Industrial Construction Estimating Manual [1 ed.] 0128233621, 9780128233627

Industrial Construction Estimating Manual focuses on industrial process plants and enables the contractor, subcontractor

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Industrial Construction Estimating Manual [1 ed.]
 0128233621, 9780128233627

Table of contents :
Cover
Industrial Construction Estimating Manual
Copyright
Contents
Preface
1 Introduction to construction estimating
1.1 Introduction
1.2 Types of construction estimates
1.2.1 Levels of estimates
1.3 Models
1.4 Labor productivity analysis
1.4.1 Labor
1.4.2 Labor man-hour
1.4.3 Cost analysis
1.5 Data collection and regression analysis
1.5.1 Construction database
1.6 Quantity takeoff
1.6.1 Material takeoff RP piping and supports
1.7 Scope of work and erection sequence
1.7.1 Scope of field work required for HRSG SB code piping
1.8 Coding
1.8.1 Job cost by cost code and type
1.8.2 Table—jJob cost by cost code and type—HRSG RP piping and supports
1.9 Productivity measurement
1.9.1 Nonrepetitive one-cycle time study
1.9.2 Field data report
1.9.3 Table—spreadsheet for field data report
1.10 Detailed estimate
1.11 Unit method
1.11.1 Table—calculation HRSG RP piping and supports average man-hour (MHa)
1.11.2 Regression model—unit method
1.11.3 Correlation
1.12 Unit-quantity model
1.12.1 Table—illustration of unit-quantity model
1.12.2 Regression model—unit-quantity model verification
1.13 Excel estimate spreadsheet for the unit quantity model
1.14 Elements of construction work
1.15 Computer-aided cost estimation
2 Construction material
2.1 Overview—introduction
2.2 Material estimate
2.3 Material takeoff
2.4 Estimate worksheet
2.5 Sample estimating worksheets for piping, structural, foundations, and vessels/towers
2.5.1 Power plant piping material takeoff
2.5.2 Power plant structural steel quantity material takeoff
2.5.3 Power plant foundations quantity material takeoff
2.5.4 Compressor station piping material takeoff
2.5.5 Vessels/columns material takeoff
2.6 Combined cycle power plant material takeoff
2.6.1 LB code piping sheet 1
2.6.2 LB code piping sheet 2
2.6.3 LB code piping sheet 3
2.6.4 LB code piping sheet 4
2.6.5 Small bore code piping sheet 5
2.6.6 Risers and down comers sheet 6
2.6.7 Heat recovery steam generator—field trim piping sheet 7
2.6.8 SP-01 AIG piping sheet 8
2.7 Combined cycle power plant STG vendor piping
2.7.1 STG vendor piping sheet 1
2.7.2 STG vendor piping sheet 2
2.7.3 STG vendor piping sheet 3
3 Construction database system
3.1 Introduction
3.2 Construction database
3.3 Development of industrial construction database
3.3.1 Benefits of unit man-hour database
3.4 Piping man-hour database
3.4.1 Pipe set and align, cast iron—lead and mechanical joint
3.4.2 Verify historical data for cast iron pipe—pipe set and align
3.4.3 Mechanical joint MH/JT, cast iron—lead and mechanical joint
3.4.4 Verify historical data for cast iron pipe—mechanical joint MH/JT
3.4.5 Handle and install fitting, cast iron—lead and mechanical joint
3.4.6 Verify historical data for cast iron pipe—handle and install fitting
3.4.7 Verification of cast iron underground piping by regression analysis
3.4.8 Handle and install pipe, cast iron—lead and mechanical joint
3.5 Illustrative examples of database for civil, structural and miscellaneous steel, and pipeline
3.5.1 Civil database for hydrogen plant
3.5.2 Facility—industrial plant (simple foundation)
3.5.3 Structural and miscellaneous steel database for combined cycle power plant
3.5.4 Pipeline database
3.5.5 Schedule A—combined cycle power plant piping
3.6 Balance of plant equipment estimating database
3.6.1 Set, align, couple, and grout pumps
4 Construction labor estimate
4.1 Introduction
4.2 Elements of construction-work estimate
4.3 Construction-work estimating
4.4 Four scopes of work illustrate estimate worksheets using the unit-quantity model
4.4.1 Combined cycle power plant; boiler foundations—HRSG Stack and HRSG
4.4.2 Combined cycle power plant—structural and miscellaneous steel
4.4.3 Refinery—vessels/columns
4.4.4 Gasifier—Feedstock Bunker A and B
4.5 Typical process piping estimate
4.5.1 Field Erect-HRSG HP piping and supports
4.5.2 Estimate sheet—Handle and install pipe-welded joint
4.5.3 Estimate sheet 2—Welding: BW, SW, PWHT arc-uphill
4.5.4 Estimate sheet 3—Boltup of flanged joint by weight class
4.5.5 Estimate sheet 4—Handle valves by weight class
4.5.6 Estimate sheet 5—Pipe supports
4.5.7 Estimate sheet 6—Instrument
4.5.8 Estimate sheet 7—Summary HP piping and supports
4.6 Piping summary converted to MH/lf
5 Computer-aided estimation
5.1 Introduction
5.2 Benefits of computer-aided estimating
5.3 Computer Excel estimate spreadsheets
5.4 Illustration computer Excel estimate spreadsheet forms
5.4.1 Quantity takeoff—detailed work-up sheet 1 (civil)
5.4.2 Labor rates and cost—calculation of labor cost sheet 2
5.4.3 Labor rates and cost—calculation of labor cost craft supervision sheet 3
5.4.4 Labor rates and cost—calculation of labor cost project staff sheet 4
