John S. Page, Conceptual Cost Estimating Manual
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Transcript of 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".
Originally published by Gulf Publishing Company,Houston, TX.
For information, please contact:Manager of Special SalesElsevier200 Wheeler RoadBurlington, MA 01803-2041Tel: 781-313-4700Fax:781-313-4882
For information on all Gulf Professional Publishing titlesavailable, contact our World Wide Web home page at:http://www.bh.com/gulf
G | P Gulf Professional Publishing
P l H An Imprint of Elsevier
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
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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
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Two-stage, Two-cylinder, Water-cooled – Equipment Cost ........................................................................ 35
Two-stage, Two-cylinder, Water-cooled – Equipment Cost ........................................................................ 36
Two-stage, Two-cylinder, Water-cooled – Erection Manhours ................................................................ 37
Dryers – Air .................................................................................... 38 Automatic, Refrigerated – Equipment Cost ...................... 38 Automatic, Refrigerated – Equipment Cost ...................... 39 Automatic, Refrigerated – Erection Manhours ................. 40 Automatic, Refrigerated – Erection Manhours ................. 41 Chiller – Equipment Cost ................................................. 42 Chiller – Erection Manhours ............................................ 43
Surge Arresters ............................................................................. 44 Hydrocarbon and Water Service – Equipment Cost ......... 44 Hydrocarbon, Water, and Sewage Service –
Equipment Cost ...................................................... 45 Hydrocarbon, Water, and Sewage Service – Erection
Manhours ................................................................ 46 Blenders, Mixers, Packers, and Feeders ...................................... 47
Dry Material Auger and Rotary Drum Blenders – Equipment Cost ...................................................... 47
Dry Material Auger and Rotary Drum Blenders – Erection Manhours .................................................. 48
Fixed Side Mounted Mixers with Top Motors – Equipment Cost ...................................................... 49
Fixed Side Mounted Mixers with Top Motors – Erection Manhours .................................................. 50
Plate Mounted Open Tank Mixers – Equipment Cost ...... 51
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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
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Condensers and Receivers ........................................................... 73 Vertical Tube Surface – Equipment Cost ......................... 73 Vertical Tube Surface – Erection Manhours .................... 74
Conveying Equipment ................................................................... 75 Conveyors – Open Belt – Equipment Cost ...................... 75 Conveyors – Open Belt – Erection Manhours .................. 76 Conveyors – Belt Enclosed with Walkway –
Equipment Cost ...................................................... 77 Conveyors – Belt Enclosed with Walkway – Erection
Manhours ................................................................ 78 Conveyors – Spaced, Bucket Elevators, Belt-driven –
Equipment Cost ...................................................... 79 Conveyors – Spaced, Bucket Elevators, Chain Driven –
Equipment Cost ...................................................... 80 Conveyors – Spaced, Bucket Elevators, Chain- or
Belt-driven – Erection Manhours ............................. 81 Conveyors – Continuous, Bucket Elevators, Belt-
driven – Equipment Cost ......................................... 82 Conveyors – Continuous, Bucket Elevators, Chain-
driven – Equipment Cost ......................................... 83 Conveyors – Continuous, Bucket Elevators, Belt- or
Chain-driven – Erection Manhours .......................... 84 Screw Conveyors – Equipment Cost ............................... 85 Screw Conveyors – Erection Manhours ........................... 86
Dryers – Drum ............................................................................... 87 Atmospheric Single Drum Type – Equipment Cost .......... 87 Atmospheric Double and Twin Drum Types –
Equipment Cost ...................................................... 88 Atmospheric Single, Double, and Twin Drum Types –
Erection Manhours .................................................. 89
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Dryers – Vacuum ........................................................................... 90 Conical Rotating – Equipment Cost ................................. 90 Double Drum and Rotary – Equipment Cost .................... 91 Conical Rotating and Double Drum – 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
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Fans and Blowers .......................................................................... 106 Blowers – Rotary – Equipment Cost ................................ 106 Blowers – Rotary – Erection Manhours ........................... 107 Centrifugal Fans – Equipment Cost ................................. 108 Centrifugal Fans – Erection Manhours ............................ 109 Cast Iron Industrial Fans – Equipment Cost .................... 110 Cast Iron Industrial Fans – Erection Manhours ................ 111 Heavy Sheet Steel Industrial Fans – Equipment Cost ...... 112 Heavy Sheet Steel Industrial Fans – Erection
