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ESTIMATING
MANUAL
SECOND
JOHN
EDITION
S. PAGE
An Imprint ofElsevier
Conceptual Cost
Estimating
Manual
2nd Edition
PlH
10 9 8 7 6
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 plantsDesign and construction
EstimatesHandbooks, manuals, etc. I. Title.
TH4524.P34 1996
690'.54dc20
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 allows
the construction industry and the engineering/management staff of chemical, refinery, and industrial plants to arrive at a reasonable cost for a specified facility. Simply 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
concerned 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 moderate 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 complete plant should be obtainable for any location in the world.
INTRODUCTION
This manual contains two methods of conceptual estimating for determining the budget amount or estimated cost to design and construct refineries, chemical/petrochemical, 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 all 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 material 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 concerned 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 acjjust the graph and table manhours as may be required. Major
items that one should consider in determining productivity are:
1. General Economy
2. Project Supervision
3. Labor Relations
4. Job Conditions
5. Construction Equipment
6. Weather
In determining the dollar rate to apply against the estimated manhours the engineer/estimator should first establish weighted composite crew rates. This is simply the
listing by craft of the various personnel required for a crewsuch as general foreman,
foreman, craftsmen, and apprentices/helpersand 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 weighted 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.
All manhour tables and graphs include the total manhours, based on 70% productivity, to complete the unit of work as listed.
All equipment and material dollar graphs and tables are based on cost as of January
1, 1996, and include the total unit equipment or material cost as outlined.
All graphs and tables that reflect shop fabrication, packaged units, and subcontracted items include the total cost of labor, material, overhead and profit of the supplier, and
vendor or subcontractor.
If the project under consideration is to be located in an area outside the continental
forty-eight states, the engineer/estimator must consider other items not covered in this
manual. Additives for any or all of the following items may be required and since their
costs vary widely for different parts of the world, they must be researched individually
for each foreign project.
1. Mobilization and demobilization of personnel and equipment
2. Foreign differential labor pay
3. Permits, licenses, fees, duties
4. Load out, tie down and material handling
5. Transportation and ocean or air freight
6. Camp, family quarters,fieldoffice, and storage facilities
7. Rest and recreation for personnel
With the established quantities and manhours the project can be scheduled and fasttrack 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 material
2. Knowledge of general specifications
3. Plant location (site conditions)
4. Equipment list (priced out)
In assembling a method one or two estimate it should be recognized that in the rounding 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 because
the items tend to average each other out.
I sincerely hope the foregoing will enable the engineer/estimator engaged in this type
work to turn out more realistic conceptual estimates and assist in the elimination of
much guesswork.
Contents
Preface .................................................................................... xv
The Human Factor in Estimating ..................................................
xv
Section 2.
vi
Contents
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
This page has been reformatted by Knovel to provide easier navigation.
Contents
vii
viii
Contents
Portable Clamp and Flanged Mounted Mixers
Equipment Cost ...................................................... 52
Flanged Top Tank Mounted and Plate Mounted Open
Tank Mixers Erection Manhours ........................... 53
Gearmotor Mixers Equipment Cost ............................... 54
Gearmotor Mixers Erection Manhours .......................... 55
Batch and Pipeline Homogenizer Mixers Equipment
Cost ........................................................................ 56
Batch and Pipeline Homogenizer Mixers Erection
Manhours ................................................................ 57
High-intensity Mixers Equipment Cost .......................... 58
High-intensity Mixers Erection Manhours ...................... 59
Bag and Rigid Container Vibrating Packers
Equipment Cost ...................................................... 60
Bag and Rigid Container Vibrating Packers Erection
Manhours ................................................................ 61
Boilers ............................................................................................ 62
Package Type Equipment Cost .................................... 62
Package Type Erection Manhours ................................ 63
Boiler Stacks Equipment Cost ...................................... 64
Boiler Stacks Erection Manhours .................................. 66
Classification Equipment ............................................................... 67
Cone Pelletizers Equipment Cost ................................. 67
Cone Pelletizers Erection Manhours ............................. 68
Turbo-screen Cyclone and Pressure Sifter
Equipment Cost ...................................................... 69
Turbo-screen Cyclone and Pressure Sifter Erection
Manhours ................................................................ 70
Rotary Screens Equipment Cost ................................... 71
Rotary Screens Erection Manhours .............................. 72
This page has been reformatted by Knovel to provide easier navigation.
Contents
ix
Contents
Dryers Vacuum ........................................................................... 90
Conical Rotating Equipment Cost ................................. 90
Double Drum and Rotary Equipment Cost .................... 91
Conical Rotating and Double Drum Erection
Manhours ................................................................ 92
Rotary Carbon and Stainless Steel Erection
Manhours ................................................................ 93
Dust Collectors .............................................................................. 94
Centrifugal Scrubbers High Capacity, Hot-rolled
Steel Equipment Cost .......................................... 94
Centrifugal Scrubbers Medium Capacity, Hot-rolled
Steel Equipment Cost .......................................... 95
Centrifugal Scrubbers High Capacity, Stainless
Steel Equipment Cost .......................................... 96
Centrifugal Scrubbers Medium Capacity, Stainless
Steel Equipment Cost .......................................... 97
Centrifugal Scrubbers High- and Medium-capacity,
Hot-rolled and Stainless Steel Erection
Manhours ................................................................ 98
Cyclones Hot-rolled Steel Equipment Cost ................ 99
Cyclones Stainless Steel Equipment Cost ................. 100
Cyclones Hot-rolled and Stainless Steel Erection
Manhours ................................................................ 101
Filter Cartridge or Tube House Filters Equipment
Cost ........................................................................ 102
Filter Cartridge or Tube House Filters Erection
Manhours ................................................................ 103
Packaged Motor Operated Blowers Equipment Cost .... 104
Packaged Motor Operated Blowers Erection
Manhours ................................................................ 105
Contents
xi
xii
Contents
Gravity Filtration Units Total Unit Installation
Manhours ................................................................ 127
Pressure Type Equipment Cost .................................... 128
Pressure Type Erection Manhours ............................... 129
Rubber-lined Equipment Cost ....................................... 130
Rubber-lined Erection Manhours .................................. 131
Vibrating Screens Equipment Cost ............................... 132
Vibrating Screens Erection Manhours ........................... 133
Flakers ........................................................................................... 134
Cooling Drum Equipment Cost ..................................... 134
Cooling Drum Erection Manhours ................................. 135
Generators ..................................................................................... 136
Inert Gas Equipment Cost ............................................ 136
Inert Gas Erection Manhours ........................................ 137
Gas Pulsation Dampers ................................................................ 138
Dampers Equipment Cost ............................................. 138
Dampers Erection Manhours ........................................ 139
Heaters .......................................................................................... 140
Deaerating Feedwater Equipment Cost ........................ 140
Deaerating Feedwater Erection Manhours ................... 141
Gas-, Oil-, and Dual-fired Equipment Cost .................... 142
Gas-, Oil-, and Dual-fired Erection Manhours ............... 143
Heat Exchangers ........................................................................... 144
Hairpin Type Equipment Cost ....................................... 144
Hairpin Type Erection Manhours .................................. 145
Shell and Tube, Fixed Tube, and U-tube Equipment
Cost ........................................................................ 146
Shell and Tube, Fixed Tube, and U-tube Erection
Manhours ................................................................ 147
Contents
xiii
xiv
Contents
Reactors ........................................................................................ 167
Glass-lined, Agitated, Jacketed Equipment Cost .......... 167
Glass-lined, Agitated, Jacketed Erection Manhours ...... 168
Steam Jet Ejectors ........................................................................ 169
Single-stage Equipment Cost ....................................... 169
Single-stage Erection Manhours ................................... 170
Gas Scrubbers .............................................................................. 171
High-energy Venturi Type Equipment Cost ................... 171
High-energy Venturi Type Erection Manhours .............. 172
Separators ..................................................................................... 173
Vane Type Equipment Cost .......................................... 173
Vane Type Equipment Cost .......................................... 174
Vane Type Erection Manhours ..................................... 175
Vibrating Equipment Cost ............................................. 176
Vibrating Erection Manhours ........................................ 177
API Type Oil/Water Equipment Cost ............................. 178
API Type Oil/Water Erection Manhours ......................... 179
Size Reduction Equipment ............................................................ 180
Crushers Equipment Cost ............................................. 180
Crushers Erection Manhours ........................................ 181
Impact Breakers Equipment Cost ................................. 182
Impact Breakers Erection Manhours ............................. 183
Reversible and Non-reversible Hammermills
Equipment Cost ...................................................... 184
Reversible and Non-reversible Hammermills Erection
Manhours ................................................................ 185
Ring Type Granulators Equipment Cost ....................... 186
Ring Type Granulators Erection Manhours ................... 187
Contents
xv
xvi
Contents
Column Trays, Shop Installation Cost Each .................. 207
Demisting Pads, Shop Installation Cost Each ............... 208
Shop Stress Relief Cost per Ton .................................. 209
Removable Type Trays Material Cost Each .................. 210
Removable Type Trays Material Cost Each .................. 211
Demisting Pads Material Cost Each ............................. 212
Demisting Pads Material Cost Each ............................. 213
Vessels Field Erection Manhours per Ton .................... 214
Tray Installation Field Erection Manhours Each ............ 215
Demisting Pads Field Erection Manhours Each ............ 216
Section 3.
