Introduction To Cost Estimation Software

Introduction to Aspen Cost Estimation Products
Sunil Patil
Principal Business Consultant
2010 Aspen Technology, Inc. All rights reserved
Agenda
Introduction and Overview
Cost Basis
Process Equipment and Bulk Modeling
Workflow Overview
Configuring Templates
Loading and Mapping Simulation Data
Evaluating the Project and Generating Reports
Detailed hands on information

Decision Analyzer (Project Scaling and Relocation)
Integrated Costing and Sizing
Asset Engineering Workflow

Safety &
Controllability
Analysis
Analyze
Economic
Performance
Process
Performance
Modeling & Analysis
Conceptual
Design / R&D
Basic
Engineering
Detailed
Engineering
Operations/
Maintenance
Detailed
Equipment
Design
Develop Basic
Design Package
Analyze
Detailed
Costs
Develop Detailed
Plant Design
Reuse Process
Model for
Operations Decisions
Reuse Process
Models for
Planning Decisions
What is Icarus technology?

Computer aided, design, estimating, and scheduling system
for the process industries
System generates scope quantities
Engineering department embodied in software
Incorporates current construction practices and costs
Used to evaluate capital costs for:
Major process plants / mills

Process alternatives
Scope changes
Work orders
Used by owner/operators and engineering/constructors
Logically Connected
Asset Optimization
Concept
Process
Design
Process
Economic Analyzer
Plant
Design
Construction
Startup
DeBottleneck
Capital Cost Estimator
Process Simulators
Retrofit
Production
In-Plant Cost Estimator
Primavera Scheduling
Aspen Plus
HYSYS
Reporter
Excel & Crystal
Reports
Aspen Basic Engineering
Data Sheets, Plot Plan
User Data
Aspen
Icarus
Excel Custom Models

CAE/CAD
Intergraph
Client
Technology
(via API)
Aspen Economic Evaluation Products

Process Economic
Analyzer
Economics for Process

Engineers
Interface to Aspen Plus
and HYSYS
Expand Unit Operations
to Equipment (Map)
Equipment sizing
PFDs
Stream list incl. utilities
Project Relocation &
Scaling
Cooling Water analysis
Financial Analysis
(CAPEX and OPEX)
Capital Cost Estimator
In-Plant Cost Estimator
Multi-contractor project
execution
Power/Process Control
systems
Optimized equipment
rental
Primavera detailed CPM
schedule (P6)
Project Relocation &
Scaling
Modular Construction
Pipelines
All Design Basis,

Equipment & Plant Bulks
as ACCE
No volumetric models
Foundation design
Primavera CPM schedule
incl. costs (P3 or P6)
Equipment Rental
User data sources
Built-In Knowledge Modules
International
Design Methods
CPM-based
Scheduling
Methods
Detailed Design
and Cost
Models
Fabrication and
Construction
Methods
Expert Systems
Knowledge Bases
Contractors
Engineering
Materials
of
Construction
AspenTech Integration Example
1) Process
simulation cases
developed
Aspen Capital
Cost Estimator
3) Preliminary
sized equipment
used to develop
conceptual cost
estimate
Aspen Process
Economic Analyzer
2) Economic
screening performed
for multiple cases
Aspen Basic
Engineering
4) Data loaded for
best case
6) Preliminary
conceptual
estimate revised
with latest project
data from Aspen
Basic
Engineering
5) Additional design
and sizing
Equipment Design and
Rating Tools and MS
Excel
New Product Nomenclature
Old Name
New Name
Aspen Icarus Process

Evaluator (IPE)
Aspen Process
Economic Analyzer
Aspen Kbase
Aspen Capital Cost

Estimator
Aspen Icarus Project

Manager (IPM)
Aspen In-Plant Cost

Estimator
What is Aspen Process Economic Analyzer?