Manhours ................................................................ 113 Feeders ......................................................................................... 114
Heavy Duty Belt – Equipment Cost .................................. 114 Heavy Duty Belt – Erection Manhours ............................. 115 Pre-wetting Dry Chemical – Equipment Cost ................... 116 Pre-wetting Dry Chemical – Erection Manhours .............. 117 Pre-wetting Dry Chemical, Package Units – Equipment
Cost ........................................................................ 118 Pre-wetting Dry Chemical, Package Units – Erection
Manhours ................................................................ 119 Dry Material, Vibrating – Equipment Cost ........................ 120 Dry Material, Vibrating – Erection Manhours ................... 121 Dry Material, Volumetric and Gravimetric – Equipment
Cost ........................................................................ 122 Dry Material, Volumetric and Gravimetric – Erection
Manhours ................................................................ 123 Dry Material, Wing and Conveyor – Equipment Cost ....... 124 Dry Material, Wing and Conveyor – Erection
Manhours ................................................................ 125 Filters ............................................................................................. 126
Gravity Filtration Units – Total Material Cost .................... 126
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Gravity Filtration Units – Total Unit Installation Manhours ................................................................ 127
Pressure Type – Equipment Cost .................................... 128 Pressure Type – Erection Manhours ............................... 129 Rubber-lined – Equipment Cost ....................................... 130 Rubber-lined – Erection Manhours .................................. 131 Vibrating Screens – Equipment Cost ............................... 132 Vibrating Screens – Erection Manhours ........................... 133
Flakers ........................................................................................... 134 Cooling Drum – Equipment Cost ..................................... 134 Cooling Drum – Erection Manhours ................................. 135
Generators ..................................................................................... 136 Inert Gas – Equipment Cost ............................................ 136 Inert Gas – Erection Manhours ........................................ 137
Gas Pulsation Dampers ................................................................ 138 Dampers – Equipment Cost ............................................. 138 Dampers – Erection Manhours ........................................ 139
Heaters .......................................................................................... 140 Deaerating Feedwater – Equipment Cost ........................ 140 Deaerating Feedwater – Erection Manhours ................... 141 Gas-, Oil-, and Dual-fired – Equipment Cost .................... 142 Gas-, Oil-, and Dual-fired – Erection Manhours ............... 143
Heat Exchangers ........................................................................... 144 Hairpin Type – Equipment Cost ....................................... 144 Hairpin Type – Erection Manhours .................................. 145 Shell and Tube, Fixed Tube, and U-tube – Equipment
Cost ........................................................................ 146 Shell and Tube, Fixed Tube, and U-tube – Erection
Manhours ................................................................ 147
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For Heating Water – Equipment Cost .............................. 148 For Heating Water – Equipment Cost .............................. 149 For Heating Water – Erection Manhours .......................... 150
Pumps ........................................................................................... 151 Centrifugal – Single-stage, Vertical Split Case –
Equipment Cost ...................................................... 151 Centrifugal – Single-stage, Horizontal Split Case –
Equipment Cost ...................................................... 152 Centrifugal – Single-stage, ANSI and API 610 –
Equipment Cost ...................................................... 153 Centrifugal – Two-stage and Multi-stage – Equipment
Cost ........................................................................ 154 Centrifugal – Single-stage, in-line – Equipment Cost ....... 155 Gear – Light and Heavy Duty – Equipment Cost ............. 156 Sewage – Horizontal and Vertical, 1,750 rpm –
Equipment Cost ...................................................... 157 Sewage – Horizontal, 1,750 rpm – Equipment Cost ......... 158 Sewage – Horizontal and Vertical, 1,150 rpm –
Equipment Cost ...................................................... 159 Sump and Plunger – Equipment Cost .............................. 160 Vertical Turbine – Single and Multi-stage – Equipment
Cost ........................................................................ 161 Centrifugal – Single, Two, Multi, and in-line Single
Stage – Erection Manhours ..................................... 162 Gear – Light and Heavy Duty – Erection Manhours ......... 163 Sewage – Horizontal and Vertical – Erection
Manhours ................................................................ 164 Sump and Plunger – Erection Manhours ......................... 165 Vertical Turbine – Single and Multi-stage – Erection
Manhours ................................................................ 166