Section 4.
Section 5.
Contents
xvii
Section 6.
xviii
Contents
Section 7.
Section 8.
Section 9.
Contents
xix
xx
Contents
Painting Equipment Total Manhours ...................................... 286
Painting Structural Steel Total Material Cost .......................... 287
Painting Structural Steel Total Manhours ............................... 288
Painting Piping Total Material Cost ......................................... 289
Painting Piping Total Manhours .............................................. 290
Painting Miscellaneous and Pipe Rack Steel Total
Material Cost ........................................................................ 291
Painting Miscellaneous and Pipe Rack Steel Total
Manhours ............................................................................. 292
Contents
xxi
xxii
Contents
Section 1
DISCIPLINES OF WORK
15. ProratablesIncludes the labor and material cost for daily area clean
up, all required scaffolding and final test, startup, and pre-commissioning assistance.
Construction Equipment
1. Rental or PurchaseCost of rental or purchase of construction equipment required to construct the project. Does not include small tools.
2. Service LaborAU labor required to service and maintain the construction equipment. Does not include the operation of the equipment
when working. Operators are included in the Direct Account Labor.
3. Fuel, Oil, Grease, SuppliesIncludes the cost of all fuels, lubricants,
and supplies required to operate and maintain the construction equipment.
To Include
Engineering salariesestimating
Engineering salariesfield technical support
Watchmen and
Janitorslabor
Holiday pay
Salariesoffice clerical
Quality assurancelabor
Salariessubcontract
administration
Salariescost engineering
Salariesscheduling and
planning
Salariestechnical clerks
Material control labor
Move in/outlabor
Non-productive labor
chainmen, rodmen, and laborers temporarily assigned to a field party performing general layout work.
Security supervisor, security coordinator, 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 estimate only.
Administrative clerks, office clerks, and
secretaries.
Chief construction inspector, construction inspectors, welding inspector, piping
inspector, electrical inspector, boiler inspector and civil inspector.
Salaries for subcontract coordinators.
Salaries for cost/schedule supervisor,
chief field cost engineer and cost engineers.
Salaries for chief field scheduler and
planner/schedulers.
Salaries for technical clerical personnel.
Material control coordinators and material control personnel assigned to implement and follow-up the material control
program.
Job payroll labor for loading, unloading,
and transporting from facilities to project construction area tools and construction 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 construction 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
Salariessupervision
Sick pay
Warehouse salaries
To Include
Tb Include
Actual cost fixed by the appropriate accounting 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.
Insuranceemployees'
life and hospitalization (for
overhead and indirect
personnel only)
InsuranceW/C, B/I, and
P/D
Taxespayroll
TD Include
Construction supplies
Workmen's supplies
Other Indirects
Description
To Include
Advertising
Bond premiums
Communications and
postage
Containers
Dues
Engineering supplies
Expediting
Heat, light, water, and
power
Insurancegeneral
Legal
Licenses and permits
Office supplies
Traveling
Welding supplies
Unclassified
Data processing services
Consulting services
Section 2
PROCESS EQUIPMENT
Equipment Cost
Equipment Cost
Square Feet
Erection Manhours
Erection Manhours
Square Feet
Equipment Cost
Equipment Cost
Diameter Inches
Erection
Manhours
Erection Manhours
Diameter Inches
HIGH-SPEED MECHANICAL
AERATORS
Equipment Cost
Equipment Cost
Motor Horsepower
HIGH-SPEED MECHANICAL
AERATORS
Erection
Manhours
Erection Manhours
Motor Horsepower
LOW-SPEED MECHANICAL
SURFACE AERATORS
Equipment Cost
Equipment Cost
Motor Horsepower
Next Page
LOW-SPEED MECHANICAL
SURFACE AERATORS
Erection Manhours
Erection Manhours
Motor Horsepower
Previous Page
Equipment Cost
Equipment Cost
Motor Horsepower
Equipment Cost
Equipment Cost
Motor Horsepower
460,575, or 230-volt
480or2,300-volt
Erection
Manhours
Erection Manhours
Motor Horsepower
AUTOMOTIVE AND
INDUSTRIAL SERVICE AIR
COMPRESSORS
Equipment Cost
Equipment Cost
Motor Horsepower
AUTOMOTIVE AND
INDUSTRIAL SERVICE AIR
COMPRESSORS
Erection Manhours
Erection Manhours
Motor Horsepower
Equipment Cost
Equipment Cost
Erection Manhours
Erection Manhours
INDUSTRIAL AIR
COMPRESSORS
Air-Cooled, Two-Stage50 to
250psig
Equipment Cost
Equipment Cost
Motor Horsepower
INDUSTRIAL AIR
COMPRESSORS
Air-Cooled, Two-Stage50 to
250psig
Erection Manhours
Erection Manhours
Motor Horsepower
Equipment Cost
Equipment Cost
Rated Hp.
(BHP)
Erection Manhours
Erection Manhours
Equipment Cost
Equipment Cost
Motor Horsepower
(DOil-lubricated-208, 230, or 460-volt.
Nonlubricated-208, 230, or 460-volt.
Erection Manhours
Erection Manhours
Motor Horsepower
For 208-, 230-, or 460-volt units.
RECIPROCATING
COMPRESSORS
Electric Motor Driven
Equipment Cost
Equipment Cost
Compressor
1)
2)
3)
4)
Horsepower
RECIPROCATING
COMPRESSORS
Electric Motor Driven
1,000 to 6,000 psi Discharge
Erection Manhours
Erection Manhours
Compressor Horsepower
TWO-STAGE, TWO-CYLINDER,
WATER-COOLED AIR COMPRESSORS
Oil-Lubricated and Nonlubricated
150 to 350 psi Discharge
Pressure
Equipment Cost
Equipment Cost
Motor Horsepower
0 Oil-lubricated
Nonlubricated
TWO-STAGE, TWO-CYLINDER,
WATER-COOLED AIR COMPRESSORS
Oil-Lubricated and Nonlubricated
350 to 500 psig Discharge
Pressure
Equipment Cost
Eauimnent Cost
Motor Horsepower
(D Oil-Lubricated
(D Nonlubricated
Next Page
TWO-STAGE, TWO-CYLINDER,
WATER-COOLED AIR COMPRESSORS
Oil-Lubricated and Nonlubricated
150 to 500 psig Discharge
Pressure
Erection
Manhours
Erection Manhours
Motor Horsepower
Previous Page
Equipment Cost
Equipment Cost
Capacity
SCFM
Equipment Cost
Equipment Cost
Capacity scfm
Erection Manhours
Erection Manhours
Capacity SCFM
Erection Manhours
Erection Manhours
Capacity SCFM
Equipment Cost
Equipment Cost
Next Page
Erection Manhours
Erection Manhours
Previous Page
SURGE ARRESTORS
Hydrocarbon and Water Service
500 psi Design Operating Pressure
ASME CodeSection VIII
Division I
Equipment Cost
Equipment Cost
Hydrocarbon Service
Water Service
SURGE ARRESTORS
Hydrocarbon, Water and Sewage Service
275 psi Design Operating Pressure
ASME CodeSection VIII
Division I
Equipment Cost
Equipment Cost
Hydrocarbon service
Water service
Sewage service
SURGE ABBESTORS
Hydrocarbon, Water and Sewage Service
275 and 500 psi Design Operating Pressures
ASME CodeSection VIII
Division I
Erection Manhours
Erection Manhours
Equipment Cost
Equipment Cost
(D Auger blenders
Rotary drum blenders
Erection Manhours
Erection Manhours
Auger blenders
Rotary drum blenders
Equipment Cost
Equipment Cost
Rating
Hors epower
Erection Manhours
Erection Manhours
Rating Horsepower
Equipment Cost
Equipment Cost
Rating Horsepower
Equipment Cost
Equipment Cost
Rating Horsepower
Erection
Manhours
Erection Manhours
Rating Horsepower
Equipment
Cost
Equipment Cost
Equipment
Cost
Equipment Cost
Horsepower
Erection Manhours
Erection Manhours
Horsepower
MIXERS
High-Intensity
Equipment
Cost
Equipment Cost
MIXERS
High-Intensity
Erection
Manhours
Erection Manhours
Equipment
Cost
Equipment Cost
Erection Manhours
Erection Manhours
BOILERS
Package Type
Equipment
Cost
Equipment Cost
BOILERS
Package Type
Erection
Manhours
Erection Manhours
BOILER STACKS
1
M-InCh Plate
Equipment
Cost
Equipment Cost
(D 24-inch diameter
(3) 42 to 48-inch diameter
30-inch diameter
54 to 60-inch diameter
36-inch diameter
Note: Cost includes stack, cable, and clamps.
