-1,000850-1,050650-850

DuplicateUnit Range

300-40050-60

200-300300-400

100-150100-150100-200100-150100-150150-200200-300200-25050-70

2,000-3,500800-1,500300-500

300-400

300-400

300-400400-450400-500425-525325-425

ENGINEERING DESIGN



Mixers And Blenders For Liquid And Liquid Solids

Propeller MixersBlender Type MixersPan And Sigma MixersHomogenizersHigh Intensity Mixers

Pumps

CentrifugalVertical Turbine And SumpPower And Internal Gear RotaryVacuumSewage Nonclog

Scales And Weighing Equipment

Mechanical Lever Truck ScalesElectronic Load Cell Truck ScalesBuilt In Industrial ScalesAutomatic Bagging ScalesBulk Weighing Scales

Separators

Centrifugal Batch Top SuspendedCentrifugal Batch Bottom DrivenCentrifugal Batch AutomaticCentrifugal High Speed

Size Reduction Equipment

Size Reduction CrushersSize Reduction Mills, Cutters, PulverizersBall Mills

ThickenersContinuous Type

Manhour Allowance ForSingle

Unit Range

50-15050-15050-15060-15060-150

700-900850-1,100700-900400-600700-900

1,000-1,2001,000-1,200

200-300200-300300-400

600-800600-800700-900700-900

400-600400-600500-700

400-600

DuplicateUnit Range

20-6020-6020-6025-6025-60

350-450425-550350-450200-300350-450

500-600500-600100-150100-150150-200

300-400300-400350-450350-450

200-300200-300250-350

200-300

ENGINEERING DESIGN



Vessels, Reactors And Tanks

Horizontal Pressure VesselsVertical Pressure Vessels (Towers)Agitated, Jacketed ReactorsVacuum Receiver TanksAgitated TanksStorage Tanks

Waste Treatment EquipmentSewage Treatment Plant PackageIncinerators—Liquid WasteIncinerators—Solid WasteSolid Waste ShreddersWastewater Treatment Package System

Water Treating Equipment

Mechanical Surface AeratorsIon Exchanger DemineralizersWater Stills


SingleUnit Range

800-1,0001,000-1,2001,000-1,200

800-1,000700-900600-1,000

600-800500-800500-800400-600600-800

850-1,000600-800200-300

DuplicateUnit Range

400-500500-600500-600400-500350-450300-500

300-400250-400250-400200-300300-400

425-500300-400100-200

ENGINEERING DESIGN

Other Cost as a Percent ofTotal Engineering Design Labor Dollars

Item PercentBlue Prints And Reproduction 14.0Computer Use 12.0Miscellaneous Expense 10.0Travel Expense 3.0Telephone, Telex And Postage 4.0Burdens And Benefits 32.0Total 75.0

ENGINEERING DESIGN

Manhour Spread Percentages

Per Cent

Discipline 1 2 3__

Operations Management 0.1 0.1 0.1Project Management 1.5 1.6 1.9Project Engineer 5.5 6.1 7.0Design Supervisor 0.9 1.0 1.0Civil/Structural 5.2 8.7 6.3Vessels 2.6 2.8 3.1Electrical 5.9 6.5 7.2Plant Design 19.7 17.0 23.8Piping 3.0 2.3 3.8Administration 4.3 4.7 5.0P & Fs Flow Diagrams 2.1 2.0 2.7Mechanical Supervision 0.4 0.4 0.4Instrument Engineering 3.6 5.0 4.4Instrument Drafting 4.9 6.4 5.8Rotating Equipment 0.8 0.8 0.9Special Equipment 1.2 1.3 1.4Heat Transfer 0.5 0.5 0.6Process 4.2 4.6 5.1Estimating 1.0 1.0 1.1Cost Engineering 1.7 1.3 1.4Computer 2.5 2.5 2.8Initial Operations 0.1 0.2 0.2Technical Information 0.1 0.1 0.1Scheduling 2.2 1.5 1.4Purchasing 3.9 3.8 0.0Inspection/Expediting 3.9 3.8 0.0Stenographic 3.8 4.1 4.6Accounting 8.8 5.8 5.8Office Services 1.5 1.6 1.7Contract Legal 0.1 0.1 0.1Home Office Construction 2.0 LO OO