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Reactors ........................................................................................ 167 Glass-lined, Agitated, Jacketed – Equipment Cost .......... 167 Glass-lined, Agitated, Jacketed – Erection Manhours ...... 168
Steam Jet Ejectors ........................................................................ 169 Single-stage – Equipment Cost ....................................... 169 Single-stage – Erection Manhours ................................... 170
Gas Scrubbers .............................................................................. 171 High-energy Venturi Type – Equipment Cost ................... 171 High-energy Venturi Type – Erection Manhours .............. 172
Separators ..................................................................................... 173 Vane Type – Equipment Cost .......................................... 173 Vane Type – Equipment Cost .......................................... 174 Vane Type – Erection Manhours ..................................... 175 Vibrating – Equipment Cost ............................................. 176 Vibrating – Erection Manhours ........................................ 177 API Type Oil/Water – Equipment Cost ............................. 178 API Type Oil/Water– Erection Manhours ......................... 179
Size Reduction Equipment ............................................................ 180 Crushers – Equipment Cost ............................................. 180 Crushers – Erection Manhours ........................................ 181 Impact Breakers – Equipment Cost ................................. 182 Impact Breakers – Erection Manhours ............................. 183 Reversible and Non-reversible Hammermills –
Equipment Cost ...................................................... 184 Reversible and Non-reversible Hammermills – Erection
Manhours ................................................................ 185 Ring Type Granulators – Equipment Cost ....................... 186 Ring Type Granulators – Erection Manhours ................... 187
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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
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Column Trays, Shop Installation – Cost Each .................. 207 Demisting Pads, Shop Installation – Cost Each ............... 208 Shop Stress Relief – Cost per Ton .................................. 209 Removable Type Trays – Material Cost Each .................. 210 Removable Type Trays – Material Cost Each .................. 211 Demisting Pads – Material Cost Each ............................. 212 Demisting Pads – Material Cost Each ............................. 213 Vessels – Field Erection Manhours per Ton .................... 214 Tray Installation – Field Erection Manhours Each ............ 215 Demisting Pads – Field Erection Manhours Each ............ 216
Section 3. Site Preparation ............................................... 217 Section Introduction ....................................................................... 217 Area Clear and Grub – Manhours per Acre .................................. 217 Area Cuts and Fills – Manhours and Material Cost per Acre ....... 218
Section 4. Site Improvements ........................................... 219 Security Fencing ............................................................................ 219 Railroad and Spurs ........................................................................ 219 Tank Dikes ..................................................................................... 220 Concrete Trenches ........................................................................ 220 Drainage ........................................................................................ 221 Catch Basins and Manholes ......................................................... 221 Road Culverts ................................................................................ 221
Section 5. Concrete ........................................................... 222 Section Introduction ....................................................................... 222 Earth Backfill Materials – Cubic Yards .......................................... 223 Excavation and Backfill – Labor Manhours .................................. 224
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Earthwork for Equipment Structures, Pipe Racks, and Sleepers – Labor Manhours ................................................ 225
Concrete Required for Equipment, Equipment Structures, Pipe Racks and Sleepers – Cubic Yards ............................ 226
Forms, Reinforcing, Embedments and Concrete – Material Cost ...................................................................................... 227
Forms, Reinforcing, Embedments and Concrete – Installation Manhours ............................................................................. 228
Nonshrink, Nonmetallic Grout – Average Square Feet ................ 229 Nonshrink, Nonmetallic Grout – Material Cost ............................. 230 Nonshrink, Nonmetallic Grout – Installation Manhours ................ 231 Fireproofing Structural Steel – Total Material Cost ....................... 232 Fireproofing Structural Steel – Installation Manhours .................. 233 Fireproofing Vessel Skirts – Material Cost .................................... 234 Fireproofing Vessel Skirts – Erection Manhours .......................... 235
Section 6. Structural Steel and Miscellaneous Iron ........ 236 Section Introduction ....................................................................... 236 Structural Steel – Tons Required .................................................. 237 Miscellaneous Iron – Tons Required ........................................... 238 Pipe Rack Steel – Tons Required ................................................. 239 Structural Steel – Equipment Supports and Structures –
