CUNO a UU CNY UW EVE VE W I THE QUICKEST, LEAST EXPENSIVE METHODS JOHN 5S. PAGE FOR REALISTIC DESIGN AND CONSTRUCTION COST ESTIMATINGConceptual Cost Estimating Manual 2nd Edition Copyright © 1984, 1996 by Elsevier, All rights reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced in any form without permission of the publisher. Permissions may be sought dirtly frm Ebevier's Science and Technology Rights Department i ‘Oxford, UK. Phone: (44) 1865 843830, Fax: (44) 1865 853333, e-rail: permissions @elscvie.co.k. ‘You may also complete your reques o-line via the Elsevier homepage: hupJiwor-eevier mm by ‘selecing “Customer Suppor” and thea “Obtaining Permissions" Originally published by Gulf Publishing Company, Houston, TX. For information, please contact: Manager of Special Sales Elsevier 200 Wheeler Road Burlington, MA 01803-2041 Tel: 781-313-4700 Fax: 781-313-4882 For information on all Gulf Professional Publishing titles available, contact our World Wide Web home page at: bttp://www.bh.com/gulf a Gulf Professional Publishing PLO Animprint of Elsevier 1098765 Library of Congress Cataloging-in-Publication Data Page, John S. Conceptual cost estimating manual / John S. Page. — 2nd ed. p. cm. ISBN 0-88415-267-7 1, Chemical plants—Design and construction— Estimates—Handbooks, manuals, etc. I. Title. TH4524.P34 1996 600'.54—dc20 95-52313 cIP Printed in the United States of America. Printed on acid-free paper (<:). ivCONTENTS 238 Section 1—DISCIPLINES OF WORK Section Introduction Direct Cost Items. Construction Equipment . Overhead And Indirects . Home Office Cost Section 2—PROCESS EQUIPMENT Bantlan Wnthodiegan ascaisnnscconswisw a cnmarcaeruneanteaeainewne animate u Acid Coolers with Pump and Motor Equipment Cost Erection Manhours Activators—Vibrating Bin Equipment Cost .... Erection Manhours .. Aerators—Mechanical High-Speed—Equipment Cost .. High-Speed—Erection Manhours . Low-Speed—Equipment Cost .. Low-Speed—Erection Manhours Compressors Air Power—Synchronous Motor Driven-Equipment Cost . Air Power—Induction Motor Driven-Equipment Cost .. Air Power—Synchronous and Induction Motor Driven—Erection SeoonnAutomotive and Industrial Service Air—Equipment Cost .... Automotive and Industrial Service Air—Erection Manhours Centrifugal Air~Plant and High-Pressure—Equipment Cost . Centrifugal Air—Plant and High-Pressure—Erection Manhours Industrial Air—Air-Cooled, Two-Stage—Equipment Cost .. Industrial Air—Air-Cooled, Two-Stage—Erection Manhours Integral Gas Engine—Four Cylinder—Equipment Cost .. Integral Gas Engine—Four Cylinder—Erection Manhours .. Packaged Air—Single-Stage, Water-Cooled—Equipment Cost . Packaged Air—Single-Stage, Water-Cooled—Erection Manhours . Reeiproeating—Electrie Motor Driven—Equipment Cost ... Reciprocating—Electrie Motor Driven—Erection Manhours Two-Stage, Two-Cylinder, Water-Cooled—Equipment Cost . Two-Stage, Two-Cylinder, Water-Cooled—Equipment Cost . Two-Stage, Two-Cylinder, Water-Cooled—Erection Manhours . Dryers—Air Automatic, Refrigerated—Equipment Cost Automatic, Refrigerated—Equipment Cost .. Automatic, Refrigerated—Erection Manhours Automatic, Refrigerated—Erection Manhours Chiller—Equipment Cost Chiller—Erection Manhours . Surge Arrestors Hydrocarbon and Water Service—Equipment Cost Hydrocarbon, Water, and Sewage Service—Equipment Cost Hydrocarbon, Water, and Sewage Service—Erection Manhours Blenders, Mixers, Packers, and Feeders Dry Material Auger and Rotary Drum Blenders—Equipment Cost ...... Dry Material Auger and Rotary Dram Blenders—Erection Manhours Fixed Side Mounted Mixers with Top Motors—Equipment Cost ... Fixed Side Mounted Mixers with Top Motors—Erection Manhours . Plate Mounted Open Tank Mixers—Equipment Cost Portable Clamp and Flanged Mounted Mixers—Equipment Cost . Flanged Top Tank Mounted and Plate Mounted Open Tank Mixers—Erection Manhours .. Gearmotor Mixers—Equipment Gearmotor Mixers—Erection Manhours . Batch and Pipeline Homogenizer Mixers—Equipment Cost . Batch and Pipeline Homogenizer Mixers—Erection Manhours High-Intensity Mixers—Equipment Cost .... High-Intensity Mixers—Erection Manhours .. Bag and Rigid Container Vibrating Packers—Equipment Cost Bag and Rigid Container Vibrating Packers—Erection Manhours Boiler Stacks—Erection Manhours . BEE BRESSR LSRRRBESRBENRRRB SSSSASKLS Bless igi: BRBRBClassification Equipment Cone Pelletizers—Equipment Cost .... Cone Pelletizers—Erection Manhours . Turbo-Screen Cyclone and Pressure Sifter—Equipment Cost Turbo-Screen Cyclone and Pressure Sifter—Erection Manhours . Rotary Screens—Equipment Cost .. Rotary Screens—Erection Manhours .. Condensers and Receivers Vertical Tube Surface—Equipment Cost . Vertical Tube Surface—Erection Manhours Conveying Equipment Conveyors—Open Belt—Equipment Cost Conveyors—Open Belt—Erection Manhours Conveyors—Belt Enclosed with Walkway—Equipment Cost . Conveyors—Belt Enclosed with Walkway—Erection Manhours Conveyors—Spaced Bucket Elevators, Belt-Driven—Equipment Cost ... Conveyors—Spaced Bucket Elevators, Chain Driven—Equipment Cost .. Conveyors—Spaced Bucket Elevators, Chain- or Belt-Driven— Erection Manhours . Conveyors—Continuous Equipment Cost Conveyors—Continuous Bucket Elevators, Chain-! Driven— Equipment Cost Conveyors—Continuous Bucket Elevators, Belt- or Chain-Driven— Erection Manhours . Screw Conveyors—Equip1 Screw Conveyors—Ereetion Manhours Dryers—Drum Atmospheric—Single Drum—Equipment Cost Atmospheric—Double and Twin Drum—Equipment. Cost . Atmospheric—Single, Double, and Twin Drum—Erection Manhours ..... Dryers—Vacuum Conical Rotating—Equipment Cost ... Double Drum And Rotary—Equipment Cost Conical Rotating and Double Drum—Erection Manhours Rotary—Carbon And Stainless Steel—Erection Manhours Dust Collectors Centrifugal Scrubbers—High-Capacity, Hot-Rolled Steel— RS NPSseg Ssariaa 2 8 8 SBR RRR esses Equipment Cost . Centrifugal Scrubb Equipment Cost ..... 