5.4.5 General conditions’ cost sheet 5
5.4.6 Material cost sheet 6
5.4.7 Subcontractor cost sheet 7
5.4.8 Estimate summary sheet 8
5.5 Sample cost estimate: Simple cycle power plant SCR Foundation estimate
5.5.1 Quantity takeoff detailed work-up sheet
5.5.2 Labor rates and cost—calculation of labor cost direct and indirect craft sheet 2
5.5.3 Labor rates and cost—calculation of labor cost craft supervision sheet 3
5.5.4 Labor rates and cost—calculation of labor cost project staff sheet 4
5.5.5 General conditions’ cost sheet 5
5.5.6 Material cost sheet 6
5.5.7 Subcontractor cost sheet 7
5.5.8 Estimate summary sheet 8
5.5.9 SCR Foundation—bid breakdown sheet 9
5.5.10 Estimate analysis sheet 10
6 Combined cycle power plant (1×1) labor estimate
6.1 Introduction
6.2 Detailed estimating unit-quantity model
6.3 Combine cycle power plant foundation summary
6.4 Work estimates are illustrated with the unit-quantity model
6.4.1 Estimate—power island equipment foundations
6.4.2 CTG and CTG-related foundations sheet 1
6.4.3 CTG and CTG-related foundations sheet 2
6.4.4 STG and STG-related foundations sheet 3
6.4.5 Circulating water pump station and cooling tower
6.4.6 Plant mechanical system–related foundations sheet 1
6.4.7 Plant mechanical system–related foundations sheet 2
6.4.8 Plant mechanical system–related foundations sheet 3
6.4.9 Plant mechanical system–related foundations sheet 4
6.4.10 Utility distribution plant electrical controls sheet 1 foundations
6.4.11 Utility distribution plant electrical controls sheet 2 foundations
6.4.12 Utility distribution plant electrical controls sheet 3 foundations
6.4.13 Utility distribution plant electrical controls sheet 4
6.5 Summary foundation man-hours
6.6 Mechanical equipment (CTG, STG, heat recovery steam generator) includes vendor piping
6.7 HRSG triple pressure; three wide-installation man-hours
6.8 Estimate heat recovery steam generator triple pressure; three wide
6.9 Heat recovery steam generator large bore vendor piping
6.9.1 Piping and supports—ASME B31.1 sheet 1
6.9.2 Piping and supports—ASME B31.1 sheet 2
6.9.3 Piping and supports—ASME B31.1 sheet 3
6.10 Heat recovery steam generator small bore vendor piping
6.10.1 Excel spreadsheet summary heat recovery steam generator vendor piping
6.10.2 Heat recovery steam generator—small bore code piping
6.11 Heat recovery steam generator—risers and down comers
6.12 Heat recovery steam generator—field trim piping
6.12.1 Heat recovery steam generator field trim piping—HP, IP, LP remote drums
6.13 SP-01 AIG piping
6.14 Excel double-flow STG installation estimate man-hours
6.15 Excel double-flow STG equipment installation estimate
6.16 Excel double-flow STG installation estimate
6.17 STG vendor piping
6.17.1 STG—vendor piping sheet 1
6.17.2 STG—vendor piping sheet 2
6.18 STG piping
6.19 Excel F class CTG installation estimate man-hours
6.20 Summary F class CTG installation man-hour estimate
6.21 Excel F class CTG installation estimate
6.22 CTG vendor piping
6.22.1 CTG—vendor piping sheet 1
6.22.2 CTG—vendor piping sheet 2
6.23 BOP equipment
6.23.2 Balance of plant equipment sheet 1
6.23.3 Balance of plant equipment sheet 2
6.24 Structural steel
6.24.1 Structural steel installation man-hour estimate
6.24.2 Structural steel estimate
6.25 Summary underground piping man-hours
6.26 Summary aboveground piping man-hours
6.27 Aboveground balance of plant piping
6.27.1 Aboveground piping sheet 1
6.27.2 Aboveground piping sheet 2
6.27.3 Aboveground piping sheet 3
6.27.4 Aboveground piping sheet 4
6.27.5 Aboveground piping sheet 5
6.27.6 Aboveground piping sheet 6
6.27.7 Aboveground piping sheet 7
6.27.8 Aboveground piping sheet 8
6.28 Heat recovery steam generator configuration
6.29 Combined cycle power plant equipment man-hour breakdown
6.29.1 Combined cycle power plant: configuration: 2×1
6.29.2 Combined cycle power plant owner-furnished equipment
6.30 Direct craft man-hour summary
6.30.1 Combined cycle power plant: configuration: 1×1
7 Gasifier labor estimate
7.1 Introduction
7.2 Gasifier bid breakdown
7.2.1 Total direct craft man-hours sheet 1
7.3 Detailed estimate using the unit quantity model to erect gasifier
7.3.1 Equipment estimate sheet 1
7.3.2 Equipment estimate sheet 2
7.3.3 Equipment estimate sheet 3
7.3.4 Equipment estimate sheet 4
7.3.5 Equipment estimate sheet 5
7.3.6 Equipment estimate sheet 6
7.3.7 Equipment estimate sheet 7
7.3.8 Equipment estimate sheet 8
7.3.9 Equipment estimate sheet 9
7.3.10 Equipment estimate sheet 10
7.3.11 Equipment estimate sheet 11
7.3.12 Equipment estimate sheet 12
7.3.13 Equipment estimate sheet 13
8 Refinery equipment and storage tank labor estimates
8.1 Introduction
8.2 Refinery equipment estimate
8.2.1 Refinery equipment installation man-hours activity
8.3 Refinery equipment bid breakdown
8.3.1 Vessels/columns sheet 1
8.3.2 Vessels/columns/tank sheet 2
8.3.3 Reactors sheet 3
8.3.4 Shell and tube heat exchanger sheet 4
8.3.5 Pumps sheet 5
8.3.6 Recycle compressor no. 1 sheet 6