BOILER STACKS
/ie- and 3/s-Inch Plate
Equipment
Cost
Equipment Cost
Next Page
BOILEB STACKS
Ai-, 5/i6-, 3/8-Inch Plate
Erection Manhours
Erection Manhours
24-inch diameter
30-inch diameter
36-inch diameter
Previous Page
CLASSIFICATION EQUIPMENT
Cone Pelletizers
Equipment
Cost
Equipment Cost
CLASSIFICATION EQUIPMENT
Cone Pelletizers
Erection
Manhours
Erection Manhours
CLASSIFICATION EQUIPMENT
Turbo-Screen Cyclone and
48"-Pressure Sifter (3-Screens)
Equipment
Cost
Equipment Cost
Diameter Inches
CLASSIFICATION EQUIPMENT
Turbo-Screen Cyclone and
48"-Pressure Sifter (3-Screens)
Erection
Manhours
Erection Manhours
Diameter
Inches
CLASSIFICATION EQUIPMENT
Rotary Screens
Equipment
Cost
Equipment Cost
CLASSIFICATION EQUIPMENT
Rotary Screens
Erection
Manhours
Erection Manhours
Equipment
Cost
Equipment Cost
Erection Manhours
Erection Manhours
CONVEYING EQUIPMENT
ConveyorsOpen Belt
Equipment
Cost
Equipment Cost
Linear Feet
(D 18-inch belt
<D 36-inch belt
24-inch belt
42-inch belt
30-inch belt
Note: See structural steel account for bents.
CONVEYING EQUIPMENT
ConveyorsOpen Belt
Erection Manhours
Erection Manhours
Linear Feet
18-inch belt
36-inch belt
24-inch belt
42-inch belt
(S) 30-inch belt
Note: See structural steel account for bents.
CONVEYING EQUIPMENT
ConveyorsBelt Enclosed
with Walkway
Equipment
Cost
Equipment Cost
Linear Feet
(D 18-inch belt
36-inch belt
24-inch belt
42-inch belt
<) 30-inch belt
Note: See structural steel account for bents.
CONVEYING EQUIPMENT
ConveyorsBelt Enclosed
with Walkway
Erection Manhours
Erection Manhours
Linear
Feet
18-inch belt
(D 36-inch belt
24-inch belt
42-inch belt
(E) 30-inch belt
Note: See structural steel account for bents.
CONVEYING EQUIPMENT
ConveyorsSpaced, Bucket
Elevators, Belt-Driven
Equipment
Equipment Cost
Linear Feet
CONVEYING EQUIPMENT
ConveyorsSpaced, Bucket
Elevators, Chain-Driven
Equipment
Cost
Equipment Cost
Linear Feet
CONVEYING EQUIPMENT
ConveyorsSpaced, Bucket
Elevators,
Chain- or Belt-Driven
Erection
Manhours
Erection Manhours
Linear Feet
CONVEYING EQUIPMENT
ConveyorsContinuous, Bucket
Elevators,
Belt-Driven
Equipment
Cost
Equipment Cost
Linear Feet
0 8- x 5-inch buckets
(D 16-x 8-inch buckets
20-x 8-inch buckets
CONVEYING EQUIPMENT
ConveyorsContinuous, Bucket
Elevators,
Chain-Driven
Equipment
Cost
Equipment Cost
Linear Feet
CONVEYING EQUIPMENT
ConveyorsContinuous, Bucket
Elevator,
Chain- or Belt-Driven
Erection
Manhours
Erection Manhours
Linear Feet
SCREW CONVEYORS
Equipment Cost
Screw Diameter:
(D 6-inch
9-inch
(E) 12-inch
014-inch
16-inch
18-inch
CD 20-inch
24-inch
SCREW CONVEYORS
Erection Manhours
Erection Manhours
DRYERSDRUM
Atmospheric Single Drum Type
Equipment
Cost
Equipment Cost
DRYERSDRUM
Atmospheric Double and Twin
Drum Types
Equipment Cost
Equipment Cost
Next Page
DRYERSDRUM
Atmospheric Single, Double, and
Twin Drum Types
Erection Manhours
Erection Manhours
Previous Page
DRYERSVACUUM
Conical Rotating Type
Equipment Cost
Equipment Cost
DRYERSVACUUM
Double Drum and Rotary Types
Equipment
Cost
Equipment Cost
0 Double drum
Rotarystainless steel
(H) Rotarycarbon steel
DRYERSVACUUM
Conical Rotating and Double
Drum Types
Erection Manhours
Erection Manhours
DRYERSVACUUM
Rotary Types Carbon Steel and
Stainless Steel
Erection Manhours
Erection Manhours
DUST COLLECTORS
CENTRIFUGAL SCRUBBERS
High Capacity, Low Energy
Loss Type
Hot-Rolled Steel Construction
Equipment Cost
Equipment Cost
(D 12-gauge
%6-inch plate
(2) 10-gauge
V4-inch plate
Note: Cfin capacity at 2.0-inch pressure drop will equal
approximately 67% of above cftn.
DUST COLLECTORS
CENTRIFUGAL SCRUBBERS
Medium Capacity, Medium
Energy Loss
Hot-Rolled Steel
Equipment Cost
Equipment Cost
DUST COLLECTORS
CENTRIFUGAL SCRUBBERS
High Capacity, Low Energy
Loss Type
T304-2B Stainless Steel Construction
Equipment Cost
Equipment Cost
12-gauge
^16-inch plate
10-gauge
V4-inch plate
Note: Cfm capacity at 2.0-inch pressure drop will equal
approximately 67% of above cfm.
DUST COLLECTORS
CENTRIFUGAL SCRUBBERS
Medium Capacity, Medium
Energy Loss Type
T304-2B Stainless Steel Construction
Equipment Cost
Equipment Cost
12-gauge
%6-inch plate
(2) 10-gauge
(D V4-inch plate
Note: Cfrn capacity at 2.0-inch pressure drop will equal
approximately 71% of above cfm.
DUST COLLECTORS
CENTRIFUGAL SCRUBBERS
High- and Medium-Capacity Units
Hot-Rolled Steel and T304-2B
Stainless Steel
Erection Manhours
Erection Manhours
DUST COLLECTORS
Hot-Rolled SteelCyclones
Equipment Cost
Equipment Cost
(D 16-gauge
(g) 12-gauge
%6-inch plate
(2) 14-gauge
0 10-gauge
Note: Cfin capacity at 2.5-inch pressure drop will equal
approximately two-thirds of above cfin.
DUST COLLECTORS
304 Stainless Steel Cyclones
Equipment Cost
Equipment Cost
16-gauge
12-gauge
%6-inch plate
14-gauge
(D 10-gauge
Note: Cftn capacity at 2.5-inch pressure drop will equal
approximately two-thirds of above cfin.
DUST COLLECTORS
Hot-Rolled Steel and 304
Stainless Steel Cyclones
Erection Manhours
Erection Manhours
DUST COLLECTORS
Filter Cartridge or Tube House
Filters
Equipment
C os t
Equipment Cost
(D Filter cartridge
Fabric filtertube house
DUST COLLECTORS
Filter Cartridge or Tube House
Filters
Erection
Manhours
Erection Manhours
Filter cartridge
Fabric filtertube house
DUST COLLECTORS
Packaged Motor Operated
Blowers for Filter Cartridge
and Tube House Dust Collectors
Equipment
Cost
Equipment Cost
Motor Horsepower
DUST COLLECTORS
Packaged Motor Operated
Blowers for Filter Cartridge
and Tube House Dust Collectors
Erection
Manhours
Erection Manhours
Motor Horsepower
Equiproe nt
Cost
Equipment Cost
InletCFM
Erection
Manhours
Erection Manhours
InletCFM
Equipment Cost
Equipment Cost
Erection Manhours
Erection Manhours
Equipment
Cost
Equipment Cost
Maximum Volume-CFM
Erection
Manhours
Erection Manhours
Maximum Volume-CFM
Equipment Cost
Equipment Cost
Next Page
Erection Manhours
Erection Manhours
Maximum Volume-CFM
Previous Page
Equipment
Cost
Equipment Cost
Erection
Manhours
Erection Manhours
Equipment Cost
Equipment Cost
Erection
Manhours
Erection Manhours
Equipment
Cost
Equipment Cost
Tank Gallons
(D Single-tank system
Two-tank system
Erection
Manhours
Erection Manhours
Tank Gallons
Single-tank system
Two-tank system
Equipment Cost
Equipment Cost
Erection Manhours
Erection Manhours
Equipment
Cost
Equipment Cost
Erection
Manhours
Erection Manhours
(D Volumetric feeders
Gravimetric feeders
Equipment
Cost
Equipment Cost
Erection Manhours
Erection Manhours
Material
Cost
Unit Diameter-Feet
Ins tallation
Manhours
Unit Diameter-Feet
FILTERS
Pressure Type
Equipment
Cost
Equipment Cost
Diameter Feet
FILTERS
Pressure Type
Erection
Manhours
Erection Manhours
Diameter
Feet
FILTERS
Rubber-Lined
Equipment
Cost
Equipment Cost
Flow Rate G. P . M.