95 Centrifugal Scrubbers—High-Capacity, Stainless Steel—Equipment 96 Centrifugal Scrubbers—Medium-Capacity, Stainless Steel— Equipment Cost ... Centrifugal Scrubbers—High- and Medium-Capacity, Hot Rolled and Stainless Steel—Erection. Manhours . . Cyclones—Hot-Rolled Steel—Equipment Cost vitCyclones—Stainless Steel—Equipment Cost. Cyclones—Hot-Rolled and Stainless Steel—Erection Manhours Filter Cartridge or Tube House Filters—Equipment Cost .. Filter Cartridge or Tube House Filters—Erection Manhours Packaged Motor Operated Blowers—Equipment Cost .... Packaged Motor Operated Blowers—Erection Manhours . Fans and Blowers Blowers—Rotary—Equipment Cost ... Blowers—Rotary—Erection Manhours Centrifugal Fans—Equipment Cost Centrifugal Fans—Erection Manhours Cast Iron Industrial Fans—Equipment Cost . Cast Iron Industrial Fans—Erection Manhours . Heavy Sheet Steel Industrial Fans—Equipment Heavy Sheet Steel Industrial Fans—Erection Manhours . Feeders Heavy Duty Belt—Equipment Cost .. Heavy Duty Belt—Erection Manhours Pre-Wetting Dry Chemical—Equipment Cost Pre-Wetting Dry Chemical—Erection Manhours Pre-Wetting Dry Chemical, Package Units—Equipment Cost Pre-Wetting Dry Chemical, Package Units—Erection Manhours Dry Material, Vibrating—Equipment Cost ... Dry Material, Vibrating—Erection Manhours Dry Material, Volumetric and Gravimetrie—Equipment Cost. Dry Material, Volumetric and Gravimetric—Erection Manhours Dry Material, Wing and Conveyor—Equipment Cost .... Dry Material, Wing and Conveyor—Erection Manhours .. Filters Gravity Filtration Units—Equipment Cost .. Gravity Filtration Units—Erection Manhours Preasure Type—Equipment Cost .. Pressure Type—Erection Manhours Rubber-Lined—Equipment Cost ... Rubber-Lined—Erection Manhours Vibrating Screens—Equipment Cost Vibrating Screens—Erection Manhours . Flakers Cooling Drum—Equipment Cost .. +121 BE BHEEEERE BEBE Inert Gas—Equipment Cost Inert Gas—Erection Manhours .. Gas Pulsation Dampers Dampers—Equipment Cost ... Dampers—Erection Manhours . RB BE viiiHeaters Deaerating Feedwater—Equipment Cost .. Deaerating Feedwater—Erection Manhours . Gas-, Oil-, and Dual-Fired—Equipment Cost . Gas-, Oil-, and Dual-Fired—Erection Manhours . Heat Exchangers Hairpin Type—Equipment Cost . Hairpin Type—Erection Manhours . Shell and Tube, Fixed Tube, and U-Tube—Equipment Cost Shell and Tube, Fixed Tube, and U-Tube—Erection Manhours . For Hesting Water—Equipment Cost For Heating Water—Equipment Cost For Heating Water—Erection Manhours Pumps Gentine Sinale Sites Vertical Split Case—Equipment Cost .... itrifugal—Single-Stage, Horizontal Split Case—Equipment Cost # eet Goeesene ANSI and API 610—Equipment Cost . Centrifugal—Two-Stage and Multi-Stage—Equipment Cost Centrifugal—Single-Stage In-Line—Equipment Cost Gear—Light and Heavy Duty—Equipment Cost . Sewage—Horizontal and Vertical, 1,750 RPM—Equipment Sewage—Horizontal, 1,750 RPM—Equipment Cost .......... Sewage—Horizontal and Vertical, 1,150 RPM—Equipment Cost Sump and Plunger—Equipment Cost .... Vertical Turbine—Single and Multi-Stage—Equipment Cost Centrifugal—Single, Two, Multi, and In-Line Single-Stage— Erection Manhours Gear—Light and Heavy Duty—Erection Manhours . Sewage—Horizontal and Vertical—Erection Manhours Sump and Plunger—Erection Manhours ............- Vertical Turbine—Single and Multi-Stage—Erection Manhours Reactors Glass-Lined, Agitated, Jacketed—Equipment Cost . Glass-Lined, Agitated, Jacketed—Erection Manhours . Steam Jet Ejectors Single-Stage—Equipment Cost .... Single-Stage—Erection Manhours . Gas Scrubbers High-Energy Venturi Type—Equipment Cost .... High-Energy Venturi Type—Erection Manhours ... Separators Vane Type—Equipment Cost . . Vane Type—Equipment Cost .. ‘Vane Type—Erection Manhours . Vibrating—Equipment Cost ... Vibrating—Erection Manhours ..Hot Process Water—Material and Equipment Cost Hot Proceas Water—Installation Manhours API Cone Roof Storage—Subcontract Installed Price . API Cone Roof Storage—Subcontract Installed Price . API Floating Roof Storage—Subcontract Installed Price ASME Spheres—Subcontract Installed Price . Fintube Heating Coils—Equipment Cost . Fintube Heating Coils—Erection Manhours . Fired Heaters, Fintube Type—Equipment Cost . Fired Heaters, Fintube Type—Erection Manhours Suction and Line Type Fuel Oil Heaters—Equipment Cost. Suction and Line Type Fuel Oil Heaters—Erection Manhours . Propane Storage—Equipment Cost . Propane Storage—Erection Manhours Vessels Shop Fabricated—Average Weight, Pounds per Linear Foot . Horizontal, Shop Fabricated—Cost per Ton .. Vertical with Angle Legs, Shop Fabricated— Cost por TON sicecacsecivisecsversveseaveressseserseve reese cease Vertical with Anchor Ring and Skirts, Shop Fabricated— Cost per Ton ge BEEEREEEEHEE BH HEBHERER 33 8 SRReR Shop Stress Relief—Cost per Ton.......... Removable Type Trays—Material Cost Each . Removable Type Trays—Material Cost Each . ‘Vessels—Field Erection Manhours per Ton - ‘Tray Installation—Field Erection Manhours Each . BERBERSaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Standards, a Tay Supports, Trays, Tubes, and Tube Bundles— Material Stanieeds tt Tray Supports, Trays, Tubes, and Tube Bundles— Installation Manhours Section 11—INSULATION Section Introduction Square Feet Required . Equipment—Material Cost Piping—Material Cost . Piping and Equipment—Installation Manhours .. Section 12—PAINTING Seetion Introduction Paint—Equipment—Square Feet Area, Pieces of Equipment . Paint—Structural Steel and Piping—Square Feet Area .... Paint—Miscellaneous and Pipe Rack Steel—Square Feet Area Paint—Equipment—Material Cost ... Paint—Equipment—Total Manhours Paint—Structural Steel—Material Cost . Paint—Structural Steel—Total Manhours . Paint—Piping—Material Cost ... Paint—Piping—Total