Material Cost ........................................................................ 240 Structural Steel for Pipe Racks – Miscellaneous Iron for
Equipment – Material Cost ................................................... 241 Structural Steel and Miscellaneous Iron – Equipment,
Equipment Supports and Structures, and Pipe Racks – Erection Manhours ............................................................... 242
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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
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Electrical Lighting – Installation Manhours ................................... 266 Miscellaneous Instrumentation – Material Cost ............................ 267 Miscellaneous Instrumentation – Installation Manhours .............. 268
Section 10. Instrumentation ................................................ 269 Section Introduction ....................................................................... 269 Instruments – Total Number of Instruments Required ................. 270 Instruments – Total Material Cost ................................................. 271 Instruments – Total Instrument Installation Manhours ................. 272 Control Valves – Total Material Cost ............................................ 273 Standards, Tray Supports, Trays, Tubes, and Tube Bundles
– Total Material Cost ............................................................ 274 Standards, Tray Supports, Trays, Tubes, and Tube Bundles
– Total Installation Manhours ............................................... 275
Section 11. Insulation .......................................................... 276 Section Introduction ....................................................................... 276 Insulating Material – Total Square Feet ........................................ 277 Insulating Material for Equipment – Total Material Cost ............... 278 Insulating Material for Piping – Total Material Cost ..................... 279 Insulating Labor for Piping and Equipment – Total
Manhours ............................................................................. 280
Section 12. Painting ............................................................. 281 Section Introduction ....................................................................... 281 Painting – Equipment – Square Feet Area ................................... 282 Painting – Structural Steel and Piping – Square Feet Area ......... 283 Painting – Miscellaneous and Pipe Rack Steel – Square Feet
Area ...................................................................................... 284 Painting – Equipment – Total Material Cost ................................. 285
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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
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Office Personnel – Total Manhours .............................................. 305 Other Indirect and Temporary Construction Labor – Total
Manhours ............................................................................. 306 Temporary Construction Materials – Total Cost ........................... 307 Payroll Burdens and Benefits and Other Indirect Materials –
Total Cost ............................................................................. 308
Section 17. Home Office Cost ............................................. 309 Section Introduction ....................................................................... 309 Engineering Design – Manhour Range Allowance per Piece
of Equipment ........................................................................ 310 Engineering Design – Other Cost as a Percent of
Engineering Labor Dollars ................................................... 314 Engineering Design – Manhour Spread Percentages .................. 315
Section 18. Ratio Estimating Factors ................................. 316 Section Introduction ....................................................................... 316 Refinery Process Systems – Direct Cost Percentages ................ 318 Liquid Type Chemical Plant – Direct Cost Percentages .............. 319 Solid Type Chemical Plants – Direct Cost Percentages .............. 320 Liquid/Solid Type Chemical Plants – Direct Cost
Percentages ......................................................................... 321 Liquid High-pressure Chemical Plants – Direct Cost
Percentages ......................................................................... 322 Liquid High-alloy Chemical Plants – Direct Cost
Percentages ......................................................................... 323 Construction Equipment as a Percent of Direct Field Labor ........ 324 Overhead and Indirects as a Percent of Direct Field Labor ......... 324 Home Office Services as a Percent of Total Cost and Indirect
Cost ...................................................................................... 324
xxii Contents
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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
TWO-STAGE, TWO-CYLINDER,WATER-COOLED AIR COMPRESSORS
Oil-Lubricated and Nonlubricated350 to 500 psig Discharge
PressureEauimnent Cost
Eq
uip
men
t C
ost
Motor Horsepower(D Oil-Lubricated(D Nonlubricated
TWO-STAGE, TWO-CYLINDER,WATER-COOLED AIR COMPRESSORS
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
DRY MATERIAL BLENDERS9PACKERS9 AND FEEDERS
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
DRY MATERIAL BLENDERS9PACKERS9 AND FEEDERS
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
Linear Feet Of Stack
® %>-inch plate 42- to 48-inch diameter© %3-inch plate 54- to 60-inch diameter® %-inch plate 54- to 60-inch diameterNote: Cost includes stack, cable, and clamps.