FILTERS
Rubber-Lined
Erection Manhours
Erection Manhours
Flow Rate G. P, M.
FILTER EQUIPMENT
Vibrating Screens
Equipment
Cost
Equipment Cost
One-deck screen
Two-deck screen
Three-deck screen
Note: Costs of all two-and three-deck screens are based
on square feet of single deck area.
FILTER EQUIPMENT
Vibrating Screens
* vjivii l-
1'iaiuiv
Q
HlIlI H JlIlIf iluilllHII44414444-4UuUIII
Erection Manhours
(D One-deck screen
Two-deck screen
Three-deck screen
Note: Manhours for two- and three-deck screens are
based on square feet of single deck area.
FLAKERS
Cooling Drum Type
Equipment Cost
Equipment Cost
FLAKEBS
Cooling Drum Type
Erection
Manhours
Erection Manhours
Equipment
Cost
Equipment Cost
Indoor construction
Outdoor construction
Explosion-proof construction
Note: Add 3% to above for two-point control. Add 5%
to above for automatic output control.
Erection
Manhours
Erection Manhours
OD Indoor construction
Outdoor construction
Explosion-proof construction
Note: Add 1% to above for two-point control. Add
1.5% to above for automatic output control.
Equipment
Cost
Equipment Cost
Next Page
Erection Manhours
Erection Manhours
Previous Page
HEATERS
Deaerating Feedwater Type
Equipment
Cost
Equipment Cost
HEATERS
Deaerating Feedwater Type
Erection Manhours
Erection Manhours
HEATERS
Gas-, Oil, and Dual-Fired Heaters
Equipment Cost
Equipment Cost
HEATERS
Gas-, Oil-, and Dual-Fired Types
Erection Manhours
Erection Manhours
HAIRPIN TYPE
HEAT EXCHANGERS
Equipment
Cost
Equipment Cost
HAIRPIN TYPE
HEAT EXCHANGERS
Erection
Manhours
Erection Manhours
HEAT EXCHANGERS
Shell and Tube, Fixed Tube Sheet,
and U-Tube
Equipment Cost
Equipment Cost
HEAT EXCHANGERS
Shell and Tube, Fixed Tube Sheet,
and U-Tube
Erection Manhours
Erection Manhours
Equipment Cost
Equipment Cost
Equipment Cost
Equipment Cost
Next Page
HEATING WATER
Erection Manhours
Erection Manhours
Previous Page
CENTRIFUGAL PUMPS
Single-Stage, Vertical Split Case
Equipment Cost
Equipment Cost
CENTRIFUGAL PUMPS
Single-Stage, Horizontal Split
Case
Equipment
Cost
Equipment Cost
CENTRIFUGAL PUMPS
Single-Stage ANSI and API 610
Equipment Cost
Equipment Cost
CENTRIFUGAL PUMPS
Two-Stage and Multi-Stage
Horizontal Split Case
Equipment Cost
Equipment Cost
CENTRIFUGAL PUMPS
Single-Stage, In-Line
Ductile Iron and Steel Cased
API-610 Standard
Equipment Cost
Equipment Cost
Motor Horsepower
Ductile iron3,550 rpmspecific gravity of 1.0
Steel Cased, API-610 Standard-3,550 r p m specific gravity of 1.0
GEAR PUMPS
Light and Heavy Duty
Equipment
Cost
Equipment Cost
Motor Horsepower
Light duty
Heavy duty
SEWAGE PUMPS
Horizontal and Vertical
1,750 rpm
Equipment
Cost
Equipment Cost
Motor Horsepower
(D Horizontall%inch solids
<2> Horizontal2-inch solids
Verticall%inch solids
(D Vertical 2-inchsolids
Vertical 3-inchsolids
SEWAGE PUMPS
Horizontal1,750 rpm
Equipment
Cost
Equipment Cost
Motor Horsepower
(D Horizontal2%ineh solids
Horizontal3-inch solids
SEWAGE PUMPS
Horizontal and Vertical
1,150 rpm
Equipment Cost
Equipment Cost
Motor Horsepower
Horizontall%ineh solids
Horizontal2-inch solids
(S) Horizontal2%inch solids
(D Horizontal3-inch solids
Vertical2-inch solids
() Vertical3-inch solids
Equipment Cost
Equipment Cost
Motor Horsepower
Equipment Cost
Equipment Cost
Motor Horsepower
(D 3,550 rpmspecific gravity of 1.0
1,750 rpmspecific gravity of 1.0
(2) 1,170 rpmspecific gravity of 1.0
CENTRIFUGAL PUMPS
Single-, Two-, Multi- and In-Line
Single Stage
Erection
Manhours
Erection Manhours
GEARPUMPS
Light and Heavy Duty
Erection Manhours
Erection Manhours
Motor Horsepower
Light duty
Heavy duty
SEWAGE FUMPS
Horizontal and Vertical
Erection
Manhours
Erection Manhours
Motor Horsepower
(D Horizontal
Vertical
Erection Manhours
Erection Manhours
Motor Horsepower
(D Sump pumps
Plunger pumps
Next Page
Erection
Manhours
Erection Manhours
Motor Horsepower
Previous Page
REACTOBS
Glass Lined, Agitated, Jacketed
25 and 100 psi
Equipment
Cost
Equipment Cost
Capacity-Gallons
REACTORS
Glass-Lined, Agitated, Jacketed
25 and 100 psi
Erection
Manhours
Erection Manhours
Capacity-Gallons
Equipment
Cost
Equipment Cost
Erection
Manhours
Erection Manhours
GAS SCRUBBERS
High-Energy Venturi Type
Equipment Cost
Equipment Cost
GAS SCRUBBERS
High-Energy Venturi Type
Erection Manhours
Erection Manhours
SEPARATORS
Vane Type
Equipment
Cost
Equipment Cost
(D 275-pound rating
<2) 720-pound rating
SEPARATORS
Vane Type
Equipment
Cost
Equipment Cost
SEPARATORS
Vane TyP 6
Erection
Manhours
Erection Manhours
VIBRATING SEPARATORS
Equipment
Cost
Equipment Cost
0 Carbon steel
Stainless steel
VIBRATING SEPABATORS
Carbon or Stainless Steel
Erection
Manhours
Erection Manhours
Equipment
Cost
Next Page
Erection
Manhours
Erection Manhours
Previous Page
Equipment Cost
Equipment Cost
Horsepower
Gyratory
Jaw
Erection Manhours
Erection Manhours
Horsepower
(D Gyratory
Jaw
Equipment
Cost
Equipment Cost
Horsepower
(D Dual rotary
Single rotary
(E) Twin rotary
Erection
Manhours
Erection Manhours
Horsepower
Dual rotary
Single rotary
Twin rotary
Equipment
Cost
Equipment Cost
Horsepower
Reversible
Non-reversible
Erection
Manhours
Erection Manhours
Horsepower
Equipment Cost
Equipment cost
Horsepower
Erection
Manhours
Erection Manhours
Horsepower
HOT PROCESS
WATER SOFTENER SYSTEM
Softener Diameter-Feet
Total System
Installation Manhours
Softener Diameter-Feet
Subcontractor
Installed Price
Capacity-Barrels
Subcontractor
Installed Price
Capacity-Barrels
Capacity-Barrels
STORAGE TANKS
ASME SPHERES
Capacity-Gallons
Equipment
Cost
Equipment Cost
Erection
Manhours
Erection Manhours
Equipment
Cost
Equipment Cost
Gas-fired
Oil-fired
Erection
Manhours
Erection Manhours
Gas- or oil-fired.
Equipment Cost
Equipment Cost
Erection Manhours
Erection Manhours
Equipment
Cost
Equipment Cost
S h e l l Length-Feet
Next Page
Erection
Manhours
Erection Manhours
Shell Length-Feet
Previous Page
Vessel Diameter-Inches
0 Horizontal vessels
(2) Vertical vessels with legs
Vertical vessels with skirt plates
SHOP FABRICATED
HORIZONTAL VESSELS
24-Inch Through 144-Inch
Diameter
Ton
SpotX-Rayed
(2)100%X-Rayed
Note: If drip legs are required, weigh drip legs and
use $2.40 per pound for spot x-rayed and $2.50
per pound for 100 percent x-rayed.
Baffels, draw-off boxes and vortex breakers
estimate weight and price at 20 percent of the
vessel per-ton cost.
(DSpotX-Rayed
100%X-Rayed
Note: For conical transmission pieces use three linear feet of the larger vessel diameter weight at
35% of the cost per ton of that diameter vessel.
See other graphs for tray rings, trays, and
demisting pads if required.
(DSpotX-Rayed
100%X-Rayed
Note: For conical transmission pieces use three linear feet of the larger vessel diameter weight at
35% of the cost per ton of that diameter vessel.
See other graphs for tray rings, trays, and
demisting pads if required.