Manhours .. Paint—Miscellaneous and Pipe Rack Steel—Material Cost. Paint—Miscellaneous and Pipe Rack Steel—Total Manhours REREREUEERED Section 183—PAVING Section Introduction Asphalt Paving—Total Subcontract Price . Concrete and Gravel Pavement—Total Material Cost . Concrete and Gravel Pavement—Total Manhours Section 14—PRORATABLES Section Introduction Proratable Materials—Total Cost Proratable Labor—Total Manhours Section 15—CONSTRUCTION EQUIPMENT BREE BER Section 16—OVERHEAD AND INDIRECTS Section Introduction .. Engineering and Supervision Personnel—Total Manhours . witiTemporary i Payroll Burdens and Benefits and Other Indirect Materials—Total Cost Section 17—HOME OFFICE COST Section Introduction Engineering Design— : Engineering Design—Manhour Range Allowance . Engineering Design—Manhour Range Allowance . Engineering Design—Manhour Range Allowance . Engineering Design~Manhour Range Allowance . . Other Cost asa Pereent of Engineering Labor Dols Engineering Design—Manhour Spread Percentages . . Section 18—RATIO ESTIMATING FACTORS Section Introduction 316-317 Refinery Process Systems—Direct Cost Percentages Liquid Chemical Plants—Direct Cost Percentages Solid Chemical Plants—Direct Cost Percentages . Liquid/Solid Chemical Plants—Direct Cost Percent Liquid High-Pressure Chemical Plants—Direct Cost Percentages Liquid High-Alloy Chemical Plants—Direct Cost Percentages . Construction Equipment as a Percent of Direct Field Labor .. Overhead And Indirects as a Percent of Direct Field Labor Home Office Services as a Percent of Total Cost Section 19—DEFINITIONS OF ESTIMATE ADJUSTMENTS Design Allowance ... Quantity Allowance . Escalation . .. Contingencies . Risk Fees... xivPREFACE Long has been the need for a manual on conceptual cost estimating that allows the construction industry and the engineering/management staff of chemical, 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 per pound produced, and the product can be sold for fifteen dollars per pound, by no means justifies the construction cost of the plant. Management of all organizations concemed demands more reasoning and is certainly within its rights to do so. When a project is in its planning and evaluating stages, the cost of a complete design and definitive estimate would be, in most cases, too great to justify the design and estimate. Therefore, it becomes apparent that a less expensive method is needed to determine the feasibility of the plant in mind. By using a very moder- ate flow sheet design, specifications, and/or equipment lists, by properly applying man-hours, dollars, percentage values (as are shown throughout this manual in graph and table form), and construction indexes, and by considering other items outlined in the Introduction, a total cost very close to the as-built cost of a 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 for labor and cost estimating, you might wonder what an estimating manual offers that a computer program does not. The answer is the human factor. In preparing acom- plete estimate for a refinery, petrochemical, or other heavy industrial project one often confronts 12-18 major accounts, and each account has 5-100 or more sub- accounts, depending on the project and its engineering design. While it would seem that such numerous variables provide the perfect opportunity for computerized algorithmic solution, accurate, cost-effective, realistic estimating is still largely a function of human insight and expertise. Each project has unique aspects that still require the seasoned consideration of an experienced professional, such as gener- al economy, projects supervision, labor relations, job conditions, construction equipment, and weather, to name a few, Computers are wonderful tools. They can solve problems as no human can, but Ido not believe construction estimating is their forté. 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 these facets. 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 estimate with an accuracy of +10%. Method two uses conceptual ratio estimating, and based on the known equipment material dollar value and the application of weighted percentage costs for ali other items, it produces an estimate with an accuracy of +30%. The information required and procedures to follow for using these two methods of estimating are defined later in this introduction. All equipment and material dollar graph and tables throughout this manual are based on average cost as of January 1, 1996. Due to the ever-changing economic conditions, the use of what is known throughout the industry as indices must be considered and applied against all equipment and mate- rial graphs and tables. This will result in a more realistic equipment and material value for a project to be designed and constructed at some future date. Indices are simply numbers for a time frame indicating a percentage of change in regard to a relative cost of a base time frame. There have been many pro and con discussions as to the use of indices; however, they are still the only means for achieving an acceptable estimate where limited information and time are available. ‘There are several indices from which one might choose. I favor the Nelson Refinery (inflation) Index, which appears in the first weekly edition of each month in the Oil and Gas Journal. The engineer/estimator may wish to use other indices that he is more familiar with and has more confidence in. Should this be the case, it is to be recognized that as far as this manual is concemed January 1, 1996 is equal to 100. ‘All labor manhour graphs and tables are based on an average productivity of 70%. The engineer/estimator must determine the labor productivity he feels he can achieve for each project and may adjust the graph and table manhours as may be required. Major ‘items that one