Tools for preliminary/relative economic analysis
Generates equipment sizes and designs using process
simulator data
Calculates estimated capital and operating costs for a
process
Allows rapid evaluation of processes alternatives to compare
relative profitability
Projects created in Aspen Process Economic Analyzer can be
refined in Aspen Capital Cost Estimator
10
Aspen Economic Evaluation

Family and the Project Lifecycle
Concept
Process
Design
Aspen
Process
Economic
Analyzer
Plant
Design
Construction
Startup
DeBottleneck
Aspen
Capital
Cost
Estimator
Retrofit
Aspen In-Plant
Cost Estimator
Two interfaces to the

same underlying model
Production
11
Aspen Process Economic Analyzer

Project Basis
Establish cost basis
Rules for generation of

preliminary sized
equipment list from
simulation data
Define investment
parameters, costs, and
product value(s)
12
Aspen Capital Cost Estimator

Project Basis
Establish
cost
basis
Customize
models
Fine tune CPM

schedule
13
Capital Costs
Costs for initial and working capital
Direct costs
Equipment
Piping
Civil
Steel, etc.
Indirect costs
Construction rental equipment
Construction management
Engineering, etc.
14
Operating Costs
Operator and supervisor costs
Feedstock costs estimated using stream data and user
entered information
Utility costs
Steam
Heating oil
Cooling water
Refrigerants
Electricity, etc.
15
Cost Basis
Cost basis updated with each annual release
Five base locations
US Gulf Coast
EU
UK
Japan
Middle East
Material and labor specifications can be adjusted to

represent site-specific conditions
16
Investment Analysis
Product sales estimated using stream data and user entered
information
Profit = Sales - (Capital Costs + Operating Costs)
Investment analysis module generates typical economic
metrics
NPV
IRR
PO, etc.
17
Process Equipment
Primary equipment items derived from simulation
Simulator blocks mapped to one or more Icarus equipment
models
User-defined parameters govern designs
Additional process equipment items added by user

Pumps
Storage tanks
Spares
Equipment models have attached P&ID

Used to estimate piping and instrumentation costs
Sizing equations used to estimate pipe quantities (length
and diameter)
Volumetric modeling used to estimate other bulk

quantities and costs (civil, paint, insulation, etc.)
18
Equipment Design and Cost Procedure

PROJECT SPECS:
Mechanical design specs
Project components specs
MECHANICAL DESIGN:
Develop physical dimensions using:
design code procedures
industry standard methods
Equipment
design generated
FABRICATION LABOR:
Shop [+ Field]
Labor
Man-hours
Equipment cost
estimated
VESSEL COST:
1. Matl cost of parts
2. Shop [+ field] fab labor
3. Labor overheads
4. G and A
5. Profit
19
Equipment Design Data and Estimated FOB

Cost from Vendor
20
Volumetric Models:
Calculation of Installation Bulks
x
x
Conceptual P&IDs
Civil
Steel
Electrical
Insulation
Paint
x
x

Total installed cost estimated

Quantities and costs for bulk
materials based upon equipment
specifications
Volumetric models for process
equipment:
21
P&ID Library:
Double Diameter Tower
22
Non-Equipment Costs
System estimates costs for additional bulk quantities
Project bulks
Process control
Power distribution
Area bulks
Grounding
Lighting
Steel structures
Users can account for additional costs using system

models
Plant bulks
Pipe rack
Rack piping
Buildings
Site development
23
Typical Workflow
Prepare library files
Load simulator data
Map simulator blocks to Icarus components
Evaluate
24
Library Files
Basis for capital costs
Project type and location
Construction workforce specifications
Material and man-hour indices
Design criteria for equipment

Investment parameters
Analysis period
Tax and interest rates
Escalation
Operating unit costs

Product and raw material specifications
25
Mapping Simulator Data

Creates Process Economic Analyzer equipment
components from computational block data
Map 1-to-1 or 1-to-many
Components are sized using simulator data and
Process Economic Analyzer design criteria
Resulting process flow diagram can be viewed in
26
Project Evaluation
Project evaluation generates design quantities and
estimates costs
Available reports
Investment analysis reports

Equipment
Project summary
Cashflow
Executive summary
Capital cost reports

Standard reports (using Crystal Reports components)

Excel reports
HTML reports
Management reports (can be exported to Excel)
27
Hands On Information
28
Loading Data from Aspen HYSYS

Tools | Aspen Economic Evaluation | Export to Process
Economic Analyzer
29
Loading Data from Aspen HYSYS

