8. Introduction to Cost Estimation Software

8/19/2019 8. Introduction to Cost Estimation Software

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© 2010 Aspen Technology, Inc. All rights reserved© 2010 Aspen Technology, Inc. All rights reserved

Sunil Patil

Principal Business Consultant

Introduction to Aspen Cost Estimation Products


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Agenda

Introduction and Overview

Cost Basis Process Equipment and Bulk Modeling

Workflow Overview

–

© 2010 Aspen Technology, Inc. All rights reserved | 2

– Loading and Mapping Simulation Data

– Evaluating the Project and Generating Reports

Detailed hands on information

Decision Analyzer (Project Scaling and Relocation) Integrated Costing and Sizing


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Asset Engineering Workflow

ConceptualDesign / R&D

ProcessPerformance

Modeling & Analysis

Safety &Controllability

Analysis

AnalyzeEconomic

Performance

Develop Basic


Reuse ProcessModel for

Operations Decisions

Reuse ProcessModels for

Planning DecisionsOperations/Maintenance

EquipmentDesign

es gn ac ageAnalyzeDetailed

Costs

BasicEngineering

Develop DetailedPlant DesignDetailed

Engineering


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What is Icarus technology?

Computer aided, design, estimating, and scheduling systemfor the process industries

System generates “scope” quantities

“Engineering department” embodied in software

Incorporates current construction practices and costs


– Major process plants / mills

– Process alternatives

– Scope changes

– Work orders

Used by owner/operators and engineering/constructors


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LogicallyConnected

Capital Cost EstimatorProcess

Economic Analyzer In-Plant Cost Estimator

Concept ProductionRetrofitDe-

Bottle-neck

StartupConstr-uction

PlantDesign

ProcessDesign

Asset Optimization


Aspen Plus

HYSYS

Primavera Scheduling

ClientTechnology

(via API)

Reporter

Excel & CrystalReports

AspenIcarus

User Data

CAE/CADIntergraph

Aspen Basic EngineeringData Sheets, Plot Plan

Excel Custom Models


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Aspen Economic Evaluation Products

•All Design Basis,Equipment & Plant Bulksas ACCE

•No volumetric models

In-Plant Cost EstimatorCapital Cost Estimator

•Multi-contractor projectexecution

•Power/Process Controls stems

•Economics for ProcessEngineers

•Interface to Aspen Plusand HYSYS

Process EconomicAnalyzer


•Foundation design•Primavera CPM scheduleincl. costs (P3 or P6)

•Equipment Rental

•User data sources

•Optimized equipmentrental

•Primavera detailed CPMschedule (P6)

•Project Relocation &Scaling

•Modular Construction

•Pipelines

•Expand Unit Operationsto Equipment (Map)

•Equipment sizing

•PFD’s

•Stream list incl. utilities

•Project Relocation &

Scaling

•Cooling Water analysis

•Financial Analysis(CAPEX and OPEX)


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International

Design Methods

Detailed Design

and CostModels

Built-In Knowledge Modules


Expert SystemsKnowledge Bases

Fabrication andConstruction

Methods

Materialsof

Construction

Contractor’sEngineering

CPM-basedScheduling

Methods


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Aspen CapitalCost Estimator

3) Preliminarysized equipment

used to developconceptual costestimate

Aspen ProcessEconomic Analyzer

2) Economicscreening performedfor multiple cases1) Process

simulation casesdeveloped

Aspen Basic

AspenTech Integration Example


Engineering4) Data loaded for

“best” case

Equipment Design and

Rating Tools and MSExcel

5) Additional design

and sizing

6) Preliminaryconceptualestimate revisedwith latest projectdata from Aspen

BasicEngineering


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New Product Nomenclature

Old Name New Name

Aspen Icarus ProcessEvaluator (IPE)

Aspen ProcessEconomic Analyzer


Aspen KbaseAspen Capital Cost

Estimator

Aspen Icarus ProjectManager (IPM)

Aspen In-Plant CostEstimator


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What is Aspen Process Economic Analyzer?

Tools for preliminary/relative economic analysis

Generates equipment sizes and designs using processsimulator data

Calculates estimated capital and operating costs for aprocess


Allows rapid evaluation of processes alternatives to comparerelative profitability

Projects created in Aspen Process Economic Analyzer can berefined in Aspen Capital Cost Estimator


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Aspen Economic EvaluationFamily and the Project Lifecycle

Concept ProductionRetrofit

De-

Bottle-neckStartup

Constr-

uction

Plant

Design

Process

Design

Aspen Aspen


Aspen In-PlantCost Estimator

EconomicAnalyzer

CostEstimator

Two interfaces to thesame underlying model


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Aspen Process Economic AnalyzerProject Basis

Establish cost basis


Rules for generation ofpreliminary sizedequipment list fromsimulation data

Define investmentparameters, costs, andproduct value(s)


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Aspen Capital Cost EstimatorProject Basis

Establish Customize Fine tune CPM


basis mo e s schedule


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Capital Costs

Costs for initial and working capital

Direct costs

– Equipment– Piping

– Civil

– Steel, etc.