should consider in determining productivity are: 1, General Economy 2. Project 3. Labor Relations 4, Job Conditions 5. Construction Equipment 6. Weather In determining the dollar rate to apply against the estimated manhours the engi- neer/estimator should first establish weighted composite crew rates. This is simply the listing by craft of the various personnel required for a crew—such as general foreman, foreman, craftsmen, and apprentices/helpers—and the weighted percentage of their time that will be devoted to the crew. The weighted percentage of each classification multiplied by the hourly rate for that classification will result in the weighted hourly rate for each. The sum of all weighted rates will equal the composite crew hourly rate. The total percent of all crew personnel is to equal 100. Using the composite crews and rates, activity crews and rates are to be formed. List the composite crew rates and the weight- ed percent of time each crew will be devoted to the activity. The weighted percent of each composite crew multiplied by the weighted composite crew rate will result in the weighted hourly activity rate for that crew. The sum of all weighted crew rates for the activity will equal the hourly weighted activity rate. The total percent of all composite crew personnel is to equal 100. See Section One for description of disciplines of work to determine activity crew personnel needed.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.2 Disciplines of Work handrails and pipe supports. Steel for buildings is included under “Diseipline, Buildings.” 6. Buildings—All cost of buildings including earthwork, foundations and other conerete, total superstructure, HVAC, plumbing and utility pip- ing to five feet outside of building, insulation, electrical, painting, and all architectual finishes. 1. Underground Piping—All project underground piping serving the project including fire water loops and their components, water lines and special process lines. 8. Above Grownd Piping—Includes the fabrication and erection of all above ground process pipe, valves and fittings required for plant op- eration. Installation only of relief valves, control valves, and orifice fittings for instrumentation are also included. The material cost of these items is included under “Discipline, Instrumentation.” 9. Underground Electrical—All labor and material for underground power and lighting, ducts, conduit, wire, cable, etc. Also includes earthwork and concrete for embedments. 10. Above Ground Electrical—All items required for the complete above ground power and lighting systems for the total project, excluding buildings. Also includes the installation of all electrical instruments and their hook-up. 11. Instrumeniation—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 instrument items plus the tubing, tube bundles, and tray materials required to install these items. © Labor cost includes the installation of the above except as noted. © Labor cost to install relief and control valves and orifice fittings is included under Above Ground Piping. Labor cost to install 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—All labor and material cost of insulation, refractories, and linings for process equipment and piping. Building insulation is in- cluded with buildings. 18. Painting—Includes all preparation and protective coating of surfaces with paint and/or epoxy for the total project excluding buildings. 14. Paving—Includes the furnishing and placing of concrete, asphalt, or gravel used for the final surfacing of roads, sidewalks, parking areas, and process work areas as required.Disciplines of Wark 3 16. Proratables—Includes the labor and material cost for daily area clean up, 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—All labor required to service and maintain the con- struction equipment. Does not include the operation of the equipment when working. Operators are included in the Direct Account Labor. 3. Fuel, Oil, Grease, Supplies—Includes the cost of all fuels, lubricants, and supplies required to operate and maintain the construction equip- ment. Overhead and Indirects The following is a comprehensive list of inclusions, and the scope of the individual project will dictate the actual item requirements. Indirect Labor (Except for Temporary Facilities Labor) All or part of the items described below are used to establish costs for: Salaried indirect Office hourly indirects Field hourly indirects The distribution will vary depending upon the type of project, local la- bor practices, and contractor preferences. Description To Indude Engineering salaries— Civil, cost, electrical, general, mechani- estimating cal and structural estimating salaries. Engineering salaries— Project chief engineer; assistant project field technical support chief engineer; chief field engineer; civil, electrical, mechanical, structural, field, staff, office, piping, instrument engi- neers; coordinators; engineering drafts- men; party chiefs, instrument men,4 Disciplines of Work Watchmen and Janitors—labor Holiday pay Salaries—office clerical Quality assurance—labor Salaries—subcontract administration Salaries—cost engineering Salaries—scheduling and planning Salaries—technical clerks Material control labor Move in/out—labor Non-productive labor chainmen, rodmen, and laborers tempo- rarily assigned to a field party perform- ing general layout work. Security supervisor, security coordina- tor, guards, watchmen, janitors, labor for supplying drinking water. Note: Does not include contract security personnel. Pay for holidays not worked. Personnel covered by overhead and indirect esti- mate only. Administrative clerks, office clerks, and secretaries. =” Chief construction inspector, construc- tion inspectors, welding inspector, piping inspector, electrical