Cost Each
COLUMN TOAYS
Shop Installation Only
36-Inch Through 144-Inch
Diameter
DEMISTING PADS
Shop Installation
36-Inch Through 144-Inch Vessel
Diameter
Material
Cost Each
Material
Cost Each
DEMISTING FADS
Four-Inch Thickness
Vessel Diameter-Inches
(D Carbon steel
(2) 410, 304, or 316 stainless steel
Monel
DEMISTING PADS
Pour-Inch Thickness
Top or Bottom Grids only
0 Carbon Steel
(D 410 or 304 Stainless Steel
316 Stainless Steel
(D Monel
VESSELS
24-Inch Through 144-Inch
Diameter
Vessel Weight-Tons
Horizontal vessels
Vertical vessels
Add for following if required:
Remove and replace manway cover1.3 manhours per tray.
Check tray and tighten retaining bolts1.8 man- hours per tray.
Vessel Diameter-Inches
DEMISTING PADS
36-Inch Through 144-Inch Vessel
Diameter
Vessel Diameter-Inches
Section 3
SITE PREPARATION
On Site
Disposal
Off Site
Disposal
Light
Medium
Medium Heavy
Heavy
30.0
40.0
50.0
60.0
40.0
50.0
60.0
70.0
Land
Average C.Y./AC.
Average M.H./AC.
Description
Cut
Fill
Cut
Fill
Level
Slightly Rolling
Rolling
Rough
Very Rough
1,080
1,613
2,420
2,952
3,870
532
1,080
1,613
1,888
2,420
40.0
60.0
85.0
105.0
135.0
5.0
10.0
15.0
17.0
22.0
Purchase
Fill/AC.
$
9,400
18,900
28,200
33,100
42,400
Section 4
SITE IMPROVEMENTS
This section includes items of work that provide permanent improvements to the plant site, such as security fencing, railroads or spurs including ballast, tank dikes and all sub-base materials for roads, parking areas,
paved areas and railroads, concrete trenches, drainage piping, catch basins, manholes and road culverts.
Pavements for roads, parking areas and process areas are included under "Discipline, Paving "
Site improvements will vary depending on site location, conditions, and
project requirements. For these reasons I have listed unit costs for various items that may be required.
The scope of work or plot plan will dictate the items required for site
improvements.
I caution the engineer/estimator to be thoroughly familiar with the introduction of this manual before applying this information.
Security Fencing
Fencing is usually listed as a subcontract price in the estimate and as
such includes his overhead and profit.
A six-foot-high chain link fence with three strands of barbwire, line and
corner post embedded in concrete, top rail and traffic and personnel gates
will cost an average of $15.50 per linear foot. Included in this price is installation labor at an average of 0.35 manhours per linear foot.
Tank Dikes
Earth type dikes include the furnishing, placing, and compaction of all
earth materials. Concrete type dikes include all operations for the forming and placing of concrete.
1. Earth type dikes material will average 1.60 cubic yards per linear
foot of dike at the average cost of:
Material$22.00 per cubic yard
Labor0.60 manhours per cubic yard
2. Concrete type dikes material will average 1.4 cubic yards of concrete
per linear foot of dike at the average cost of:
Material$180.00 per cubic yard
Labor10.00 manhours per cubic yard
Concrete Trenches
Concrete trenches two feet wide by two feet deep, with standard sumps
and basins and grated cover including all earthwork, concrete and related
items will average:
Material$35.00 per linear foot
Labor2.50 manhours per linear foot
Drainage
Drainage items such as raw water, oily water, and pressurized systems
will vary depending on pipe size, elevations, etc. The following represents
an average cost of all items involved:
Material$30.00 per linear foot
Labor3.00 manhours per linear foot
Road Culverts
Road culverts will vary in size depending on volume requirements. The
following costs are based on using 24-inch reinforced concrete pipe which
seems to be predominant for this item:
Material$18.00 per linear foot
Labor0.60 manhours per linear foot
Section 5
CONCRETE
Logarithmic graphs in this section indicate the value of labor in manhours and materials in dollars of earthwork, concrete, fireproofing and
grout for equipment foundations and equipment structure foundations.
Earthwork and concrete for buildings are included with the buildings
and are not to be considered here.
The earth and concrete graphs are average and are based on the total
equipment count, even though some pieces of equipment may not require
foundations.
Earthwork graphs include labor in manhours for all hand and machine
excavation and backfill. There is also a graph showing average quantities
of required backfill in the event special fill material is required. Should
special fill material be required it should be priced at the current material
value for that particular type of fill.
Concrete graphs include the furnishing, fabricating, and placing of
forms, reinforcing steel; miscellaneous embedments; concrete and curing;
protecting and finishing concrete. There is also a graph showing estimated cubic yards of concrete for cost control and reporting purpose.
Piling as such has been excluded. The graphs represent the use of
spread type footings and reflect enough manhour and material values to
include 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 labor
manhours and material value based on total equipment count for equipment support and total tons of steel for base plates.
I caution the engineer/estimator to be thoroughly familiar with the introduction to this manual before applying this information.
CONCRETE FOUNDATIONS
Earth Backfill Materials
Cubic Yards
Pieces Of Equipment
Equipment foundations
Equipment structure foundations
Pipe rack or sleeper foundations
CONCRETE FOUNDATIONS
Excavation and Backfill
for Equipment Foundations
Labor Manhours
Labor Manhours
Pieces Of Equipment
(D Hand excavation
Machine excavation
(H) Hand backfill
Machine backfill
CONCRETE FOUNDATIONS
For Equipment Structures
and Pipe Rack and Sleepers
Labor Manhours
Labor Manhours
Pieces Of Equipment
Equipment Structures
(D Hand Excavation
Machine Excavation
Hand Backfill
(D Machine Backfill
CONCRETE FOUNDATIONS
Concrete Quantities
Cubic Yards
Pieces Of Equipment
(D Equipment foundations
Equipment structure foundations
Pipe rack and sleeper foundations
CONCRETE FOUNDATIONS
Forms, Reinforcing, Embedments,
Concrete
Material Cost
Pieces Of Equipment
0 Equipment foundations
(D Equipment structure foundations
Pipe rack and sleeper foundations
CONCRETE FOUNDATIONS
Forms, Reinforcing, Embedments,
Concrete
Installation Manhours
Installation Manhours
Pieces Of Equipment
Equipment foundations
Equipment structure foundations
Pipe rack and sleeper foundations
CONCRETE FOUNDATIONS
NonshrinkNonmetallic Grout
Square
Feet
CONCRETE FOUNDATIONS
NonshrinkNonmetallic Grout
Material Cost
Material Cost
Equipment
Steel
CONCRETE FOUNDATIONS
NonshrinkNonmetallic Grout
Installation Manhours
Installation Manhours
CONCRETE FOUNDATIONS
Fireproofing Structural Steel
Tons Of S t e e l
CONCRETE FOUNDATIONS
Fireproofing Structural Steel
Installation Manhours
Installation Manhours
Tons Of S t e e l
CONCRETE FOUNDATIONS
Fireproofing Vessel Skirts
Material Cost
CONCRETE FOUNDATIONS
Fireproofing Vessel Skirts
Erection
Manhours
Erection Manhours
Section 6
STRUCTURAL STEEL AND
MISCELLANEOUS IRON
The curves in this section represent the material cost in dollars and the
erection manhours required for equipment supports, equipment structures and piperacks, and miscellaneous steel and iron for equipment platforms, walkways, and ladders.
All steel items are based on the total pieces of equipment even though
some 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 introduction to this manual before applying this information.
STRUCTURAL STEEL
Tons Required
Tons Required
Pieces Of Equipment
MISCELLANEOUS IRON
Tons Required
Tons Required
Pieces Of Equipment
Tons Required
Tons Required
Pieces Of Equipment
STRUCTURAL STEEL
Equipment Supports and
Structures
Material Cost
Material Cost
Pieces Of Equipment
Material Cost
Material Cost
Pieces Of Equipment
Miscellaneous iron
Pipe racks
Erection Manhours
Erection Manhours
Pieces Of Equipment
Structural steel
Miscellaneous iron
Pipe racks
Section 7
BUILDINGS
Laboratory Building:
Same type construction as office building with additional plumbing and
electrical outlets for laboratory equipment.
Note: No laboratory equipment or furniture is included.
Control Building
StructureStructural steel framing.
Exterior WallsConcrete block, hollow metal frames and doors and steel
sash.
Interior WallsOffice and toilet with metal studs and drywall, hollow
metal frames and doors.
RoofPre-cast concrete slabs with insulation and built up roof.
CeilingsExposed.
PlumbingToilet utilities and drinking fountain.
HVACAmple for size of structure.
ElectricalLighting and power.
Note: No instrumentation included.
Warehouse Building:
StructureStructural steel framing.
Exterior WallsCorrugated asbestos or insulated metal siding with hollow metal doors and frames, truck doors and steel sash.
Interior WallsOffice and toilet room partitions of metal studs and drywall with hollow metal doors and frames, storage shelving and bins included.
RoofSame as exterior wall siding.