BOILEB STACKS1Ai-, 5/i6-, 3/8-Inch Plate
Erection Manhours
Ere
cti
on
M
anho
urs
Linear Feet Of Stack
® 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
CONVEYING EQUIPMENTConveyors—Spaced, Bucket
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
CONVEYING EQUIPMENTConveyors—Spaced, Bucket
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
CONVEYING EQUIPMENTConveyors—Continuous, Bucket
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
CONVEYING EQUIPMENTConveyors—Continuous, Bucket
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
Approximate Weight Pounds
(D Single Drum©Double Drum©Twin Drum
Next Page
DRYERS—VACUUMConical Rotating Type
Equipment Cost
Equ
ipm
ent
Cos
t
Approximate Weight Pounds
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
Approximate Weight Pounds
® 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.
DUST COLLECTORSCENTRIFUGAL SCRUBBERS
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.
DUST COLLECTORSCENTRIFUGAL SCRUBBERS
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
approximately 67% of above cfm.
DUST COLLECTORSCENTRIFUGAL SCRUBBERS
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
approximately 71% of above cfm.
DUST COLLECTORSCENTRIFUGAL SCRUBBERS
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
DRY MATERIAL FEEDEREQUIPMENT
Vibrating FeedersErection Manhours
Ere
ctio
n M
anho
urs
Tons Per Hour
DRY MATERIAL FEEDEREQUIPMENT
Volumetric and GravimetricFeeders
Equipment Cost
Equ
ipm
ent
Cos
t
Approximate Weight In Pounds
©Volumetric feeders© Gravimetric feeders
DRY MATERIAL FEEDEREQUIPMENT
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
Approximate Weight Pounds
FLAKEBSCooling Drum Type
Erection Manhours
Erection
Manhours
Approximate Weight Pounds
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
Approximate Weight Pounds
® Gas-fired©Oil-fired©Dual-fired
HEATERSGas-, Oil-, and Dual-Fired Types
Erection Manhours
Erec
tion Manhours
Approximate Weight Pounds
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.
HEAT EXCHANGERS FORHEATING WATER
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
HEAT EXCHANGERS FORHEATING WATER
Erection Manhours
Heating Surface Square Feet
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
Prime Mover Horsepower
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
Prime Mover Horsepower
(D ANSI pumps—3,500 rpm—specific gravity of 1.0.(2) ANSI pumps—1,750 rpm—specific gravity of 1.0.® API 610 pumps—3,500 rpm—specific gravity of 1.0.
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
Unit Diameter Inches
0 Carbon steel© Stainless steel
VIBRATING SEPABATORSCarbon or Stainless Steel
Erection Manhours
Erection
Manhours
Unit Diameter Inches
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
Subcontractor Installed Priceon Foundations by Others
Su
bco
ntr
acto
r In
sta
lled
P
rice
Capacity-Barrels
API FLOATING ROOF STORAGETANKS
Subcontractor Installed Priceon Foundations by Others
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
Heating Surface Square Feet
TANK HEATING COILSFintube Type
Erection Manhours
Ere
ctio
n
Man
hour
s
Heating Surface Square Feet
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
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 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
Vessel Diameter - Inches
® 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
Vessel Diameter - Inches
©Removable type single downflow valve or perfo-rated type trays
© Removable type double downflow valve or perfo-rated type trays
Note: Includes shop installation only. Does not 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
Vessel Diameter - Inches
® 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
Vessel Diameter-Inches
(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
Vessel Diameter - Inches
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 man- hours per tray.
VESSEL TRAY INSTALLATION36-Inch Through 144-Inch Vessel
DiameterField Erection Manhours Each
Erection Manhours Each
Vessel Diameter-Inches
® 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.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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:
Material—$22.00 per cubic yardLabor—0.60 manhours per cubic yard
2. Concrete type dikes material will average 1.4 cubic yards of concreteper linear foot of dike at the average cost of:
Material—$180.00 per cubic yardLabor—10.00 manhours per cubic yard
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:
Material—$30.00 per linear footLabor—3.00 manhours per linear foot
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:
Material—$18.00 per linear footLabor—0.60 manhours per linear foot
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.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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 FOUNDATIONSNonshrink—Nonmetallic Grout
Material Cost
Mat
eria
l C
ost
Pieces Of Equipment Or Tons Of Steel
©Equipment©Steel
CONCRETE FOUNDATIONSNonshrink—Nonmetallic Grout
Installation Manhours
Installation
Manhours
Pieces Of Equipment Or Tons Of Steel
® Equipment©Steel
CONCRETE FOUNDATIONSFireproof ing Structural Steel
Total Material Cost
To
tal
Mate
rial
Co
st
Tons Of Stee l
CONCRETE FOUNDATIONSFireproof ing Structural Steel
Installation Manhours
Installation Manhours
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.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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
SHOP FURNISH ANDFABRICATE PIPE AND
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
SHOP FURNISH ANDFABRICATE PIPE AND
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,
AND VALVESMaterial Cost For Pieces Of Equipment
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
AND VALVESMaterial Cost For Pieces Of Equipment
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."