inspector, boiler in- spector and civil inspector. Salaries for subcontract coordinators. Salaries for cost/schedule supervisor, chief field cost engineer and cost engi- neers. Salaries for chief field scheduler and planner/schedulers. Salaries for technical clerical personnel. Material control coordinators and mate- rial control personnel assigned to imple- ment and follow-up the material control program. Job payroll labor for loading, unloading, and transporting from facilities to proj- ect construction area tools and construc- tion equipment, temporary facilities, etc. Move-in is defined as assembly of tools and construction equipment at jobsite. Move-out is the return of tools and con- struction equipment to other approved destination, in the immediate area of the Project. ‘Wages paid to hourly employees during a temporary period when work is stopped. Also wages paid to craftsmen for votingSafety and medical expense—labor Salaries—office Salaries—supervision Sick pay Warehouse salaries Disciplines of Work 5 in accordance with union or government regulations. Welding test labor and jury pay differential. Note: Work stoppage due to weather and show-up time are considered in productivity factors used elsewhere. Safety supervisor, safety inspectors, and medics. Chief accountant, accountants, book- keepers, invoice auditors, expeditors, chief timekeeper, timekeepers, person- nel manager, assistant personnel man- ager, personnel interviewer, data con- trollers, data entry operators, purchas- ing agents, and buyers. Project manager, general superinten- dent, craft superintendents, area super- intendents, assistant project manager, assistant superintendents, administra- tive manager, office manager, area coor- dinators and master mechanic. ‘Wages paid overhead and indirect em- ployees only for authorized absence due to personal illness, as approved by proj- ect construction manager. Warehouse supervisor, assistant ware- house supervisor, warehousemen, tool- room attendants, warehouse laborers— assigned full time to warehouse opera- tion. Note: Must be on job payroll only. ‘Temporary Construction Facilities (Labor and Material) Description ‘Temporary buildings and utilities—labor ‘To Include Labor only for construction or erection, maintenance and dismantling of the tem- porary facilities, in accordance with but not limited to the following: Roads, ditches, bridges, storage areas, parking lots, fencing, buildings, water system, sanitary system, power distribution, tel-6 Disciplines of Work Temporary buildings and utilities—material and supplies ephone and communications systems, and plant air system. Note: Does not in- clude construction camp, quartering or catering facilities. Material and supplies and maintenance for construction and dismantling of the temporary facilities in accordance with but not limited to the following. Also in- cludes rental of temporary field offices and warehouses, roads, ditches, bridges, storage areas, parking lots, fencing, buildings, water system, sanitary sys- tem, power distribution, telephone and communications systems, and plant air system. Note: Does not include construc- tion camp, quartering or catering facili- Labor Burdens and Overhead Personnel Benefits Description Retirement and savings plan (for overhead and indirect personnel only) Insurance—employees’ life and hospitalization (for overhead and indirect personnel only) Insurance—W/C, B/I, and P/D Taxes—payroll ‘Vacation pay (for overhead and indirect personnel only) ‘To Include Actual cost fixed by the appropriate ac- counting office. Note: Does not include any like or similar item which is a part of a union fringe benefit. Direct premium charges only. Note: Does not include any like or similar item which is a part of a union fringe benefit. Premium expense based on payrolls. Limits conform to the requirements for the state as specified in the contract. FICA and Medicare, state unemploy- ment insurance and federal unemploy- ment insurance. Actual cost for overhead and indirect personnel only based on gross payroll as billed by the appropriate Accounting Of- fice. Note: Does not include any like or similar item which is a part of a union fringe benefit.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Testing and laboratory analysis Traveling Welding supplies Unclassified Data processing services Consulting services Trade journals, books, publications, and subscriptions Contract Guard Service Quality Assurance— Material and Supplies Employee Educational Assistance Disciplines of Work 9 aid equipment, fire extinguishers, and refills. Soil surveys, concrete cylinder tests, in- dependent inspectors. Lab charges to test welders. Transportation and subsistence expense of overhead and indirect employees on business trips (excluding quality assur- ance personnel travel). All material, supplies, and tools required by a welder, ie., acetylene, oxygen, flux, welding rods, lighters, flints, chipping, hammers, wire brushes, stingers, hel- mets, lenses, asbestos gloves, goggles, gauges, welding qualification test mate- rial, ete. Flowers, weather reports and forecasts, and bank service charges. Cost for data processing services for the project. Terminal rental, supplies, com- puter charges from outside jobsite sources, ete. Cost for outside consulting services which might be required in connection with the projects which are not a part of Cost of books or subscriptions. Cost of subcontract guard service Normally includes travel costs for qual- ity control personnel. Cost of employee educational assistance, for overhead and indirect personnel only.10 =‘ Disciplines of Work ‘Home Office Cost 1. Engineering/Design Services—Total labor and material cost for the complete engineering and design of the project including engineering fee. 2. Construction Services—Services furnished by various home office de- partments such as estimating, scheduling, expediting, etc., as may be required to assist the project. Services are charged to the project only for time actually spent on the project. 