Total 100.0 100.0 100.0

Code:1—Engineering, Procurement And Construction Contract2—Engineering And Procurement Contract3—Engineering Only Contract

Section 18

RATIO ESTIMATING FACTORS

Ratio estimating factors are simply the relationship, in percentageranges, 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 ofthis type is:

1. Information regarding plant capacity, product form, basic processand raw material.

2. A complete process equipment list with individual shipping datesand 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 appliedagainst the total material dollar value of the process equipment. The con-struction equipment and overhead and indirects percent ranges are a per-cent of the direct field labor dollar value. The home office percent range isapplied against the total direct and indirect cost of the project.

The percentages for the various disciplines of work are averages ofmany 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 merit shop type operations. Ifclosed shop methods are to be employed additional consideration shouldbe given and applied against the labor dollar value.

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.

For a description of items included under the various disciplines of worksee Section 1, "Disciplines of Work."

Ratio Estimating Factors

The Refinery Process Systems table is based on any one or all of thefollowing process systems and includes all discipline requirements.

1. Atmosphere and vacuum crude distillation2. Saturates gas plant3. Naphtha hydrodesulphurization4. Distillate hydrotreater5. Flexicoker6. Heavy oil hydrodesulphurization7. Fluid catalytic cracker8. Unsaturates gas plant9. Cycle oils hydrodesulphurization

10. C5, C6 isomerization11. Catalytic reformer12. Aromatics extractions13. Steam reforming hydrogen plant14. Butane alkylation15. Olifin poly plant16. H2S recovery and sulphur manufacturing

Tables on Chemical Plants are self-explanatory.I caution the engineer/estimator to be thoroughly familiar with the in-


REFINERY PROCESS SYSTEMS

Ratio PercentagesDirect Cost

AveragePercent

Percentage Ratio Ranges of TotalsDiscipline 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 49.972. Site Preparation 0.02-0.05 0.25-0.30 2.75-2.85 0.01 0.55 3.59 1.013. Site Improvements 0.95-1.10 * 1.10-1.12 0.55 * 1.43 0.694. Concrete 4.25-4.75 0.10-0.12 12.70-12.90 2.41 0.22 16.42 5.635. Structural Steel 8.00-8.30 * 3.70-3.75 4.53 * 4.82 3.906. Buildings 1.10-1.25 2.20-2.40 1.70-1.75 0.66 4.81 2.21 1.717. Underground Piping 1.10-1.20 * 1.40-1.48 0.62 * 1.84 0.838. Above-ground Piping 32.00-35.00 0.75-0.80 21.30-22.40 18.59 1.60 27.51 18.199. 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 5.8111. Instrumentation 10.30-10.70 * 3.20-3.50 5.82 * 4.16 4.4812. Insulation 4.50-5.00 * 7.40-7.50 2.55 * 9.57 3.9413. Painting 1.50-1.70 * 3.90-4.00 0.93 * 5.06 1.8414. Paving 0.40-0.60 * 0.60-0.70 0.27 * 0.81 0.3615. Proratables 1.00-1.10 * 2.80-2.95 0.60 * 3.79 1.32

** lbtal 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**)

LIQUID TYPE CHEMICAL PLANT


AveragePercent


1. Process Equipment 100.00 24.00-25.50 3.75-5.50 43.50 61.30 5.44 37.602. Site Preparation 1.75-2.50 0.01-0.01 0.50-1.00 1.00 0.01 0.72 0.823. Site Improvements 2.75-3.50 0.60-0.75 1.50-2.25 1.30 1.74 2.95 1.704. Concrete 7.50-8.75 2.00-3.00 9.00-12.00 3.58 6.30 15.04 6.395. Structural Steel 11.50-12.50 * 4.00-6.00 5.20 * 6.51 4.896. Buildings 4.00-5.00 3.00-3.50 3.50-4.50 1.90 8.23 6.08 3.557. Underground Piping 4.00-5.00 0.01-0.02 2.75-3.25 2.00 0.02 4.04 2.178. Above-ground Piping 37.00-43.00 2.75-3.25 24.00-27.00 18.30 7.35 34.54 20.409. Underground Electric 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 6.8511. Instrumentation 22.00-25.00 * 3.25-4.50 10.90 * 4.59 8.2412. Insulation 7.50-8.50 * 4.50-5.25 3.60 * 6.44 3.7413. Painting 2.50-3.25 * 2.75-2.90 6.30 * 3.93 1.7014. Paving 1.00-1.50 0.30-0.40 0.50-1.00 0.50 0.85 1.05 0.6615. Proratables 1.00-1.50 * 2.00-2.40 0.60 * 3.09 1.04