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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
Installation 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".
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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
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-
troduction to this manual before applying this information.
INSULATING MATERIALTotal Square Feet
Tot
al S
quar
e F
eet
Pieces Of Equipment
©Pipe© Equipment
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
INSULATING LABOR FOBPIPING AND EQUIPMENT
Total Manhours
Installation Manhours
Pieces Of Equipment
©Pipe© 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-
troduction to this manual before applying this information.
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
PAINTING—MISCELLANEOUSAND PIPE RACK STEEL
Total Material Cost
Tot
al M
ater
ial
Cos
t
Pieces Of Equipment
©Miscellaneous iron© Pipe rack steel
PAINTING—MISCELLANEOUSAND PIPE RACK STEEL
Total Manhours
Pai
nti
ng
Man
hour
s
Pieces Of Equipment
©Miscellaneous iron© Pipe rack steel
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.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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
Total Direct Labor In Hundred Thousand Dollars
OTHER INDIRECT ANDTEMPORARY CONSTRUCTION
LABORTotal Manhours
Total Manhours
Total Direct Labor In Hundred Thousand Dollars
® 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.
I caution the engineer/estimator to be thoroughly familiar with the in-troduction to this manual before applying this information.
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
Manhour Range AllowancePer Piece of Equipment
Equipment Classification
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
Manhour Allowance For
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
Manhour Range AllowancePer Piece of Equipment
Equipment Classification
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
Manhour Allowance For
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
Manhour Range AllowancePer Piece of Equipment
Equipment Classification
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
Manhour Range AllowancePer Piece of Equipment
Equipment Classification
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
Manhour Allowance For
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-
troduction to this manual before applying this information.
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
Ratio PercentagesDirect Cost
AveragePercent
Percentage Ratio Ranges of TotalsDiscipline I II HI IV V VI VII
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
* 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**)
SOLID TYPE CHEMICAL PLANTSRatio Percentages
Direct Cost
AveragePercent
Percentage Ratio Ranges of TotalsDiscipline I II IH IV V VI VlT
1. Process Equipment 100.00 25.00-26.00 3.75-4.75 44.16 69.24 4.99 37.802. Site Preparation 2.50-3.00 0.01-0.01 0.50-1.00 1.19 0.02 0.78 0.973. Site Improvements 3.50-3.75 0.80-0.90 2.25-3.00 1.57 2.32 3.20 2.024. Concrete 8.75-10.25 2.50-3.00 12.00-13.75 4.33 7.37 17.08 7.595. Structural Steel 12.50-14.30 * 5.50-6.25 6.30 * 7.06 5.816. Buildings 5.00-5.50 3.75-4.25 4.00-5.25 2.34 10.99 6.51 4.227. Underground Piping 4.75-5.50 0.01-0.01 3.00-3.25 2.18 0.02 4.05 2.388. Above-ground Piping 45.50-46.00 3.25-3.50 27.00-28.25 20.27 9.06 34.59 22.379. Underground Electric 0.50-0.70 * 0.30-0.50 0.25 * 0.35 0.25
10. Above-ground Electric 15.50-17.00 * 6.75-7.25 7.35 * 8.72 6.8911. 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
* 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/SOLID TYPE CHEMICAL PLANTS