8. Project General Management—Includes the portion of time that the contractor's management staff applies in regard to overall direction of the project.Section 2 PROCESS EQUIPMENT The most important component of physical plant cost is that of process equipment. From it the prime basis can be formed for the estimation of the entire plant. Once the production rate has been established and a rough flow sheet presented, an equipment list can be compiled noting the type, size, capac- ity and material of construction. From the logarithmic graphs that appear on 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 ability to realize that the items covered are of a standard nature for chemical plants, refineries, and industrial plants. All installation manhours include offloading equipment at job site, haul- ing up to 2,000 feet and rigging, picking, setting, and aligning of the equipment. The equipment graphs include the total cost of the equipment, but do not include structural steel or miscellaneous iron such as supports, lad- ders, walkways, platforms, or handrails. See other sections for these items. All shop fabricated equipment graphs, as in the case of vessels, include the total shop cost, overhead, and profit for fabricating and furnishing of all material and components required for that piece of equipment. Packaged unit graphs include the total skid-mounted cost of the equip- ment and piping, electrical components and instrumentation, which may be an integral part of the package. Sub-contract equipment graphs include the total sub-contractors cost and profit for the furnishing and installing of the equipment. All equipment graphs include an average allowance for freight cost within the continental forty-eight states. I caution the engineer/estimator to be thoroughly familiar with the in- troduction to this manual before applying this information. awACID COOLERS WITH PUMP AND MOTOR Equipment Cost $100,000. 10, 000} Equipment Cost ° = 3 100 : stitt 1 10 100 1,000 Heat Exchanger Area Square Feet1,000, 101 Erection Manhours Acid Coolers ACID COOLERS WITH PUMP AND MOTOR 10 100 Heat Exchanger Area Square Feet 13 1,000aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.100 Erection Manhours » ° Aerators—Mechanical 10 Motor Horsepower 17 100aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.18 Process Equipment $1,000,000, . 3 3 2 pee a 3 a a 10,000 10 100 1,000 Motor Horsepower @ Fixed low-speed unit @ Floating low-speed unitaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Compressors 21 AIR POWER COMPRESSORS Induction Motor Driven Rated for Sea Level to 3,300-Foot Altitude at 125 psig Maximum Discharge Pressure Equipment Cost $1,000,000 100,000 Equipment Cost 10,000 10 100 1,000 Motor Horsepower (460, 575, or 280-volt 480 or 2,300-volt22 Process Equipment AIR POWER COMPRESSORS Synchronous and Induction Motor Driven Rated for Sea Level to 3,300-Foot Altitude at 125 psig Maximum Discharge Pressure Erection Manhours 1,000 100 Erection Manhours 10) 10 100 #000 Motor Horsepoweraa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Compressors 25 CENTRIFUGAL AIR COMPRESSORS Plant and High-Pressure (Soot Blower) Types 100 to 350 psig Discharge Pressure Equipment Cost $1,000,000 100,000 Equipment Cost 10,000, 100 1,000 10,000 Nominal Motor Horsepower @ Plant air compressors @ High-Pressure (soot blower) compressorsaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.$10,000,000. 1,000, 000} Equipment Cost 100,000} 10,000) 100 INTEGRAL GAS ENGINE COMPRESSOR linder Equipment Cost 000 100,000 1,000 10, Rated Hp. (BHP) @ Cast iron cylinders, 1,000 psig discharge @ Nodular cylinders, 1,500 psig discharge @ Forged steel cylinders, 2,500 psig discharge @ Forged steel cylinders, 6,000 psig dischargeaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.RECIPROCATING COMPRESSORS Electric Motor Driven Equipment Cost $10,000,000, 1,000,000 Equipment Cost 100,000 10,000 100 1,000 10,000 100,000 Compressor Horsepower 1) Cast Iron Cylinders 1000 PSI Discharge 2) Nodular Iron Cylinders 1500 PSI Discharge 2 Steel Cylinders 2500 PSI Discharge Steel Cylinders 6000 PSI Dischargeaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Compressors 37 TWO-STAGE, TWO-CYLINDER, WATER-COOLED AIR COMPRESSORS Oil-Lubricated and Nonlubricated 150 to 500 psig Discharge Pressure Erection Manhours 1,000 Erection Manhours 10 100 1,000 Motor Horsepoweraa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Dryers—Air 41 REFRIGERATED AIR DRYERS Automatic Type 1,200 to 15,000 scfm Erection Manhours 100 Erection Manhours 3 100,000 10,000 Capacity SCFMaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Surge Arrestors 45 SURGE ARRESTORS Hydrocarbon, Water and Sewage Service 275 psi Design Operating Pressure ASME Code—Section VIII Division I Equipment Cost $100,000, 10,000} Equipment Cost 1,000 100 se : = a 10 100 1,000 Nominal Size Gallons @ Hydrocarbon service @ Water service @ Sewage serviceaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.50 Process Equipment MIXERS AND BLENDERS Fixed Side Mounted Mixers 1,000, Erection Manhours 8 8 » ° 100 1,000 10 Rating Horsepoweraa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.MIXERS AND BLENDERS Equipment Cost $1,000,000 100,000 8 ° i 4 a 101 1,0¢0 100 1,000 10,000 100,000 Approximate Weight - Pounds gir 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 mechanical seals Note: Motor horsepower range 2-200, shaft length range 100”-230”, impeller range 29°-75".aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.BOILERS Equipment Cost $1,000,000 Cost ” 3° 3 ° 3 Ss Equipment 10,00 10,000 100,000 1,000,000 Pounds Per Hour Note: Cost is for total boiler including forced draft fan assembly. Boiler capacity pounds per hour-satu- rated steam at 100 to 285 psig.