Indirect costs– Construction rental equipment

– Construction management

– Engineering, etc.


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Operating Costs

Operator and supervisor costs

Feedstock costs estimated using stream data and userentered information

Utility costs

– Steam


– Heating oil

– Cooling water

– Refrigerants

– Electricity, etc.


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Cost Basis

Cost basis updated with each annual release

Five base locations

– US Gulf Coast

– EU

– UK


–

– Middle East

Material and labor specifications can be adjusted torepresent site-specific conditions


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Investment Analysis

Product sales estimated using stream data and user enteredinformation

Profit = Sales - (Capital Costs + Operating Costs)

Investment analysis module generates typical economicmetrics


–

– IRR

– PO, etc.


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Process Equipment

Primary equipment items derived from simulation

– Simulator blocks mapped to one or more Icarus equipmentmodels

– User-defined parameters govern designs Additional process equipment items added by user

– Pumps


–

– Spares

Equipment models have attached P&ID

– Used to estimate piping and instrumentation costs

– Sizing equations used to estimate pipe quantities (lengthand diameter)

Volumetric modeling used to estimate other bulkquantities and costs (civil, paint, insulation, etc.)


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Equipment Design and Cost Procedure

MECHANICAL DESIGN:Develop physical dimensions using:

• design code procedures

• industry standard methods

PROJECT SPECS:

• Mechanical design specs

• Project components specs

Equipmentdesign generated


VESSEL COST:1.Mat’l cost of parts

2.Shop [+ field] fab labor

3.Labor overheads

4.G and A

5.Profit

FABRICATION LABOR:• Shop [+ Field]

• Labor

• Man-hours

Equipment costestimated


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Equipment Design Data and Estimated FOBCost from Vendor



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Volumetric Models:Calculation of Installation Bulks

– Total installed cost estimated

– Quantities and costs for bulk

materials based upon equipmentspecifications

– Volumetric models for processequipment:

x

x

x


Conceptual P&IDs Civil

Steel

Electrical

Insulation

Paint

x

x


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P&ID Library:Double Diameter Tower



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Non-Equipment Costs

System estimates costs for additional bulk quantities

– Project bulks Process control

Power distribution– Area bulks

Grounding


Steel structures Users can account for additional costs using system

models

– Plant bulks

Pipe rack Rack piping

– Buildings

– Site development


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Typical Workflow

Prepare library files

Load simulator data

Map simulator blocks to Icarus components

Evaluate



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Library Files

Basis for capital costs– Project type and location

– Construction workforce specifications– Material and man-hour indices

Design criteria for equipment


– Analysis period– Tax and interest rates

– Escalation

Operating unit costs

Product and raw material specifications


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Mapping Simulator Data

Creates Process Economic Analyzer equipmentcomponents from computational block data

Map 1-to-1 or 1-to-many

Components are sized using simulator data andProcess Economic Analyzer design criteria


Resulting process flow diagram can be viewed inAspen Process Economic Analyzer


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Project Evaluation

Project evaluation generates design quantities andestimates costs

Available reports– Investment analysis reports

Equipment


Cashflow

Executive summary

– Capital cost reports Standard reports (using Crystal Reports components)

Excel reports HTML reports

Management reports (can be exported to Excel)


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Hands On Information


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Loading Data from Aspen HYSYS

Tools | Aspen Economic Evaluation | Export to ProcessEconomic Analyzer



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Loading Data from Aspen HYSYS

After being prompted to load simulation data, the followinginterface window appears

•Confirms that HYSYS is running•Establishes link


•Extracts simulation data•Changes to “Export Again”when export is complete

•Disconnects interface

•Closes interface


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Loading Data from Aspen Plus

File | Send To | Aspen Process Economic Analyzer



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Creating a New Project in Aspen Plus

Create using “Aspen IPE Stream Properties” template to ensureall necessary stream properties transferred to Aspen ProcessEconomic Analyzer


Addi P ti t E i ti A


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Adding Properties to Existing AspenPlus Project

Import IPE-1, IPE-2, and IPE-3 Prop-Sets from “Aspen IPEStream Properties” template



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Interface – No Open Project

PaletteView


PropertiesWindow


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Interface – Open Project

PaletteView


PropertiesWindow

ProjectExplorer ListView


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Palette View

Three tabs– Projects

– Libraries (Template files)

– Components (Equipment, bulk items, buildings, and sitedevelopment models)

Locations of projects / libraries


– pec e us ng e oca ons a o re erences menu oo s

Options | Preferences)– Locations can be on a local or network drive

Use drag-and-drop from Components tab (to Project View orList View) to select components into project


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Properties Window

Contains location information for items in the Projects andLibraries tabs of the Palette View

Provides details for fields within a component specification form– Allowable data type

– Default value(s)