8.3.7 Recycle compressor no. 2 sheet 7
8.3.8 Rich solvent hydraulic turbine, 1292 HP Sheet 8
8.3.9 Miscellaneous equipment and special specialty items sheet 9
8.4 API 650 oil storage tanks
8.4.1 Tank data
8.5 Tank construction estimate
8.5.1 Introduction
8.5.2 Tank erection bid breakdown
8.5.3 Bottom plate placement
8.5.4 Bottom plate placement and welding sequence
8.5.5 Shell plate erection
8.5.6 Shell plate erection
8.5.7 Roof erection
8.5.8 Tank testing
9 Circulating fluidized bed combustion (FBC) labor estimates
9.1 Introduction
9.2 Combustor bid breakdown
9.3 Combustor
9.3.1 Combustor equipment labor hours sheet 1
9.3.2 Combustor equipment labor hours sheet 2
9.3.3 Combustor equipment labor hours sheet 3
9.4 Boiler bid breakdown
9.5 Boiler
9.5.1 Boiler labor hours sheet 1
9.5.2 Boiler labor hours sheet 2
9.6 Boiler circulation water bid breakdown
9.7 Boiler circulation water
9.7.1 Boiler circulating water piping labor hours sheet 1
9.7.2 Boiler circulating water piping labor hours sheet 2
9.8 Fans bid breakdown
9.9 Fans
9.9.1 Fans labor hours sheet 1
9.10 Fans—FD, ID, OFA bid breakdown
9.11 Fans—FD, ID, OFA ductwork
9.11.1 Fans—FD, ID, OFA labor hours sheet 1
9.12 Economizer/inlet duct/hoppers bid breakdown
9.13 SCR/economizer support structure
9.13.1 SCR/economizer support structure labor hours sheet 1
9.14 Multiclonebid breakdown
9.15 Multiclone
9.15.1 Multicone labor hours sheet 1
9.16 Spray dryer bid breakdown
9.17 Spray dryer
9.17.1 Spray dryer labor hours sheet 1
9.18 Ductwork—multiclone to spray dryer
9.18.1 Ductwork—multicone to spray dryer labor hours sheet 1
9.19 Baghouse bid breakdown
9.20 Baghouse
9.20.1 Baghouse labor hours sheet 1
9.21 Ductwork to baghouse labor hours sheet 1
9.22 Ash tank 15′ dia×40′ labor hours
9.23 Ash piping bid breakdown
9.24 Ash piping
9.24.1 Ash piping labor hours sheet 1
9.24.2 Ash piping labor hours sheet 2
9.24.3 Ash piping labor hours sheet 3
9.25 Sand system bid breakdown
9.26 Sand system
9.26.1 Sand system labor hours sheet 1
9.27 BOP interconnecting pipe
9.27.1 BOP interconnecting pipe labor hours sheet 1
9.28 Bid breakdown circulating fluidized bed boiler (FBC)
10 Bid assurance
10.1 Introduction
10.2 Unbalanced bidding strategy
10.3 Analysis of estimates
10.3.1 Regression analysis—deviation of estimate ratio from actual value
10.3.2 Estimate error
10.3.3 Mistakes
10.3.4 Policy
10.3.5 Risk
10.4 Estimate assurance
11 Detailed estimating applications to construction
11.1 Introduction
11.2 Illustrative example for construction estimating process—lube oil supply
11.2.1 Scope of work is defined by the plant process, piping and instrument diagrams, and process flow diagrams
11.2.2 Make detailed material takeoff for lube oil supply piping
11.2.3 Set up cost codes—job cost by cost code and type
11.2.4 Collect direct craft data in the field—field report
11.2.5 Summarize, verify, and validate data using the regression model
11.3 Man-hour database for combined cycle power plant and industrial plant
11.3.1 Schedule A—Combined cycle power plant piping
11.3.2 Hydrostatic testing
11.3.3 Schedule G—Alloy and nonferrous weld factors
11.4 Lube oil supply piping estimate
11.4.1 Estimate sheet 1-Handle and install pipe-welded joint
11.4.2 Estimate sheet 2-Welding: BW, SW, PWHT arc-uphill
11.4.3 Estimate sheet 3-Boltup of flanged joint by weight class
11.4.4 Estimate sheet 4-Handle valves by weight class
11.4.5 Estimate sheet 5-Pipe supports
11.4.6 Estimate sheet 6-Instrument
11.4.7 Estimate sheet 7-Summary HP piping and supports
11.5 Piping summary converted to MH/LF
11.6 Excel estimate sheet
11.7 STG-lube oil supply piping installation man-hours
11.8 Illustrative example to develop a database for tank farm boltup flanged joints
11.8.1 Field data report
11.8.2 Least squares regression model—150 lb/300 lb
11.8.3 Least squares regression model—600 lb field boltup
11.8.4 Verification of tank farm–bolted flange connections
11.9 Illustrative example for verification of LP piping and supports—ASME Section 1 installation
11.9.1 LP piping and supports MTO
11.9.2 LP piping and supports—ASME Section 1 field estimate
11.9.3 Least squares regression model LP piping
11.10 Illustrative example for verification of STG utility bridge steel
11.10.1 Power plant structural steel quantity MTO
11.11 STG utility bridge steel field estimate
11.11.1 Least squares regression model STG utility bridge steel
11.12 Illustrative example for verification of hydrogen plant foundations
11.12.1 MTO hydrogen plant foundation work
11.12.2 Job cost by cost code and type—hydrogen plant foundations
11.12.3 Civil databases for hydrogen plant
11.12.4 Excel estimate spreadsheet for hydrogen plant foundations
11.12.5 Least squares regression model hydrogen plant foundations
Appendix A Statistical and mathematical formulas
Appendix B Excel functions and mathematical functions
Appendix C Area and volume formulas
Appendix D Standard to metric
Lengths
Volumes
Areas
Appendix E Boiler man hour tables
Index
Back Cover