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.68 Process Equipment BOILER STACKS 1/a-, 5/16-, /8-Inch Plate Erection Manhours 1,000, » ° Ss Erection Manhours » S 1 1,000 10 " 100 Linear Feet Of Stack @ 24-inch diameter @ 42- to 48-inch diameter @ 30-inch diameter © 54- to 60-inch diameter @)36-inch diameteraa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.70 Process Equipment CLASSIFICATION EQUIPMENT Turbo-Screen Cyclone and 48” -Pressure Sifter (8-Screens) Erection Manhours Manhours » ° Erection 1 100 10 Diameter Inches @ Carbon or stainless steel cyclone @48-inch pressure sifter (3-screens)aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.74 Process Equipment VERTICAL TUBE SURFACE 1,000, Erection Manhours 10 100 1,000 Cooling Surface Square Feetaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.1 Erection Manhours CONVEYING EQUIPMENT Conveyors—Belt Enclosed 0,000, 1,000) 100! 10 i 10 101 10 1,000 10,000 Linear Feet @ 18:inch belt @26.inch belt @ 2-inch belt ® 42.inch belt @30.inch belt Note: See structural steel account for bents.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.SCREW CONVEYORS Equipment Cost $100,000 10,000aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Dryers—Drum 89 10,000, 1,000) Erection Manhours 100 10 f : 100 1,000 10,000 100,000 Approximate Weight Pounds @Single Drum @Double Drum @Twin Drumaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.DRYERS—VACUUM Rotary Types Carbon Steel and Stainless Steel Erection Manhours 1,000,000 100,000 Erection Manhours 10,000 1,000 z 1,000 10,000 100,000 1,000,000 Approximate Weight Pounds @Carbon Steel @Stainless Steelaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.100 = Process Equipment DUST COLLECTORS 304 Stainless Steel Cyclones Equipment Cost $100,000, 10,000} ost + Equipment 100 100 10,000 100,000 1000 Capacity Chi at 6.0" Preseure Drop © 16-gauge @ 12-gauge ® %ieinch plate @ 14-gauge @ 10-gauge Note: Cfm capacity at 2.5-inch pressure drop will equal approximately two-thirds of above cfm.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.104 Process Equipment DUST COLLECTORS Packaged Blowers for Filter and Tube House Dust Collectors Equipment Cost $10,000, Cost ns ’ ° Equipment § 100, 1 10 100 Motor Horsepoweraa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.108 Process Equipment FANS AND BLOWERS Centrifugal Fans with Equipment Cost $100,000 10,000] Equipment Cost 1,000} 100 1,000 10,000 100,000 1,000,000 Naximum Volume - CFii @ Binches @ 2,300 fpm to 24inches @ 3,200 fpm @ 8% inches @ 3,000 fpm to 4% inches @ 4,175 fpm 13%inches @ 3,780 fpm to 6%inches @ 6,260 fpm Above Class Three specification Note: Performance range designations are indicated by stati pressure (inches of water) at fan outlet ve locity eet per minute). Performance range-sin- gle widthan class.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.112 = Process Equipment FANS AND BLOWERS Heavy Sheet Steel Industrial Fans Equipment Cost $100, 000, 10,00 Equipment Cost 1,00 10 a =: 100 1,000 10,000 Maximum Volune-CFK 100,000aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.116 Process Equipment PRE-WETTING DRY CHEMICAL FEEDERS Equipment Cost $10,000 Equipment Cost - 8 S 100) 100 10 Hopper Cubic Feetaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.DRY MATERIAL FEEDER EQUIPMENT Vibrating Feeders Equipment Cost $100,000 10,000: 2 8 8 2 & 1,000) 100 1 10 100 1,000 Tons Per Houraa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.124 Process Equipment DRY MATERIAL FEEDERS Wing and Conveyor Types Equipment Cost $100,000 10,000 Equipment Cost 1,000 100 10 100 1,000 10,000 Naximum Cubic Feet Per Hour @ Wing-type feeders-ratchet drive @ Wing-type feeders-micro master drive @ Conveyor type feeders @ Sanitary wing-type feedersaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.FILTERS Pressure Type Erection Manhours 100 Manhours ” 3° Erection 10 100 Diameter Feetaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.134 Process Equipment Cooling Drum Type $1,000,000. 100,001 3 Equipment Cost 100 1,000 10,000 100, 000 Approximate Weight Poundsaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.GAS PULSATION DAMPERS Equipment Cost $100,000 10,000 2 3 8 4a s 2 Ray 3 = a 1,000 100 = 100 1,000 10,000 100,000 Volume Cubic Inchesaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.142 Process Equipment HEATERS Gas-, Oil-, and Dual-Fired Heaters Equipment Cost $1,000, 000, 100,000 it Equipment Cos: 10,000 1,000 100 1,000 10,000 100,000 Approximate Weight Pounds @Gas-fired @ Oilfired @ Dualfiredaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.146 Process Equipment HEAT EXCHANGERS Shell and Tube, Fixed Tube Sheet, and U-Tube Equipment Cost 31,000,000 100,000 Equipment Cost 10,000 1,000 x 100 1,000 10,000 Heating Surface Square Feet @ 150# Rating @ 3008 Rating @600# Rating Note: Above is for carbon steel, straight tube exchangers, Add following percent to the above for: 10 Straight Tubes U-Tubes Tube Sheet Carbon Steel _ 6% 10% Stainless Steel 20% 26% 30% Copper 10% 16% 20%aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.160 Process Equipment HEAT EXCHANGERS FOR HEATING WATER Erection Manhours 1,000, Erection Manhours 00 1,000 10 1 Heating Surface Square Feetaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.154 Process Equipment CENTRIFUGAL PUMPS Two-Stage and Multi-Stage Horizontal Split Case Equipment $100,000 10,000 8 Equipment Cost 100 3 : = 10 100 1,000 10,000 Prime Mover Horsepower OTwostage, 3,550 rpm—specific gravity of 1.0 @ Multi-stage, 3,550 rpm—specific gravity of 1.0aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.INSTRUMENTS ‘Total Instrument Installation Manhours 100, 000, 10,001 » 2 3 Installation Manhours 101 1,000 10 100 Pieces Of Equipmentaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.INSULATING MATERIAL Total Square Feet 1,000,000, 100,000} Total Square Feet 10,000] 1,000 1 1,000 10 100 Pieces Of Equipment ®Pipe @ Equipmentaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.PAINTING—EQUIPMENT ‘Square Feet Area 1,000,000, 100,000 Square Peet Area 10,000} 1,000 2 1,000 10 100 Pieces Of Equipmentaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.100,000, 10,000 Painting Manhours 1,000; 100) PAINTING—EQUIPMENT ‘Total Manhours 10 100 Pieces Of Equipment 1,000aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.PAINTING—PIPING ‘Total Manhours 100,000, 10,000) Painting Manhours 1,000} 100 1,000 100 10 Pieces Of Equipmentaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Paving 295 CONCRETE AND GRAVEL ‘Total Material Cost $100,000, 10, 00( Total Material Cost » ° 3} 10 1 10 100 1,000 Square Yards @ 12-inch base material and Ginch reinforced concrete @6inch gravel pavementaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Section 16 OVERHEADS AND INDIRECTS Included in this section are logarithmic graphs reflecting average cost of labor, materials, temporary facilities, small tools, consumable supplies, burdens and benefits, etc., required to supervise and construct a project. Various items have been grouped together on the following graphs for ease of listing and application. For a comprehensive listing of total cover- age of items under this section refer to the overhead and indirect listings under 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.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Overheads and Indirects 307 PAYROLL BURDENS AND BENEFITS Other Indirect and Temporary Construction Materials ‘Total Cost 1,000,000 1,000, 000} 2 8 8 $ a 3 g 8 a 200,000 10,000 3 a $1 $10 $100 $1,000 Total Direct Labor In Hundred Thousand Dollars @ Payroll burdens and benefits © Other indi sal @ Temporary construction materials Note: See next page for continuation of these items.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.312 Home Office Cost ENGINEERING DESIGN Manhour Range Allowance Per Piece of Equipment _Manhour Allowance For_ Single Duplicate Equipment Classification Unit Range Unit Range Fang.And Blowers Heavy Gauge Centrifugal Fans 600-800 300-400 Motors And V-Belt Drive For Fans 100-150 50-60 Rotary Blowers 400-600 200-300 Centrifugal Turbo Blowers 600-800 300-400 Filters Pressure Type 200-300 100-150 Oil Mist Collectors 200-300 100-150 Plate And Frame Type 200-400 100-200 Sparkler 200-300 100-150 Leaf 200-300 100-150 Sewage And Rotary 300-400 150-200 Screen Vibrating 400-600 200-300 Flotation Machines 400-600 200-250 Gas Holders 150-200 50-70 Generates Steam Turbine Units 5,000-8,000 2,000-3,500 Inert Gas Generators 2,000-4,000 800-1,500 Skid Mounted—Diesel Engine Driven 1,000-2,000 300-500 Heat Exc Evaporators And Condensers Shell And Tube, Floating Head Exchangers 600-800 300-400 Shell And Tube, Fixed-Tube Sheet, U-Tube Exchangers 600-800 300-400 Steel Fin Tubes, Steel ReBoilers And Jacketed Pipe 600-800 900-400 Long Tube Vertical Evaporators 800-900 400-450 Horizontal Tube Evaporators 800-1,000 400-500 Jacketed, Glass Lined Steel Vessel Evaporators 850-1,050 425-525 Condensers—Barometric 650-850 825-425aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Section 18 RATIO ESTIMATING FACTORS Ratio estimating factors are simply the relationship, in percentage ranges, between two or more things and are the transformation of statis- tical data into combinations of variables that are usually not correlated. The minimum basic information required to assemble an estimate of this type is: 1. Information regarding plant capacity, product form, basic process and raw material. 2. A complete process equipment list with individual shipping dates and total material dollar cost. 3. The general plant location. The accuracy of this type estimate should fall in the range of + 80% to — 30%. Accuracy Definition + % = Add to total cost excluding contingency for highest cost. —% = Deduct from total cost excluding contingency for lowest cost. The direct cost percent ranges in the following tables are to be applied against 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 is applied against the total direct and indirect cost of the project. The percentages for the various disciplines of work are averages of many projects located in the Gulf Coast Area. When determining a per- centage to be applied for a specific project from the percentage range ta- bles consideration should be given to this fact. The percentages for labor are for open or merit shop type operations. If closed shop methods are to be employed additional consideration should be given and applied against the labor dollar value. 316aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.ae CONCEPTUAL rast ESTIMATING VW St ST al See page ii for information about John S. Page. Bre st Ue www.bhusa.com/gulf COST ESTIMATING ere’s another valuable component of Gulf’s classic estimator’s series. This new printing of Conceptual Cost Estimating gives the construction industry and the management staff of chemical, refinery, and industrial plants the information they need to generate fast, reasonably accurate costs for designing and constructing a specified facility. COVERAGE INCLUDES— * Process Equipment © Site Preparation © Site Improvements © Concrete ® Structural Steel ° Iron © Buildings * Piping * Installation and Material Cost of Electrical Equipment * Insulation * Paint and Painting © Construction Equipment © Ratio Estimating Factors © Definitions of Estimate Adjustments PRODUCT #5267 ISBN 0-88415. 9'780884"15 267-7 il iil Iii. 26