** Total Direct Cost 217.9-237.5 32.57-36.43 68.7-85.7 100.0 100.0 100.0 100.0





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**)

SOLID TYPE CHEMICAL PLANTSRatio Percentages

Direct Cost

AveragePercent

Percentage Ratio Ranges of TotalsDiscipline I II IH IV V VI VlT


10. Above-ground Electric 15.50-17.00 * 6.75-7.25 7.35 * 8.72 6.8911. Instrumentation 12.25-14.00 * 1.50-2.50 5.51 * 2.11 4.1412. Insulation 5.50-6.50 * 3.00-4.00 2.47 * 4.03 2.5613. Painting 2.00-2.75 * 1.75-2.25 0.91 * 2.46 1.1714. Paving 1.10-1.80 0.30-0.40 0.75-1.00 0.52 0.98 0.98 0.6815. 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










LIQUID/SOLID TYPE CHEMICAL PLANTS


AveragePercent



10. Above-ground Electric 17.00-18.00 * 7.15-8.00 7.30 * 9.00 6.9411. Instrumentation 24.00-27.00 * 3.30-4.60 10.48 * 4.17 8.0012. Insulation 8.00-9.00 * 4.50-5.50 3.37 * 5.72 3.5513. Painting 3.00-3.50 * 2.80-3.10 2.14 * 3.49 1.6214. Paving 1.25-1.75 0.30-0.50 0.75-1.25 0.47 0.96 0.94 0.6315. 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




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)


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**)

CHEMICAL PLANT—LIQUID HIGH PRESSURE TYPE4000 TO 5000 PSI


AveragePercent

Percentage Ratio Ranges of TotalsDiscipline I II III IV V VI VII


10. Above-ground Electric 16.50-17.25 * 6.75-7.25 7.19 * 9.34 6.9411. Instrumentation 26.50-27.50 * 3.50-4.00 11.66 * 4.88 9.0412. Insulation 8.00-8.50 * 4.50-5.00 3.54 * 6.33 3.7913. Painting 2.75-3.25 * 2.75-3.00 1.30 * 3.86 1.7314. Paving 0.75-1.25 0.02-0.04 0.50-0.70 0.37 0.80 0.79 0.5115. Proratables 1.25-1.50 * 2.00-2.50 0.63 * 3.28 1.15











CHEMICAL PLANT—LIQUID HIGH ALLOY TYPE


AveragePercent

Percentage Ratio Ranges of TotalsDiscipline I II HI IV V VI V lT


10. Above-ground Electric 11.00-12.00 * 4.50-5.25 5.06 * 6.69 4.8811. Instrumentation 23.50-25.00 * 3.00-4.00 10.75 * 4.58 8.3112. Insulation 6.75-7.25 * 3.50-4.00 3.11 * 5.67 3.3313. Painting 2.50-3.00 * 2.25-2.50 1.14 * 3.46 1.5214. Paving 0.75-1.00 0.25-0.50 0.50-0.70 0.42 0.81 0.87 0.5415. Proratables 1.25-1.50 * 2.00-2.50 0.65 *• 3.44 1.18