Citation preview

Industrial Construction Estimating Manual

Industrial Construction Estimating Manual

Kenneth Storm

Gulf Professional Publishing is an imprint of Elsevier 50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States The Boulevard, Langford Lane, Kidlington, Oxford, OX5 1GB, United Kingdom Copyright © 2020 Elsevier Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions. This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress ISBN: 978-0-12-823362-7 For Information on all Gulf Professional Publishing publications visit our website at https://www.elsevier.com/books-and-journals

Publisher: Joe Hayton Acquisitions Editor: Katie Hammon Editorial Project Manager: Michelle W. Fisher Production Project Manager: Sojan P. Pazhayattil Cover Designer: Matthew Limbert Typeset by MPS Limited, Chennai, India

Contents Preface

1.

2.

xv

Introduction to construction estimating

1

1.1 Introduction 1.2 Types of construction estimates 1.3 Models 1.4 Labor productivity analysis 1.4.1 Labor 1.4.2 Labor man-hour 1.4.3 Cost analysis 1.5 Data collection and regression analysis 1.5.1 Construction database 1.6 Quantity takeoff 1.6.1 Material takeoff RP piping and supports 1.7 Scope of work and erection sequence 1.7.1 Scope of field work required for HRSG SB code piping 1.8 Coding 1.8.1 Job cost by cost code and type 1.8.2 Table—jJob cost by cost code and type—HRSG RP piping and supports 1.9 Productivity measurement 1.9.1 Nonrepetitive one-cycle time study 1.9.2 Field data report 1.9.3 Table—spreadsheet for field data report 1.10 Detailed estimate 1.11 Unit method 1.12 Unit-quantity model 1.13 Excel estimate spreadsheet for the unit quantity model 1.14 Elements of construction work 1.15 Computer-aided cost estimation

1 1 2 3 3 3 3 4 4 4 4 5 5 5 5 6 6 7 7 8 8 8 10 12 13 13

Construction material

15

2.1 2.2 2.3 2.4

15 15 15 16

Overview—introduction Material estimate Material takeoff Estimate worksheet

vi

3.

Contents

2.5 Sample estimating worksheets for piping, structural, foundations, and vessels/towers 2.5.1 Power plant piping material takeoff 2.5.2 Power plant structural steel quantity material takeoff 2.5.3 Power plant foundations quantity material takeoff 2.5.4 Compressor station piping material takeoff 2.5.5 Vessels/columns material takeoff 2.6 Combined cycle power plant material takeoff 2.6.1 LB code piping sheet 1 2.6.2 LB code piping sheet 2 2.6.3 LB code piping sheet 3 2.6.4 LB code piping sheet 4 2.6.5 Small bore code piping sheet 5 2.6.6 Risers and down comers sheet 6 2.6.7 Heat recovery steam generator—field trim piping sheet 7 2.6.8 SP-01 AIG piping sheet 8 2.7 Combined cycle power plant STG vendor piping 2.7.1 STG vendor piping sheet 1 2.7.2 STG vendor piping sheet 2 2.7.3 STG vendor piping sheet 3

16 16 17 19 21 24 25 25 27 28 30 31 33 35 37 38 38 39 40

Construction database system

43

3.1 Introduction 3.2 Construction database 3.3 Development of industrial construction database 3.3.1 Benefits of unit man-hour database 3.4 Piping man-hour database 3.4.1 Pipe set and align, cast iron—lead and mechanical joint 3.4.2 Verify historical data for cast iron pipe—pipe set and align 3.4.3 Mechanical joint MH/JT, cast iron—lead and mechanical joint 3.4.4 Verify historical data for cast iron pipe—mechanical joint MH/JT 3.4.5 Handle and install fitting, cast iron—lead and mechanical joint 3.4.6 Verify historical data for cast iron pipe—handle and install fitting 3.4.7 Verification of cast iron underground piping by regression analysis 3.4.8 Handle and install pipe, cast iron—lead and mechanical joint 3.5 Illustrative examples of database for civil, structural and miscellaneous steel, and pipeline 3.5.1 Civil database for hydrogen plant 3.5.2 Facility—industrial plant (simple foundation) 3.5.3 Structural and miscellaneous steel database for combined cycle power plant

43 43 43 44 45 45 45 46 47 48 48 49 49 50 50 51 52

Contents

4.

5.

vii

3.5.4 Pipeline database 3.5.5 Schedule A—combined cycle power plant piping 3.6 Balance of plant equipment estimating database 3.6.1 Set, align, couple, and grout pumps

52 53 54 54

Construction labor estimate

57

4.1 4.2 4.3 4.4

57 57 58

Introduction Elements of construction-work estimate Construction-work estimating Four scopes of work illustrate estimate worksheets using the unit-quantity model 4.4.1 Combined cycle power plant; boiler foundations—HRSG Stack and HRSG 4.4.2 Combined cycle power plant—structural and miscellaneous steel 4.4.3 Refinery—vessels/columns 4.4.4 Gasifier—Feedstock Bunker A and B 4.5 Typical process piping estimate 4.5.1 Field Erect-HRSG HP piping and supports 4.6 Piping summary converted to MH/lf

59 60 61 61 61 73

Computer-aided estimation

75

5.1 5.2 5.3 5.4

75 75 76 77 77 77

Introduction Benefits of computer-aided estimating Computer Excel estimate spreadsheets Illustration computer Excel estimate spreadsheet forms 5.4.1 Quantity takeoff—detailed work-up sheet 1 (civil) 5.4.2 Labor rates and cost—calculation of labor cost sheet 2 5.4.3 Labor rates and cost—calculation of labor cost craft supervision sheet 3 5.4.4 Labor rates and cost—calculation of labor cost project staff sheet 4 5.4.5 General conditions’ cost sheet 5 5.4.6 Material cost sheet 6 5.4.7 Subcontractor cost sheet 7 5.4.8 Estimate summary sheet 8 5.5 Sample cost estimate: Simple cycle power plant SCR Foundation estimate 5.5.1 Quantity takeoff detailed work-up sheet 5.5.2 Labor rates and cost—calculation of labor cost direct and indirect craft sheet 2 5.5.3 Labor rates and cost—calculation of labor cost craft supervision sheet 3 5.5.4 Labor rates and cost—calculation of labor cost project staff sheet 4 5.5.5 General conditions’ cost sheet 5

58 58

78 79 80 81 82 83 84 84 84 86 87 88

viii

Contents

5.5.6 5.5.7 5.5.8 5.5.9 5.5.10

6.