CeilingsExposed except office and toilet area with same type construction as interior partitions.
PlumbingToilet utilities and drinking fountains.
HVAC-Office area only.
ElectricalPower and lighting.
BUILDING MATERIALS
(D Office building
(D Laboratory building
(E) Control building
Warehouse building
Maintenance shop building
Change house building
BUILDING ERECTION
(D Office building
Laboratory building
Control building
(D Warehouse building
Maintenance shop building
Change house building
Section 8
PIPING
In the absence of plot plans, piping and instrument diagrams, and flow
sheets the cost of process piping can be determined from the following
logarithmic 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 material cost is included in the instrumentation section.
Labor manhour graphs are average and include all necessary installation operations. Installation of control valves furnished under the instrumentation section is included here.
The offsite fabrication graphs include all labor, material, and shop costs
for furnishing and fabricating pipe spools and delivery within reasonable
distance of job site.
Graphs for underground potable water, fire loops, etc., include all material and labor operations to five feet outside of buildings.
The field x-ray and stress relief graphs are to be considered as subcontract work.
Building piping for plumbing, etc., to five feet outside the building, is
included under the building section and is not to be considered here.
I caution the engineer/estimator to be thoroughly familiar with the introduction to this manual before applying this information.
Pieces Of Equipment
Pieces Of Equipment
Pieces Of Equipment
Alloy 2 ^ " and over
Carbon steel 2te" and over
Alloy 2" and under
Pieces Of Equipment
1
Material Cast
Pieces Of Equipment
Pieces Of Equipment
Pieces Of Equipment
Material Cost
Pieces Of Equipment
Erection Manhours
Pieces Of Equipment
Erection Manhours
Pieces Of Equipment
Erection Manhours
Pieces Of Equipment
Material Cost
Pieces Of Equipment
Total Manhours
Pieces Of Equipment
Pieces Of Equipment
Section 9
ELECTRICAL
ELECTRICAL POWER
Pieces Of Equipment
ELECTRICAL POWER
Installation Manhours
Installation Manhours
Pieces Of Equipment
ELECTRICAL LIGHTING
Pieces Of Equipment
ELECTRICAL LIGHTING
Installation Manhours
Installation Manhours
Pieces Of Equipment
ELECTRICAL
INSTRUMENTATION
Miscellaneous Electrical Instrument Material Cost
Pieces Of Equipment
ELECTRICAL
INSTRUMENTATION
Installation Manhours
Pieces Of Equipment
Section 10
INSTRUMENTATION
The following graphs represent the average number of instruments required, their material value in dollars and installation in manhours based
on total pieces of equipment.
Included with the instrument graphs are dollars and manhours for the
furnishing 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 installation of these valves is discussed in Section 8, "Piping."
Furnishing and installation of miscellaneous electrical hook-up materials is discussed in Section 9, "Electrical".
I caution the engineer/estimator to be thoroughly familiar with the introduction to this manual before applying this information.
INSTRUMENTS
Number Of Instruments
Pieces Of Equipment
INSTRUMENTS
Cost Of Instruments
Pieces Of Equipment
INSTRUMENTS
Installation Manhours
Pieces Of Equipment
CONTROL VALVES
Pieces Of Equipment
Pieces Of Equipment
Installation Manhours
Pieces Of Equipment
Section 11
INSULATION
The following piping and equipment insulation graphs are based on total pieces of equipment for a project and are average for various types
and thickness that are more or less standard for refinery and petrochemical 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 introduction to this manual before applying this information.
INSULATING MATERIAL
Pieces Of Equipment
Pipe
Equipment
INSULATING MATERIAL
FOR EQUIPMENT
Pieces Of Equipment
INSULATING MATERIAL
FOR PIPING
Pieces Of Equipment
Installation Manhours
Total Manhours
Pieces Of Equipment
Pipe
Equipment
Section 12
PAINTING
PAINTINGEQUIPMENT
Pieces Of Equipment
PAINTINGSTRUCTURAL
STEEL AND PIPING
Pieces Of Equipment
(D Structural steel
Piping
PAINTINGMISCELLANEOUS
AND PIPE RACK STEEL
Pieces Of Equipment
0 Miscellaneous iron
Pipe rack steel
PAINTINGEQUIPMENT
Pieces Of Equipment
PAINTINGEQUIPMENT
Painting Manhours
Total Manhours
Pieces Of Equipment
PAINTINGSTRUCTURAL
STEEL
Pieces Of Equipment
PAINTINGSTRUCTURAL
STEEL
Painting Manhours
Total Manhours
Pieces Of Equipment
PAINTINGPIPING
Pieces Of Equipment
PAINTINGPIPING
Painting Manhours
Total Manhours
Pieces Of Equipment
PAINTINGMISCELLANEOUS
AND PIPE RACK STEEL
Pieces Of Equipment
Miscellaneous iron
Pipe rack steel
PAINTINGMISCELLANEOUS
AND PIPE RACK STEEL
Painting Manhours
Total Manhours
Pieces Of Equipment
Miscellaneous iron
Pipe rack steel
Section 13
PAVING
This section includes items of work for the installation of road, parking
area and yard pavements.
The placement of sub-base materials for these items is described in Section 4, "Site improvement." The furnishing and placing of finish base and
asphalt, concrete or gravel pavement is included.
The scope of work or other proposal documents should indicate the
pavement requirements. In the absence of this information, the following
allowances can be added based on the total equipment count.
1. Asphalt Pavement40.0 square yards per piece of equipment.
2. Concrete Pavement4.5 square yards per piece of equipment.
I caution the engineer/estimator to be thoroughly familiar with the introduction to this manual before applying this information.
ASPHALT PAVEMENT
6-Inch Base2 Inches Asphalt
Square Yards
Square Yards
Total Manhours
Total Manhours
Square Yards
Section 14
PRORATABLES
PRORATABLE MATERIAL
Pieces Of Equipment
PRORATABLE LABOR
Total
Manhours
Total Manhours
Pieces Of Equipment
Section 15
CONSTRUCTION EQUIPMENT
Total
Cost
CONSTRUCTION EQUIPMENT
BASE RENTAL OR PURCHASE COST
FUEL, OIL, GREASE, AND
SUPPLIES COST
CONSTRUCTION EQUIPMENT
SERVICE LABOR
Total Manhours
Total Manhours
Section 16
OVERHEADS AND INDIRECTS
INDIRECT LABOR
Engineering and Supervision
Personnel
Total Manhours
Total Manhours
INDIRECT LABOR
Office Personnel
Total Manhours
Total Manhours
Total Manhours
Total Manhours
Total Cost
Total Cost
Total
Cost
Total Cost
Section 17
HOME OFFICE COST
Total engineering design, including construction services such as estimating, scheduling, expediting, etc., project general management, design
allowance, and fee are included as a part of home office cost and as such
are considered under this section.
Manhour range tables listing manhour ranges for single and duplicate
pieces of equipment are included to establish the total home office manhours required.
After total manhours are established they are to be spread, on a percentage basis, to the various personnel disciplines, as outlined in the following manhour spread percentage table.
Simply by multiplying the established discipline manhours by your established discipline rates a total labor manhour and dollar cost is obtained.
Other cost such as blueprints, reproductions, computer use, miscellaneous expenses, travel expenses, telephone, telex, postage, and burdens
and benefits are to be established as a percent of the total labor dollars in
accordance with the following percentage spread table for these items.
After the total labor and material dollars are established, the estimator
need only apply a cost for design allowance and fee for a complete home
office engineering design cost.
See Section 19, "Definition of Estimate Adjustments," for design allowance and fee definitions.
I caution the engineer/estimator to be thoroughly familiar with the introduction to this manual before applying this information.