Ratio PercentagesDirect Cost
AveragePercent
Percentage Ratio Ranges of TotalsDiscipline I II HI IV V VI VII
1. Process Equipment 100.00 25.00-26.50 4.00-6.00 42.00 70.31 4.93 36.522. Site Preparation 2.25-3.00 0.01-0.01 0.60-1.25 1.08 0.02 0.74 0.903. Site Improvements 3.30-3.80 0.75-0.85 2.25-3.00 1.43 2.25 3.02 1.874. Concrete 9.25-10.50 2.75-3.50 12.50-14.00 3.94 7.16 16.15 7.015. Structural Steel 13.50-14.50 * 5.50-6.50 5.73 * 6.68 5.376. Buildings 5.00-5.50 3.75-4.25 4.75-5.25 2.13 10.67 6.16 3.907. Underground Piping 4.50-5.25 0.01-0.01 3.00-3.50 1.94 0.01 3.75 2.158. Above-ground Piping 43.00-45.00 3.00-3.50 25.50-28.00 18.06 8.62 32.03 20.259. Underground Electric 0.60-0.90 * 0.30-0.50 0.25 * 0.36 0.25
10. Above-ground Electric 17.00-18.00 * 7.15-8.00 7.30 * 9.00 6.9411. 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
* 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**)
CHEMICAL PLANT—LIQUID HIGH PRESSURE TYPE4000 TO 5000 PSI
Ratio PercentagesDirect Cost
AveragePercent
Percentage Ratio Ranges of TotalsDiscipline I II III IV V VI VII
1. Process Equipment 100.00 25.00-26.00 3.75-5.00 43.16 74.86 5.34 38.102. Site Preparation 1.70-2.25 0.01-0.01 0.25-0.50 0.75 0.01 0.54 0.633. Site Improvements 2.30-3.00 0.50-0.75 1.50-1.75 0.99 1.62 2.21 1.314. Concrete 6.50-7.25 1.75-2.00 9.25-10.00 2.92 5.30 12.62 5.265. Structural Steel 9.00-10.00 * 3.50-4.00 3.98 * 4.88 3.786. Buildings 3.25-4.00 2.50-3.00 3.25-3.75 1.48 7.67 4.50 2.757. Underground Piping 4.75-5.25 0.01-0.01 3.00-3.25 2.12 0.02 4.30 2.388. Above-ground Piping 45.25-47.00 3.25-3.50 27.00-28.00 19.66 9.72 36.75 22.389. Underground Electric 0.50-1.00 * 0.25-0.40 0.25 * 0.38 0.25
10. Above-ground Electric 16.50-17.25 * 6.75-7.25 7.19 * 9.34 6.9411. 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
** Total Direct Cost 229.0-239.0 33.04-35.31 71.75-79.10 100.0 100.0 100.0 100.0
* Not applicable or no significant trend data available.
Roman Numeral Codes:
I. Discipline, Other Materials as a percent of Process Equipment costs. (1,1)
II. Discipline, Subcontracts as a percent of Process Equipment costs. (1,1)
III. Discipline, Direct Labor as a percent of Process Equipment costs. (1,1)
IV. Discipline, Material cost as a percent of Total Material costs. (IV**)
V. Discipline, Subcontract cost as a percent of Total Subcontract costs. (V**)
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 ALLOY TYPE
Ratio PercentagesDirect Cost
AveragePercent
Percentage Ratio Ranges of TotalsDiscipline I II HI IV V VI V lT
1. Process Equipment 100.00 25.00-25.50 3.75-4.25 45.58 75.07 5.74 40.182. Site Preparation 1.50-2.00 0.01-0.01 0.25-0.50 0.81 0.01 0.59 0.683. Site Improvements 2.25-3.00 0.50-0.75 1.50-1.75 1.07 1.65 2.42 1.424. Concrete 6.25-7.00 1.50-2.00 8.75-10.00 2.95 5.09 12.97 5.315. Structural Steel 9.25-9.75 * 3.50-3.75 4.28 * 5.35 4.066. Buildings 3.25-4.00 2.50-3.00 3.25-3.50 1.59 7.84 4.93 2.957. Underground Piping 4.50-5.00 0.01-0.01 3.00-3.50 2.18 0.02 4.51 2.458. Above-ground Piping 44.25-45.00 3.00-3.25 26.00-27.50 20.24 9.51 38.51 23.019. Underground Electric 0.25-0.50 * 0.01-0.02 0.17 * 0.27 0.18
10. Above-ground Electric 11.00-12.00 * 4.50-5.25 5.06 * 6.69 4.8811. 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
** Total Direct Cost 217.3-226.0 32.77-35.02 65.76-73.72 100.0 100.0 100.0 100.0
* Not applicable or no significant trend data available.
Roman Numeral Codes:
I. Discipline, Other Materials as a 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**)
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
Description Range Average
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
Description Range Average
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.