Material cost sheet 6 Subcontractor cost sheet 7 Estimate summary sheet 8 SCR Foundation—bid breakdown sheet 9 Estimate analysis sheet 10

Combined cycle power plant (1 3 1) labor estimate 6.1 Introduction 6.2 Detailed estimating unit-quantity model 6.3 Combine cycle power plant foundation summary 6.3.1 Estimate summary—power island equipment foundations 6.3.2 Utility distribution plant electrical controls foundations 6.4 Work estimates are illustrated with the unit-quantity model 6.4.1 Estimate—power island equipment foundations 6.4.2 CTG and CTG-related foundations sheet 1 6.4.3 CTG and CTG-related foundations sheet 2 6.4.4 STG and STG-related foundations sheet 3 6.4.5 Circulating water pump station and cooling tower 6.4.6 Plant mechanical systemrelated foundations sheet 1 6.4.7 Plant mechanical systemrelated foundations sheet 2 6.4.8 Plant mechanical systemrelated foundations sheet 3 6.4.9 Plant mechanical systemrelated foundations sheet 4 6.4.10 Utility distribution plant electrical controls sheet 1 foundations 6.4.11 Utility distribution plant electrical controls sheet 2 foundations 6.4.12 Utility distribution plant electrical controls sheet 3 foundations 6.4.13 Utility distribution plant electrical controls sheet 4 6.5 Summary foundation man-hours 6.6 Mechanical equipment (CTG, STG, heat recovery steam generator) includes vendor piping 6.7 HRSG triple pressure; three wide-installation man-hours 6.8 Estimate heat recovery steam generator triple pressure; three wide 6.8.1 HRSG—module casing 6.8.2 HRSG—ductwork SCR and inlet 6.8.3 HRSG—erect gas baffles, pressure vessels, modules, and duct burner 6.8.4 HRSG—steel (ladders, platforms, and grating), skids, SCR, and CO 6.8.5 HRSG—stack and breeching (XX0-Xv OD3XXX0-Xv high) 6.9 Heat recovery steam generator large bore vendor piping 6.9.1 Piping and supports—ASME B31.1 sheet 1 6.9.2 Piping and supports—ASME B31.1 sheet 2 6.9.3 Piping and supports—ASME B31.1 sheet 3

89 90 91 92 92 95 95 95 96 96 99 100 100 101 102 103 105 106 107 108 109 111 112 113 114 115 115 115 116 116 117 118 119 120 121 123 123 125

Contents

6.10 Heat recovery steam generator small bore vendor piping 6.10.1 Excel spreadsheet summary heat recovery steam generator vendor piping 6.10.2 Heat recovery steam generator—small bore code piping 6.11 Heat recovery steam generator—risers and down comers 6.11.1 HP, IP, and LP drums risers and down comers 6.12 Heat recovery steam generator—field trim piping 6.12.1 Heat recovery steam generator field trim piping—HP, IP, LP remote drums 6.13 SP-01 AIG piping 6.14 Excel double-flow STG installation estimate man-hours 6.15 Excel double-flow STG equipment installation estimate 6.16 Excel double-flow STG installation estimate 6.16.1 Estimate—centerline equipment 6.16.2 Estimate HP/IP turbine and front standard 6.16.3 Generator acoustic enclosure 6.16.4 Generator installation 6.17 STG vendor piping 6.17.1 STG—vendor piping sheet 1 6.17.2 STG—vendor piping sheet 2 6.18 STG piping 6.19 Excel F class CTG installation estimate man-hours 6.20 Summary F class CTG installation man-hour estimate 6.21 Excel F class CTG installation estimate 6.21.1 Estimate—centerline equipment 6.21.2 Turbine enclosure, grating, and walkways 6.21.3 Inlet filter house, transition duct, ductwork 6.21.4 Inlet plenum, exhaust system, duct/stack 6.22 CTG vendor piping 6.22.1 CTG—vendor piping sheet 1 6.22.2 CTG—vendor piping sheet 2 6.23 BOP equipment 6.23.1 Balance of plant installation man-hour estimate 6.23.2 Balance of plant equipment sheet 1 6.23.3 Balance of plant equipment sheet 2 6.24 Structural steel 6.24.1 Structural steel installation man-hour estimate 6.24.2 Structural steel estimate 6.25 Summary underground piping man-hours 6.25.1 Underground piping 6.26 Summary aboveground piping man-hours 6.27 Aboveground balance of plant piping 6.27.1 Aboveground piping sheet 1 6.27.2 Aboveground piping sheet 2 6.27.3 Aboveground piping sheet 3 6.27.4 Aboveground piping sheet 4 6.27.5 Aboveground piping sheet 5 6.27.6 Aboveground piping sheet 6

ix 125 125 126 127 127 128 128 130 131 131 131 131 132 134 134 135 136 136 137 138 138 138 138 139 140 140 141 141 142 143 143 143 144 145 145 145 146 147 148 148 148 150 150 151 152 153

x

7.

8.

Contents

6.27.7 Aboveground piping sheet 7 6.27.8 Aboveground piping sheet 8 6.28 Heat recovery steam generator configuration 6.29 Combined cycle power plant equipment man-hour breakdown 6.29.1 Combined cycle power plant: configuration: 2 3 1 6.29.2 Combined cycle power plant owner-furnished equipment 6.30 Direct craft man-hour summary 6.30.1 Combined cycle power plant: configuration: 1 3 1

154 155 156

Gasifier labor estimate

161

7.1 Introduction 7.2 Gasifier bid breakdown 7.2.1 Total direct craft man-hours sheet 1 7.3 Detailed estimate using the unit quantity model to erect gasifier 7.3.1 Equipment estimate sheet 1 7.3.2 Equipment estimate sheet 2 7.3.3 Equipment estimate sheet 3 7.3.4 Equipment estimate sheet 4 7.3.5 Equipment estimate sheet 5 7.3.6 Equipment estimate sheet 6 7.3.7 Equipment estimate sheet 7 7.3.8 Equipment estimate sheet 8 7.3.9 Equipment estimate sheet 9 7.3.10 Equipment estimate sheet 10 7.3.11 Equipment estimate sheet 11 7.3.12 Equipment estimate sheet 12 7.3.13 Equipment estimate sheet 13

161 162 162

Refinery equipment and storage tank labor estimates

171

8.1 Introduction 8.2 Refinery equipment estimate 8.2.1 Refinery equipment installation man-hours activity 8.3 Refinery equipment bid breakdown 8.3.1 Vessels/columns sheet 1 8.3.2 Vessels/columns/tank sheet 2 8.3.3 Reactors sheet 3 8.3.4 Shell and tube heat exchanger sheet 4 8.3.5 Pumps sheet 5 8.3.6 Recycle compressor no. 1 sheet 6 8.3.7 Recycle compressor no. 2 sheet 7 8.3.8 Rich solvent hydraulic turbine, 1292 HP Sheet 8 8.3.9 Miscellaneous equipment and special specialty items sheet 9