After being prompted to load simulation data, the following
interface window appears
Confirms that HYSYS is running
Establishes link
Extracts simulation data
Changes to Export Again
when export is complete
Disconnects interface
Closes interface
30
Loading Data from Aspen Plus

File | Send To | Aspen Process Economic Analyzer
31
Creating a New Project in Aspen Plus

Create using Aspen IPE Stream Properties template to ensure
all necessary stream properties transferred to Aspen Process
Economic Analyzer
32
Adding Properties to Existing Aspen

Plus Project
Import IPE-1, IPE-2, and IPE-3 Prop-Sets from Aspen IPE
Stream Properties template
33
Interface No Open Project
Palette
View
Properties
Window
34
Interface Open Project
Palette
View
Project
Explorer
List
View
Properties
Window
35
Palette View
Three tabs
Projects
Libraries (Template files)
Components (Equipment, bulk items, buildings, and site
development models)
Locations of projects / libraries

Specified using the Locations tab of Preferences menu (Tools |
Options | Preferences)
Locations can be on a local or network drive
Use drag-and-drop from Components tab (to Project View or

List View) to select components into project
36
Properties Window
Contains location information for items in the Projects and
Libraries tabs of the Palette View
Provides details for fields within a component specification form
Allowable data type

Default value(s)
Minimum / maximum allowable values
Description
37
Project Explorer
Three tabs
Project Basis View
Process View
Project View
Project Basis View tab allows input of project level specifications

Process View tab displays unit operations loaded from process
simulator data
Yellow unit operations are unmapped
Green unit operations have been mapped to equipment
Project View tab allows addition of components
38
Project Basis Specifications
39
Project Basis Specifications
Capital cost basis

General specifications
Construction workforce
Indexing
Process design
Simulator file
Mapping specifications
Design criteria
Investment analysis
Operating unit costs
Raw material and product specifications
40
Loading Simulator Data

Not necessary if data is sent from HYSYS or Aspen Plus
Load data
Specify simulator type
and file name
Aspen Plus - .apw or .xml
HYSYS - .hsc
41

Loads block and stream data from simulator
Populates Process View tab with unit operations
View streams list and block flow diagram
42

Simulator type and simulator file name specified in
project basis
Block and stream data loaded from simulator
Block flow diagram and streams list can be viewed in
Simulator link allows Aspen Plus and HYSYS simulation

data to be exported directly to Aspen Process Economic
Analyzer
43
Mapping Simulator Items

Map simulator items
44
Mapping Simulator Items

Maps unit operations to equipment models
Simple (1-to-1 mapping)
Complex (1-to-many mapping)
Defaults are based upon Project Component Map

Specifications in the Project Basis
A default file is available out of the box for each supported
simulator type
Customers can create their own files and store as a template
(found in the Libraries tab of the Palette View)
Performs preliminary sizing using design criteria specified in

project basis, unit operation, and stream data
Populates Project View tab
After mapping, user can view a process flow diagram
45
Tower Configurations
Tower configuration selected
during mapping
Configuration drives equipment
generated by unit operation
Single - Tower has one condenser
Split - Tower has multiple condensers
Total - Reflux pump handles the total outlet liquid flow from the
accumulator. In such configurations, the splitting into a reflux and
overhead liquid product occurs after the reflux pump
Circ. There is a pump between the bottoms splitter and reboiler giving a
forced circulation configuration around the reboiler
Full configurations include the following equipment (not found in Standard
configurations)
overhead pump
overhead product heat exchanger
bottoms product pump
bottoms product heat exchanger
46
Process Flow Diagram: Radfrac Block

PFD is interactive
Additional equipment
(pumps, storage tanks,
etc.) can be added to a
project manually
Manually added equipment
can be placed on the
appropriate stream and
sized using design
parameters
47
Evaluating the scenario

Generates designs, quantities, and estimated costs
Evaluate project
48
Additional Modules
Decision Analyzer
Analyzer Scale-Up Module (ASM)
Analyzer Relocation Module (ARM)
Analyzer Economic Module (AEM)
Utility Models
Air (instrument and plant)
Cooling water
49
Decision Analyzer module
50
Decision Analyzer module