CONSTRUCTION EQUIPMENT

Ratio PercentagesAs A Percent Of Direct Field Labor

Percent ofDirect Field Labor

Description Range Average

16. Rental or Purchase 12.0-18.0 15.017. Service Labor 2.0-6.0 4.018. Fuel, Oil, Grease, Supplies 7.0-15.0 1^0

Tbtal 21.0-39.0 31.0

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

OVERHEAD AND INDIRECTS

Ratio PercentagesAs A Percent Of Direct Field Labor

Percent ofDirect Field Labor


19. Salaried Indirect 8.0-12.0 10.0Office Hourly Indirects 4.0-8.0 16.0Field Hourly Indirects 3.0-7.0 5.0

20. Temporary Construction 10.0-20.0 15.0Facilities*

21. Burdens and Benefits 25.0-28.0 27.022. Small Tools and Consumables 5.0-10.0 7.023. Other Indirects 10.0-20.0 1^0

Tbtal 65.0-105.0 85.0

* Includes Labor for Constructing.

HOME OFFICE SERVICES

Ratio PercentagesAs A Percent Of Tbtal Direct And Indirect Cost

Percent of TotalDirect and Indirect


24. Engineering/Design Services 8.0-16.0 12.025. Construction Services 0.1-0.4 0.226. Project General Management 1.0-1.5 U

Tbtal 9.1-17.9 13.3

Section 19

ESTIMATE ADJUSTMENTS

Each estimate, in all probability, will need some or all of the followingadjustments dependent upon the scope of work, amount of pre-bid infor-mation available, and the type of estimate to be prepared. The followingare definitions of these adjustments:

Design Allowance. The design allowance is an adjustment to the es-timated mechanical equipment cost to provide for nominal and routinechanges in equipment design. The design allowance is included in the de-tails of the estimate and is considered as part of the direct base cost. Themagnitude of the design allowance is a function of the amount of designinformation available to the estimator, and it decreases as the accuracylevel of the estimate increases. An example of a design allowance is theaddition of money for routine nozzle and clip changes on a fabricated ves-sel. It is expected that all design allowance money will be expended dur-ing the project.

Quantity Allowance. The quantity allowance is an adjustment tothe estimated construction activity take-off quantities to provide for (1)the difference between neat take-off quantities and in-place quantitiesand for (2) consideration of fabrication waste. The quantity allowance isincluded in the details of the estimate and is considered as a part of thedirect base cost. The magnitude of the quantity allowance is a function ofthe amount of design information available to the estimator and de-creases as the accuracy level of the estimate increases. An example of aquantity allowance is adding to the piping take-off an allowed quantity ofsmall diameter pipe and valves for vents and drains not shown on esti-mate drawings. It is expected that all quantity allowance money will beexpended during the project.

Escalation. The escalation is the amount of dollars or percentage ofcost added to the estimated base cost to provide for procurement at a fu-ture date later than the estimate. The magnitude of the escalation is a

function of an appraisal of anticipated market conditions during the de-sign and construction phases of the project. It is expected that all escala-tion money will be expended during the project.

Contingencies. A percentage of base cost plus escalation and taxesor amounts added to same providing coverage for human calculation orjudgement error in accumulation of estimate scope. Contingencies are an-ticipated to be spent and form a part of the cost of the project. Contingen-cies vary directly with the accuracy level of the estimate. The more grossthe method of estimating, the higher the contingencies. Contingencies donot provide any funds for scope changes. Examples of items covered bycontingency are: piping lines missed on take-off, extension errors, dimen-sion errors, etc.

Bisk. An amount of money or percent of base cost plus lower level ad-ditives (except fee) normally added to the base cost plus additives tocover the chances of probabilities that the base cost estimate plus addi-tives is not ample for financing of the project. Risk is normally associatedwith the monies applied by a contractor's management in the case of a"lump sum" or "guaranteed maximum" or an owner for other contractualarrangements to cover costs that might occur, but hopefully will not. Riskmonies may or may not be spent. These monies are added to provide fi-nancial protection and quantify management or executive judgements forfinal project cost outcome. Considerations of changes in scope normallygenerated by an organization should be covered in these amounts. In rarecases, risk could be expressed as a deduction from the base cost plus addi-tives. Examples of items covered by risk are: inclement weather condi-tions, time extensions of the project, prototype processes, productivityloss, etc.

Fees. The amount of money anticipated to be recovered by the con-tractor to provide funds for payments of his non-project overhead andprofit.

john s. page, conceptual cost estimating manual

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