ENGINEERING DESIGN
Manhour Range Allowance
Per Piece of Equipment
Equipment Classification
Boilers And Heaters
Packaged Steam Boilers
Packaged Electric Hydronic Boilers
Cast Iron Gas Fired Boilers
Steel Boiler Stacks
Fired Heaters
Deaerating Heaters
Classification Equipment
Cone Type Pelletizers
Pressure Sifters
Rotary Screens
Turbo-Screen Classifiers
Compressors And Air Dryers
Reciprocating Gas Engine Compressors
Reciprocating Electric Compressors
Centrifugal Package Unit Compressors
Air Cooled Service Compressors
Air DryerRefrigerated Type
Air DryerChiller Type
Conveyors And Bucket Elevators
ConveyorOpen Belt
ConveyorBelt Enclosed With Walkway
ConveyorSteel Screw
ConveyorReciprocating
ConveyorScroll
ConveyorSpaced Bucket Elevator
ConveyorContinuous Bucket Elevator
Crystallizers
Batch Vacuum
Mechanical
Dow Therm Units
400-500
400-500
350-450
200-250
300-400
300-400
400-600
450-650
400-600
500-700
200-400
225-325
200-400
250-350
1,000-1,200
1,000-1,200
850-1,000
600-800
650-850
650-850
600-700
600-700
425-500
300-400
325-425
325-425
800-1,000
1,000-1,200
850-1,000
800-1,000
800-1,000
800-1,000
800-1,000
400-500
500-600
400-500
400-500
400-500
400-500
400-500
650-850
700-900
750-850
325-425
350-450
300-400
ENGINEERING DESIGN
Manhour Range Allowance
Per Piece of Equipment
Equipment Classification
Dry Material Blenders And Feeders
Blenders
Vibrating Packers
Electric Vibrating Feeders
Gravimetric Feeders
Volumetric Feeders
Wing-Type Feeders
Conveyor Type Feeders
Sanitary Type Feeders
Dry Polymer Feeders
Dryers And Flakers
Atmospheric Drum Dryer
Vacuum Drum Dryer
Twin Drum Dryer
Tray Atmospheric Dryer
Tray Vacuum Dryer
Rotary Dryer
Spray Dryer
Cooling Drum Flakers
Dust Collectors
Cyclone
Multi Cyclones
Washers
Automatic Cloth Filters
Centrifugal Precipitators
Electrical Precipitators
Feeder Valves
Ejectors
Single-Stage Noncondensing
Two-Stage Barometric Intercondenser
Extractors
Continuous Centrifugal
20-40
20-40
20-40
20-40
20-40
20-40
30-70
30-70
30-50
700-900
700-900
800-1,000
800-1,000
800-1,000
800-900
800-900
700-900
350-450
350-400
400-500
400-500
400-500
400-450
400-450
350-450
700-900
800-1,000
800-1,000
800-1,000
1,000-1,200
1,000-1,200
300-400
350-450
400-500
400-500
400-500
500-600
500-600
150-200
200-400
200-400
100-200
100-200
200-500
100-200
ENGINEERING DESIGN
Manhour Range Allowance
Per Piece of Equipment
Equipment Classification
Fans And Blowers
Heavy Gauge Centrifugal Fans
Motors And V-BeIt Drive For Fans
Rotary Blowers
Centrifugal Turbo Blowers
Filters
Pressure Type
Oil Mist Collectors
Plate And Frame Type
Sparkler
Leaf
Sewage And Rotary
Screen Vibrating
Flotation Machines
Gas Holders
Generators
Steam Turbine Units
Inert Gas Generators
Skid MountedDiesel Engine Driven
Heat Exchangers, Evaporators And Condensers
Shell And Tube, Floating Head Exchangers
Shell And Tube, Fixed-Tube Sheet, U-Tube
Exchangers
Steel Fin Tubes, Steel ReBoilers And
Jacketed Pipe
Long Tube Vertical Evaporators
Horizontal Tube Evaporators
Jacketed, Glass Lined Steel Vessel Evaporators
CondensersBarometric
300-400
50-60
200-300
300-400
200-300
200-300
200-400
200-300
200-300
300-400
400-600
400-600
150-200
100-150
100-150
100-200
100-150
100-150
150-200
200-300
200-250
50-70
5,000-8,000
2,000-4,000
1,000-2,000
2,000-3,500
800-1,500
300-500
600-800
300-400
600-800
300-400
600-800
800-900
800-1,000
850-1,050
650-850
300-400
400-450
400-500
425-525
325-425
ENGINEERING DESIGN
Manhour Range Allowance
Per Piece of Equipment
Equipment Classification
Mixers And Blenders For Liquid And Liquid Solids
Propeller Mixers
Blender Type Mixers
Pan And Sigma Mixers
Homogenizers
High Intensity Mixers
Pumps
Centrifugal
Vertical Turbine And Sump
Power And Internal Gear Rotary
Vacuum
Sewage Nonclog
Scales And Weighing Equipment
Mechanical Lever Truck Scales
Electronic Load Cell Truck Scales
Built In Industrial Scales
Automatic Bagging Scales
Bulk Weighing Scales
Separators
Centrifugal Batch Top Suspended
Centrifugal Batch Bottom Driven
Centrifugal Batch Automatic
Centrifugal High Speed
Size Reduction Equipment
Size Reduction Crushers
Size Reduction Mills, Cutters, Pulverizers
Ball Mills
Thickeners
Continuous Type
50-150
50-150
50-150
60-150
60-150
20-60
20-60
20-60
25-60
25-60
700-900
850-1,100
700-900
400-600
700-900
350-450
425-550
350-450
200-300
350-450
1,000-1,200
1,000-1,200
200-300
200-300
300-400
500-600
500-600
100-150
100-150
150-200
600-800
600-800
700-900
700-900
300-400
300-400
350-450
350-450
400-600
400-600
500-700
200-300
200-300
250-350
400-600
200-300
ENGINEERING DESIGN
Manhour Range Allowance
Per Piece of Equipment
Equipment Classification
Vessels, Reactors And Tanks
Horizontal Pressure Vessels
Vertical Pressure Vessels (Towers)
Agitated, Jacketed Reactors
Vacuum Receiver Tanks
Agitated Tanks
Storage Tanks
Waste Treatment Equipment
Sewage Treatment Plant Package
IncineratorsLiquid Waste
IncineratorsSolid Waste
Solid Waste Shredders
Wastewater Treatment Package System
Water Treating Equipment
Mechanical Surface Aerators
Ion Exchanger Demineralizers
Water Stills
400-500
500-600
500-600
400-500
350-450
300-500
600-800
500-800
500-800
400-600
600-800
300-400
250-400
250-400
200-300
300-400
850-1,000
600-800
200-300
425-500
300-400
100-200
ENGINEERING DESIGN
Other Cost as a Percent of
Total Engineering Design Labor Dollars
Item
Blue Prints And Reproduction
Computer Use
Miscellaneous Expense
Travel Expense
Telephone, Telex And Postage
Burdens And Benefits
Total
Percent
14.0
12.0
10.0
3.0
4.0
32.0
75.0
ENGINEERING DESIGN
Manhour Spread Percentages
Per Cent
Discipline
Operations Management
Project Management
Project Engineer
Design Supervisor
Civil/Structural
Vessels
Electrical
Plant Design
Piping
Administration
P & Fs Flow Diagrams
Mechanical Supervision
Instrument Engineering
Instrument Drafting
Rotating Equipment
Special Equipment
Heat Transfer
Process
Estimating
Cost Engineering
Computer
Initial Operations
Technical Information
Scheduling
Purchasing
Inspection/Expediting
Stenographic
Accounting
Office Services
Contract Legal
Home Office Construction
0.1
1.5
5.5
0.9
5.2
2.6
5.9
19.7
3.0
4.3
2.1
0.4
3.6
4.9
0.8
1.2
0.5
4.2
1.0
1.7
2.5
0.1
0.1
2.2
3.9
3.9
3.8
8.8
1.5
0.1
2.0
0.1
1.6
6.1
1.0
8.7
2.8
6.5
17.0
2.3
4.7
2.0
0.4
5.0
6.4
0.8
1.3
0.5
4.6
1.0
1.3
2.5
0.2
0.1
1.5
3.8
3.8
4.1
5.8
1.6
0.1
LO
0.1
1.9
7.0
1.0
6.3
3.1
7.2
23.8
3.8
5.0
2.7
0.4
4.4
5.8
0.9
1.4
0.6
5.1
1.1
1.4
2.8
0.2
0.1
1.4
0.0
0.0
4.6
5.8
1.7
0.1
OO
100.0
100.0
100.0
Total
Code:
1Engineering, Procurement And Construction Contract
2Engineering And Procurement Contract
3Engineering Only Contract
3__
Section 18
RATIO ESTIMATING FACTORS
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 construction equipment and overhead and indirects percent ranges are a percent 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 percentage to be applied for a specific project from the percentage range tables 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.
Manhours for the various disciplines of work can be obtained by dividing the labor percentage dollars by the established hourly activity rate.
A construction schedule can be executed utilizing the discipline manhours coupled with equipment shipping dates.
For a description of items included under the various disciplines of work
see Section 1, "Disciplines of Work."