171 171 171 172 173 174 175 176 177 178 178 179

156 156 157 158 158

163 163 163 164 165 166 166 167 167 168 168 169 169 170

179

Contents

9.

xi

8.4 API 650 oil storage tanks 8.4.1 Tank data 8.5 Tank construction estimate 8.5.1 Introduction 8.5.2 Tank erection bid breakdown 8.5.3 Bottom plate placement 8.5.4 Bottom plate placement and welding sequence 8.5.5 Shell plate erection 8.5.6 Shell plate erection 8.5.7 Roof erection 8.5.8 Tank testing

179 180 180 180 180 180 181 181 181 182 182

Circulating fluidized bed combustion (FBC) labor estimates

183

9.1 Introduction 9.2 Combustor bid breakdown 9.3 Combustor 9.3.1 Combustor equipment labor hours sheet 1 9.3.2 Combustor equipment labor hours sheet 2 9.3.3 Combustor equipment labor hours sheet 3 9.4 Boiler bid breakdown 9.5 Boiler 9.5.1 Boiler labor hours sheet 1 9.5.2 Boiler labor hours sheet 2 9.6 Boiler circulation water bid breakdown 9.7 Boiler circulation water 9.7.1 Boiler circulating water piping labor hours sheet 1 9.7.2 Boiler circulating water piping labor hours sheet 2 9.8 Fans bid breakdown 9.9 Fans 9.9.1 Fans labor hours sheet 1 9.10 Fans—FD, ID, OFA bid breakdown 9.11 Fans—FD, ID, OFA ductwork 9.11.1 Fans—FD, ID, OFA labor hours sheet 1 9.12 Economizer/inlet duct/hoppers bid breakdown 9.13 SCR/economizer support structure 9.13.1 SCR/economizer support structure labor hours sheet 1 9.14 Multiclonebid breakdown 9.15 Multiclone 9.15.1 Multicone labor hours sheet 1 9.16 Spray dryer bid breakdown 9.17 Spray dryer 9.17.1 Spray dryer labor hours sheet 1 9.18 Ductwork—multiclone to spray dryer 9.18.1 Ductwork—multicone to spray dryer labor hours sheet 1

183 183 184 184 185 186 187 187 187 188 189 189 189 190 191 191 191 192 192 192 192 192 192 193 193 193 194 194 194 195 195

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Contents

9.19 Baghouse bid breakdown 9.20 Baghouse 9.20.1 Baghouse labor hours sheet 1 9.21 Ductwork to baghouse labor hours sheet 1 9.22 Ash tank 150 dia 3 400 labor hours 9.23 Ash piping bid breakdown 9.24 Ash piping 9.24.1 Ash piping labor hours sheet 1 9.24.2 Ash piping labor hours sheet 2 9.24.3 Ash piping labor hours sheet 3 9.25 Sand system bid breakdown 9.26 Sand system 9.26.1 Sand system labor hours sheet 1 9.27 BOP interconnecting pipe 9.27.1 BOP interconnecting pipe labor hours sheet 1 9.28 Bid breakdown circulating fluidized bed boiler (FBC)

10. Bid assurance 10.1 Introduction 10.2 Unbalanced bidding strategy 10.3 Analysis of estimates 10.3.1 Regression analysis—deviation of estimate ratio from actual value 10.3.2 Estimate error 10.3.3 Mistakes 10.3.4 Policy 10.3.5 Risk 10.4 Estimate assurance

11. Detailed estimating applications to construction 11.1 Introduction 11.2 Illustrative example for construction estimating process—lube oil supply 11.2.1 Scope of work is defined by the plant process, piping and instrument diagrams, and process flow diagrams 11.2.2 Make detailed material takeoff for lube oil supply piping 11.2.3 Set up cost codes—job cost by cost code and type 11.2.4 Collect direct craft data in the field—field report 11.2.5 Summarize, verify, and validate data using the regression model 11.3 Man-hour database for combined cycle power plant and industrial plant 11.3.1 Schedule A—Combined cycle power plant piping

195 196 196 197 197 197 198 198 199 200 201 201 201 202 202 202 203 203 203 204 204 204 205 205 205 206 209 209 210

210 210 211 211 211 212 212

Contents

11.4

11.5 11.6 11.7 11.8

11.9

11.10

11.11

11.12

11.3.2 Hydrostatic testing 11.3.3 Schedule G—Alloy and nonferrous weld factors Lube oil supply piping estimate 11.4.1 Estimate sheet 1-Handle and install pipe-welded joint 11.4.2 Estimate sheet 2-Welding: BW, SW, PWHT arc-uphill 11.4.3 Estimate sheet 3-Boltup of flanged joint by weight class 11.4.4 Estimate sheet 4-Handle valves by weight class 11.4.5 Estimate sheet 5-Pipe supports 11.4.6 Estimate sheet 6-Instrument 11.4.7 Estimate sheet 7-Summary HP piping and supports Piping summary converted to MH/LF Excel estimate sheet STG-lube oil supply piping installation man-hours Illustrative example to develop a database for tank farm boltup flanged joints 11.8.1 Field data report 11.8.2 Least squares regression model—150 lb/300 lb 11.8.3 Least squares regression model—600 lb field boltup 11.8.4 Verification of tank farmbolted flange connections Illustrative example for verification of LP piping and supports—ASME Section 1 installation 11.9.1 LP piping and supports MTO 11.9.2 LP piping and supports—ASME Section 1 field estimate 11.9.3 Least squares regression model LP piping Illustrative example for verification of STG utility bridge steel 11.10.1 Power plant structural steel quantity MTO STG utility bridge steel field estimate 11.11.1 Least squares regression model STG utility bridge steel Illustrative example for verification of hydrogen plant foundations 11.12.1 MTO hydrogen plant foundation work 11.12.2 Job cost by cost code and type—hydrogen plant foundations 11.12.3 Civil databases for hydrogen plant 11.12.4 Excel estimate spreadsheet for hydrogen plant foundations 11.12.5 Least squares regression model hydrogen plant foundations

xiii 213 214 215 215 216 216 217 217 218 218 218 219 219 219 220 220 222 223 224 224 224 225 226 226 226 226 227 227 228 228 228 228

xiv

Contents

Appendix Appendix Appendix Appendix Appendix Index

A: Statistical and mathematical formulas B: Excel functions and mathematical functions C: Area and volume formulas D: Standard to metric E: Boiler man hour tables