–


– Description


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Project Explorer

Three tabs

– Project Basis View

– Process View– Project View

Project Basis View tab allows input of project level specifications


Process View tab displays unit operations loaded from process

simulator data– Yellow unit operations are unmapped

– Green unit operations have been mapped to equipment

Project View tab allows addition of components


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Project Basis Specifications



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Project Basis Specifications

Capital cost basis– General specifications

– Construction workforce– Indexing

Process design– Simulator file


– Mapping specifications– Design criteria

Investment analysis– Operating unit costs

– Raw material and product specifications


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Loading Simulator Data

Specify simulator typeand file name

Load data

Not necessary if data is sent from HYSYS or Aspen Plus


Aspen Plus - .apw or .xmlHYSYS - .hsc


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Loads block and stream data from simulator

Populates Process View tab with unit operations

View streams list and block flow diagram



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Simulator type and simulator file name specified inproject basis

Block and stream data loaded from simulator

Block flow diagram and streams list can be viewed inAspen Process Economic Analyzer


Simulator link allows Aspen Plus and HYSYS simulationdata to be exported directly to Aspen Process EconomicAnalyzer

Mapping Simulator Items


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Map simulator items




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Maps unit operations to equipment models

– Simple (1-to-1 mapping)

– Complex (1-to-many mapping)

Defaults are based upon “Project Component MapSpecifications” in the Project Basis

– A default file is available out of the box for each supported


simulator type

– Customers can create their own files and store as a template(found in the Libraries tab of the Palette View)

Performs preliminary sizing using design criteria specified inproject basis, unit operation, and stream data

Populates Project View tab

After mapping, user can view a process flow diagram


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Tower Configurations

Tower configuration selected

during mapping

Configuration drives equipment

generated by unit operation

Single - Tower has one condenser

Split - Tower has multiple condensers


Total - Reflux pump handles the total outlet liquid flow from the

accumulator. In such configurations, the splitting into a reflux andoverhead liquid product occurs after the reflux pump

Circ. – There is a pump between the bottoms splitter and reboiler giving aforced circulation configuration around the reboiler

Full configurations include the following equipment (not found in Standardconfigurations)– overhead pump

– overhead product heat exchanger

– bottoms product pump

– bottoms product heat exchanger


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Process Flow Diagram: Radfrac Block

PFD is interactive

Additional equipment

(pumps, storage tanks,etc.) can be added to aproject manually


Manually added equipmentcan be placed on theappropriate stream andsized using designparameters


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Evaluating the scenario

Evaluate project

Generates designs, quantities, and estimated costs



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Additional Modules

Decision Analyzer

– Analyzer Scale-Up Module (ASM)

– Analyzer Relocation Module (ARM)– Analyzer Economic Module (AEM)


Utility Models– Air (instrument and plant)

– Cooling water


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Decision Analyzer module



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Decision Analyzer module

Conceptual scale-up and relocation of a base case

Allows a user to generate relative costs for changedcapacity or construction/engineering in a new location

Scale-up module resizes equipment and associatedbulk quantities (piping, instrumentation, foundations,etc.)


Scale-up module will not automatically model multipletrains of equipment

Relocation module primarily indexes material costsand modifies workforce specifications (wages and

productivities) – These changes will overridespecifications that the customer may have made

Relocation module does not modify design codes andconstruction/fabrication models


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Integrated Simulation & Cost Analysis

ViewUnit Op

Grid

ActivateCostingEngine

MapModels toEquipment

EvaluateEquipment

Costs

ShowCurrent

State


LoadSimulation

Data

SizeEquipment

Object

ViewEquipment

Grid

Integrated Simulation & Cost Analysisi i id


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Unit Operation Summary Grid

View Unit OpSummary Grid


One tab for each type of unit operationmodel in the simulation case

ew esu s an

Change Inputs

Integrated Simulation & Cost AnalysisM i U it O ti M d l t E i t


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Mapping Unit Operation Models to Equipment

E1210Condenser

T1220Reciever

C1200PackedColumn

Map Unit OperationModels to Equipment


P1230A/B

Reflux Pumps

E1260Reboiler

P1240Pump

E1250ExchangerPacking

Section 2

C1200

Section 1

Conceptual UnitOperation Models

Equipment Modelsfor Cost Analysis

Integrated Simulation & Cost AnalysisM i U it O ti M d l t E i t


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Mapping Unit Operation Models to Equipment

Map Unit OperationModels to Equipment

Equipment objects are


mapping process

Integrated Simulation & Cost AnalysisVie ing / Changing Eq ipment Specifications


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Viewing / Changing Equipment Specifications

View/Change EquipmentSpecifications


Summary of Equipment Costs and

Net Process Costs

Integrated Workflow Advantages


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Integrated Workflow Advantages

• One environment = faster learning curve

• Interactive sizing from inside the simulator

• Enables concurrent design & costing

• Rigorous cost modeling allows rapid evaluation


• Resulting project file can be opened directly inAspen Capital Cost Estimator

8. Introduction to Cost Estimation Software

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