Discipline
1. Process Equipment
2. Site Preparation
3. Site Improvements
4. Concrete
5. Structural Steel
6. Buildings
7. Underground Piping
8. Above-ground Piping
9. Underground Electric
10. Above-ground Electric
11. Instrumentation
12. Insulation
13. Painting
14. Paving
15. Proratables
** lbtal Direct Cost
Average
Percent
of Totals
V
VI
92.82 10.03
0.55 3.59
*
1.43
0.22 16.42
*
4.82
4.81 2.21
*
1.84
1.60 27.51
*
0.87
*
7.90
*
4.16
*
9.57
*
5.06
*
0.81
*
3.79
100.0 100.0
VII
49.97
1.01
0.69
5.63
3.90
1.71
0.83
18.19
0.32
5.81
4.48
3.94
1.84
0.36
1.32
100.0
Discipline
1. Process Equipment
2. Site Preparation
3. Site Improvements
4. Concrete
5. Structural Steel
6. Buildings
7. Underground Piping
8. Above-ground Piping
9. Underground Electric
10. Above-ground Electric
11. Instrumentation
12. Insulation
13. Painting
14. Paving
15. Proratables
** Total Direct Cost
Average
Percent
of Totals
V
VI
VII
61.30 5.44 37.60
0.01 0.72 0.82
1.74 2.95 1.70
6.30 15.04 6.39
*
6.51 4.89
8.23 6.08 3.55
0.02 4.04 2.17
7.35 34.54 20.40
*
0.39 0.25
*
9.50 6.85
*
4.59 8.24
*
6.44 3.74
*
3.93 1.70
0.85 1.05 0.66
*
3.09 1.04
100.0 100.0 100.0
Discipline
1. Process Equipment
2. Site Preparation
3. Site Improvements
4. Concrete
5. Structural Steel
6. Buildings
7. Underground Piping
8. Above-ground Piping
9. Underground Electric
10. Above-ground Electric
11. Instrumentation
12. Insulation
13. Painting
14. Paving
15. Proratables
** Tbtal Direct Cost
Average
Percent
of Totals
V
VI
VlT
69.24 4.99 37.80
0.02 0.78 0.97
2.32 3.20 2.02
7.37 17.08 7.59
*
7.06 5.81
10.99 6.51 4.22
0.02 4.05 2.38
9.06 34.59 22.37
*
0.35 0.25
*
8.72 6.89
*
2.11 4.14
*
4.03 2.56
*
2.46 1.17
0.98 0.98 0.68
*
3.09 1.15
100.0 100.0 100.0
Discipline
1. Process Equipment
2. Site Preparation
3. Site Improvements
4. Concrete
5. Structural Steel
6. Buildings
7. Underground Piping
8. Above-ground Piping
9. Underground Electric
10. Above-ground Electric
11. Instrumentation
12. Insulation
13. Painting
14. Paving
15. Proratables
** Total Direct Cost
Average
Percent
of Totals
V
VI
70.31 4.93
0.02 0.74
2.25 3.02
7.16 16.15
*
6.68
10.67 6.16
0.01 3.75
8.62 32.03
*
0.36
*
9.00
*
4.17
*
5.72
*
3.49
0.96 0.94
*
2.86
100.0 100.0
VII
36.52
0.90
1.87
7.01
5.37
3.90
2.15
20.25
0.25
6.94
8.00
3.55
1.62
0.63
1.04
100.0
Discipline
1. Process Equipment
2. Site Preparation
3. Site Improvements
4. Concrete
5. Structural Steel
6. Buildings
7. Underground Piping
8. Above-ground Piping
9. Underground Electric
10. Above-ground Electric
11. Instrumentation
12. Insulation
13. Painting
14. Paving
15. Proratables
** Total Direct Cost
Average
Percent
Percentage Ratio Ranges
of Totals
I
II
III
IV
V
VI VII
100.00
25.00-26.00 3.75-5.00
43.16 74.86 5.34 38.10
1.70-2.25
0.01-0.01
0.25-0.50
0.75 0.01 0.54 0.63
2.30-3.00
0.50-0.75
1.50-1.75
0.99 1.62 2.21 1.31
6.50-7.25
1.75-2.00
9.25-10.00
2.92 5.30 12.62 5.26
9.00-10.00
*
3.50-4.00
3.98 *
4.88 3.78
3.25-4.00
2.50-3.00
3.25-3.75
1.48 7.67 4.50 2.75
4.75-5.25
0.01-0.01
3.00-3.25
2.12 0.02 4.30 2.38
45.25-47.00
3.25-3.50 27.00-28.00 19.66 9.72 36.75 22.38
0.50-1.00
*
0.25-0.40
0.25 *
0.38 0.25
16.50-17.25
*
6.75-7.25
7.19 *
9.34 6.94
26.50-27.50
*
3.50-4.00
11.66 *
4.88 9.04
8.00-8.50
*
4.50-5.00
3.54 *
6.33 3.79
2.75-3.25
*
2.75-3.00
1.30 *
3.86 1.73
0.75-1.25
0.02-0.04
0.50-0.70
0.37 0.80 0.79 0.51
1.25-1.50
*
2.00-2.50
0.63 *
3.28 1.15
229.0-239.0 33.04-35.31 71.75-79.10 100.0 100.0 100.0 100.0
Discipline
1. Process Equipment
2. Site Preparation
3. Site Improvements
4. Concrete
5. Structural Steel
6. Buildings
7. Underground Piping
8. Above-ground Piping
9. Underground Electric
10. Above-ground Electric
11. Instrumentation
12. Insulation
13. Painting
14. Paving
15. Proratables
** Total Direct Cost
Average
Percent
of Totals
V
VI
VlT
75.07 5.74 40.18
0.01 0.59 0.68
1.65 2.42 1.42
5.09 12.97 5.31
*
5.35 4.06
7.84 4.93 2.95
0.02 4.51 2.45
9.51 38.51 23.01
*
0.27 0.18
*
6.69 4.88
*
4.58 8.31
*
5.67 3.33
*
3.46 1.52
0.81 0.87 0.54
*
3.44
1.18
100.0 100.0 100.0
CONSTRUCTION EQUIPMENT
Ratio Percentages
As A Percent Of Direct Field Labor
Description
16. Rental or Purchase
17. Service Labor
18. Fuel, Oil, Grease, Supplies
Tbtal
Percent of
Direct Field Labor
Range
Average
12.0-18.0
15.0
2.0-6.0
4.0
7.0-15.0
1^0
21.0-39.0
31.0
Description
19. Salaried Indirect
Office Hourly Indirects
Field Hourly Indirects
20. Temporary Construction
Facilities*
21. Burdens and Benefits
22. Small Tools and Consumables
23. Other Indirects
Tbtal
Percent of
Direct Field Labor
Range
Average
8.0-12.0
10.0
4.0-8.0
16.0
3.0-7.0
5.0
10.0-20.0
15.0
25.0-28.0
5.0-10.0
10.0-20.0
65.0-105.0
27.0
7.0
1^0
85.0
Description
24. Engineering/Design Services
25. Construction Services
26. Project General Management
Tbtal
Percent of Total
Direct and Indirect
Range
Average
8.0-16.0
12.0
0.1-0.4
0.2
1.0-1.5
U
9.1-17.9
13.3
Section 19
ESTIMATE ADJUSTMENTS
Each estimate, in all probability, will need some or all of the following
adjustments dependent upon the scope of work, amount of pre-bid information available, and the type of estimate to be prepared. The following
are definitions of these adjustments:
Design Allowance. The design allowance is an adjustment to the estimated mechanical equipment cost to provide for nominal and routine
changes in equipment design. The design allowance is included in the details of the estimate and is considered as part of the direct base cost. The
magnitude of the design allowance is a function of the amount of design
information available to the estimator, and it decreases as the accuracy
level of the estimate increases. An example of a design allowance is the
addition of money for routine nozzle and clip changes on a fabricated vessel. It is expected that all design allowance money will be expended during the project.
Quantity Allowance. The quantity allowance is an adjustment to
the estimated construction activity take-off quantities to provide for (1)
the difference between neat take-off quantities and in-place quantities
and for (2) consideration of fabrication waste. The quantity allowance is
included in the details of the estimate and is considered as a part of the
direct base cost. The magnitude of the quantity allowance is a function of
the amount of design information available to the estimator and decreases as the accuracy level of the estimate increases. An example of a
quantity allowance is adding to the piping take-off an allowed quantity of
small diameter pipe and valves for vents and drains not shown on estimate drawings. It is expected that all quantity allowance money will be
expended during the project.
Escalation. The escalation is the amount of dollars or percentage of
cost added to the estimated base cost to provide for procurement at a future date later than the estimate. The magnitude of the escalation is a
function of an appraisal of anticipated market conditions during the design and construction phases of the project. It is expected that all escalation money will be expended during the project.
Contingencies. A percentage of base cost plus escalation and taxes
or amounts added to same providing coverage for human calculation or
judgement error in accumulation of estimate scope. Contingencies are anticipated to be spent and form a part of the cost of the project. Contingencies vary directly with the accuracy level of the estimate. The more gross
the method of estimating, the higher the contingencies. Contingencies do
not provide any funds for scope changes. Examples of items covered by
contingency are: piping lines missed on take-off, extension errors, dimension errors, etc.
Bisk. An amount of money or percent of base cost plus lower level additives (except fee) normally added to the base cost plus additives to
cover the chances of probabilities that the base cost estimate plus additives is not ample for financing of the project. Risk is normally associated
with the monies applied by a contractor's management in the case of a
"lump sum" or "guaranteed maximum" or an owner for other contractual
arrangements to cover costs that might occur, but hopefully will not. Risk
monies may or may not be spent. These monies are added to provide financial protection and quantify management or executive judgements for
final project cost outcome. Considerations of changes in scope normally
generated by an organization should be covered in these amounts. In rare
cases, risk could be expressed as a deduction from the base cost plus additives. Examples of items covered by risk are: inclement weather conditions, time extensions of the project, prototype processes, productivity
loss, etc.
Fees. The amount of money anticipated to be recovered by the contractor to provide funds for payments of his non-project overhead and
profit.