231 237 239 241 243 251

Preface This first edition of Industrial Construction Estimating Manual provides a detailed estimating method using the unit-quantity model to prepare construction estimates for process plants using computerized estimation. Most estimating methods are qualitative and are not based on historical data. The unit method uses historical and quantitative data that leads to a cost driver easily understood. The unit method is used extensively in construction estimating. This method is extended by developing the unit method and historical man-hours into the unit-quantity model. When given historical data from previous similar work task, the estimator uses the unit-quantity model to calculate cost and man-hours by category and produce reliable detailed cost and man-hour estimates. This detailed estimating method is the most accurate and timely method and when the computer does the manual and repetitive work, the estimator can spend more time on quantity takeoff and use graphical, statistical, or mathematical methods. This will enable the estimator to set up company cost and man-hour databases on a computer-estimating system that are timely, accurate, reliable and enable the estimator to verify historical data, using statistical methods and to compile bid proposals, RFP’s and change orders. Companies must develop and maintain their own historical man-hour databases for earthwork, foundations, structural and miscellaneous steel, process equipment, piping, instrumentation, boilers, tanks, and pipelines and they need to be revised continuously. The purpose of this manual is to enable the reader to use detailed estimating using the unit-quantity model to estimate industrial process plant construction work. The first chapter, in the manual, is an introduction to construction estimating. The chapter provides the reader basic information on construction databases, job cost by cost code and type, productivity measurement, and development of detailed estimating using the unit-quantity model. Successful bidding ensures the cost and material requirements associated with the installation of the materials. Chapter 2, Construction Material, deals with construction materials and provides sample material takeoffs. Estimating data systems use historical data from quantity takeoff quantities and man-hours for estimating new projects of similar equipment or systems. Chapter 3, Construction Database System, will enable the reader to develop labor tables that can be used to set up and implement a man-hour database

xv

xvi

Preface

system using comparable cost and man-hour data to estimate future projects. Construction labor estimates, covered in Chapter 4, Construction Labor Estimate, provide the elements of the construction-work estimate and illustrate estimate worksheets using the unit-quantity model. In Chapter 5, Computer Aided Estimation, we consider computerized estimating as a standard tool in the construction industry to automate and control estimating spreadsheets used to estimate more effectively and efficiently. Chapters 6 9 provide the reader labor estimates based on detailed estimating using the unit-quantity model to estimate construction work in industrial process plants. The four chapters, six through nine, provide labor estimates for the following process plants: G G G G

Chapter Chapter Chapter Chapter

6, Combined Cycle Power Plant (1 3 1) Labor Estimate 7, Gasifier Labor Estimate 8, Refinery Equipment and Storage Tank Labor Estimates 9, Circulating Fluidized Bed Boiler Labor Estimates

Then Chapter 10, Bid Assurance, introduces the reader to the analysis of estimates. The purpose of Bid Assurance is to provide the reader methods, and techniques that optimize the bid and regulate cost to match the estimate. An estimates accuracy, reliability, and consistency are important. If the bid is successful then there is an opportunity to verify the estimate using statistical analysis. Chapter 10, Bid Assurance, describes the unbalanced bidding strategy, estimate errors, estimate analysis, and assurance. Chapter 11, Detailed Estimating Applications to Construction, provides practical applications to construction using Excel statistical and mathematical functions that model the work of construction. The manual has been written to appeal to engineering, technology, construction estimating, and management settings. An effort has been made to provide the reader methods, model’s procedures, formats, and technical data for preparing industrial process plant estimates using the unit-quantity model for detailed estimating. This manual will be an excellent reference for readers engaged in the construction industry.

Chapter 1

Introduction to construction estimating 1.1

Introduction

This chapter provides the reader methods, models, procedures, formats, and technical data for developing industrial process plant construction estimates. Detailed construction estimates are critical for engineering firms, contractors, and subcontractors to prepare accurate, reliable, verifiable, and consistent construction estimates. The term industrial process plants include firms involved with the construction of power plants, petroleum plants, petrochemical plants, and manufacturing plants. These process plants have a common reliance on process flow diagrams (PFDs), piping and instrument diagrams (P&IDs), vendor equipment scopes of work, and erection sequences as primary scopedefining documents. These documents are key deliverables in determining the scope of work and erection sequence and provide the level of detail required for a detailed work estimate. The detailed estimate is developed by combining the unit method and historical man-hours with the unit-quantity model to estimate industrial process plant construction work. Estimates for industrial process plants include mechanical process equipment and involve piping, instrumentation, structural and miscellaneous steel, and civil work. The methods, procedures, formats, and technical data throughout this manual provide information for compiling detailed construction estimates. The data must be modified as the user’s experience and operational situation suggests. Man-hours are based upon direct labor and do not include indirect and overhead labor. The manhours in this manual are based on each process plant’s scope of work and erection sequence. Standard man-hours have been verified by regression models and adjusted for idle time, fatigue, and delays (PF&D). The man-hours are competitive in all geographical areas in the United States and should be factored for each contractor workforce productivity, weather, and any factors that may affect field craft productivity.

1.2 Types of construction estimates Levels of accuracy for construction estimates vary depending on the stages of project development. Accuracy of construction estimates range where no Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00001-6 © 2020 Elsevier Inc. All rights reserved.

1

2

Industrial Construction Estimating Manual

information is available and the cost estimate is expected to be less accurate to when the scope of work is clearly defined and the erection sequence identified. Many types of cost estimates are used at different stages of the project development, and the cost estimate will reflect the information available at the time of estimation. Cost estimates can be best classified into three levels of estimates according to their functions. The focus of this manual is to provide estimators and engineers a detailed estimating method using the unitquantity model to prepare construction estimates for process plants using computer-aided cost estimation.