Conceptual scale-up and relocation of a base case
Allows a user to generate relative costs for changed
capacity or construction/engineering in a new location
Scale-up module resizes equipment and associated
bulk quantities (piping, instrumentation, foundations,
etc.)
Scale-up module will not automatically model multiple
trains of equipment
Relocation module primarily indexes material costs
and modifies workforce specifications (wages and
productivities) These changes will override
specifications that the customer may have made
Relocation module does not modify design codes and
construction/fabrication models
51
Integrated Simulation & Cost Analysis
View
Unit Op
Grid
Show
Current
State
Activate
Costing
Engine
Map
Models to
Equipment
Load
Simulation
Data
Size
Equipment
Object
52
Evaluate
Equipment
Costs
View
Equipment
Grid

Unit Operation Summary Grid
View Unit Op
Summary Grid
View Results and

Change Inputs
One tab for each type of unit operation

model in the simulation case
53

Mapping Unit Operation Models to Equipment
Map Unit Operation
Models to Equipment
E1210
Condenser
C1200
Packed
Column
T1220
Reciever
Packing
Section 1
P1230A/B
Reflux Pumps
E1250
Exchanger
Packing
Section 2
P1240
Pump
C1200
E1260
Reboiler
Conceptual Unit
Operation Models
Equipment Models
for Cost Analysis
54

Mapping Unit Operation Models to Equipment
Map Unit Operation
Models to Equipment
Equipment objects are

created during the
mapping process
55

Viewing / Changing Equipment Specifications
View/Change Equipment
Specifications
Summary of
Equipment Costs and
Net Process Costs
56
Integrated Workflow Advantages
One environment = faster learning curve

Interactive sizing from inside the simulator
Enables concurrent design & costing
Rigorous cost modeling allows rapid evaluation
of process scenarios
Resulting project file can be opened directly in
Aspen Capital Cost Estimator
57

Introduction To Cost Estimation Software

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Introduction to Aspen Cost Estimation Products

2010 Aspen Technology, Inc. All rights reserved

Detailed hands on information

2010 Aspen Technology, Inc. All rights reserved

Asset Engineering Workflow

2010 Aspen Technology, Inc. All rights reserved

What is Icarus technology?

Major process plants / mills

Used by owner/operators and engineering/constructors

2010 Aspen Technology, Inc. All rights reserved

Capital Cost Estimator

In-Plant Cost Estimator

Excel Custom Models

2010 Aspen Technology, Inc. All rights reserved

Aspen Economic Evaluation Products

Economics for Process

Capital Cost Estimator

In-Plant Cost Estimator

2010 Aspen Technology, Inc. All rights reserved

All Design Basis,

Built-In Knowledge Modules

2010 Aspen Technology, Inc. All rights reserved

AspenTech Integration Example

New Product Nomenclature

Aspen Icarus Process

Aspen Capital Cost

Aspen Icarus Project

Aspen In-Plant Cost

2010 Aspen Technology, Inc. All rights reserved

What is Aspen Process Economic Analyzer?

2010 Aspen Technology, Inc. All rights reserved

Aspen Economic Evaluation

Two interfaces to the

2010 Aspen Technology, Inc. All rights reserved

Aspen Process Economic Analyzer

Establish cost basis

Rules for generation of

Aspen Capital Cost Estimator

2010 Aspen Technology, Inc. All rights reserved

Fine tune CPM

2010 Aspen Technology, Inc. All rights reserved

2010 Aspen Technology, Inc. All rights reserved

Material and labor specifications can be adjusted to

2010 Aspen Technology, Inc. All rights reserved

2010 Aspen Technology, Inc. All rights reserved

Additional process equipment items added by user

Equipment models have attached P&ID

Volumetric modeling used to estimate other bulk

Equipment Design and Cost Procedure

Equipment Design Data and Estimated FOB

2010 Aspen Technology, Inc. All rights reserved

2010 Aspen Technology, Inc. All rights reserved

Total installed cost estimated

2010 Aspen Technology, Inc. All rights reserved

Users can account for additional costs using system

2010 Aspen Technology, Inc. All rights reserved

Design criteria for equipment

Operating unit costs

2010 Aspen Technology, Inc. All rights reserved

Mapping Simulator Data

2010 Aspen Technology, Inc. All rights reserved

Capital cost reports

Standard reports (using Crystal Reports components)