1.2.1 Levels of estimates 1. Preliminary estimates (or conceptual estimates) a. Preliminary plans and specifications. b. Little or no detail. c. General description of project. 2. Detailed estimates (or definitive estimates) a. A detailed work estimate is the most accurate and timely work estimate. b. Duplication of design enables an estimator to define and set up work scope and erection sequences for field construction work. c. The estimate requires historical data that has been collected, organized, and verified by statistical analysis. d. The data must be updated with respect to changes that will incur. e. The detailed estimate enables the contractor to schedule the work and complete construction successfully. f. Trends in man-hour units and cost will occur over time and forecasting future cost will be required. g. Time series—use moving averages and exponential smoothing to forecast changes over time. 3. Engineer’s estimates a. Based on plans and specifications.

1.3

Models

Statistical and mathematical models are used in construction estimating to enhance construction cost analysis by graphic and analytical techniques. Statistical and mathematical models are easy to manipulate and can be used: G G G G G G

to estimate the unit-quantity model, to explain the real situation, to provide a quick and inexpensive estimate, to use computers to handle regression models, to allow discovery of pertinent variables and comparison, and to use computer Excel spreadsheets and Excel functions to solve linear regression equations and statistical measures of reliability.

Introduction to construction estimating Chapter | 1

1.4 1.4.1

3

Labor productivity analysis Labor

Labor is the most important item in estimating construction work. Craft labor is classified into directindirect and unionnonunion. Labor productivity is concerned with direct craft labor. Craft labor time means the craft is working in the field on construction activities. Indirect craft labor is supportive of direct craft labor. Labor cost is defined by the following formulas: G G

Man-hour 5 time 3 quantity (refer to the unit-quantity method) Labor cost 5 man-hour 3 labor rate (refer to unit method)

where time is in hours per unit and the labor rate is expressed in dollars per hour. Once time values are known for a construction task, they are multiplied by the quantity. Time may be individuals or for crew work, and it is based on the construction task. Time is expressed relative to a unit of measure, such as LF, EA, SF, and ton. The unit of time may be a minute, hour, day, month, or year.

1.4.2 G

G

Labor man-hour

The “man-hour” is dependent on the historical value of time spent doing construction activities. This basic unit is defined as one worker working for 1 hour. Examples of man-hour units:

G

G G G

Welding butt weld, carbon steel, arc-uphill, 0.562v $ WT # 0.688, 1.05 MH/diameter in. Erect structural steel; .100 ton, X heavy—80120 lb/ft., 11.8 MH/ton Structure backfill and compact—loader and wacker, 0.60 MH/CY Fabricate, install, and strip foundation forms—1 use, 0.30 MH/SF

1.4.3 G G

Cost analysis

Man-year is 52 weeks at 40 h/week, equal to 2080 hours. Man-month is 173.3 h/month (40 3 52)/12 5 173.3.

Man-hours are used for estimating industrial construction work. Manhours are effective when measurements and analysis of worker’s time with respect to constructive and nonproductivity effort and idleness have been made. Man-hours have interface dependencies and must be based on quantitative measurement supported by historical data that has been verified by graphic and statistical analysis.

4

Industrial Construction Estimating Manual

1.5

Data collection and regression analysis

Historical data is cost coded and collected in field construction. The data is collected from similar projects and is used as detailed backup for the estimate. When using cost data the estimator must be aware of the source of the data and make adjustments when necessary. If historical data is used, the data may not be accurate, and not applicable due to escalation. It must be reviewed and verified using regression analysis and, if necessary, use time series to account for escalation before the data is used in the estimate.

1.5.1

Construction database

Using software and technology the contractor can build and maintain an accurate and reliable craft labor database as well as create simple and easy to use Excel spreadsheets that anyone in the company can use to access, edit, and manipulate the craft labor. The estimator collects historical estimating data from previous projects to develop the estimating database for process equipment, piping, civil, and structural steel installed from previous projects.

1.6

Quantity takeoff

The quantity takeoff is developed during the bid preparation and quantifies the materials required to complete the project. Steps in creating the material estimate depend on the accuracy of the material estimate derived from the material takeoff (MTO), also known as the quantity takeoff. The takeoff refers to taking each of the required materials off from the drawings for the project. The takeoff is a count of how much material will be required for the project to complete it per the specifications provided in the bid package.

1.6.1

Material takeoff RP piping and supports

RP piping and supports

SB

SB

Line no.

Material

Size

Sch/ Thk

Pipe

SW

Valve

PS

RP-50 RH desuperheater spray water RP-51 reheater 1 to 2 drain 1.5v RP-50

SA-106-B

1.5

80

65

25

5

3

SA-106-B

2

80

40

12

2

2

SA-106-B

1.5

80

60

19

7

3

Instrument

(Continued )

Introduction to construction estimating Chapter | 1

5

(Continued) RP piping and supports

SB

Line no.

Material

CRH boot drain HRH boot drain Preheater drains

1.7

SB

Size

Sch/ Thk

Pipe

SW

Valve

SA-106-B

2

80

20

4

1

SA-106-B

2

80

20

4

1

SA-106-B

2

80

180

54

9

PS

Instrument

9

Scope of work and erection sequence

Process plants identified by the process of the plant and the equipment, regardless of the manufacturer, have designs similar to the previous designed systems. The duplication of design enables the estimator to define the scope of work and erection sequence. The process plants have a common reliance on PFDs, P&IDs, vendor equipment scopes of work, and erection sequences as primary scope-defining documents. These documents are key deliverables in determining the scope of work and erection sequence.

1.7.1

Scope of field work required for HRSG SB code piping

Scope of work-field erection RP piping and supports RP piping and supports RP-50 RH desuperheater spray water RP-51 reheater 1 to 2 drain 1.5v RP-50 CRH boot drain HRH boot drain Preheater drains

1.8 1.8.1

Coding Job cost by cost code and type

Cost codes 1. Identifies a specific task within a job. 2. Cost type identifies specific cost within the activity, such as labor and material.

6

Industrial Construction Estimating Manual

3. Cost code is used to describe the task and cost type to describe the manhours associated with the task. Coding advantages: G G

Estimate preparation Data management

The company must develop a detailed code that has a structured scope of work and erection sequence corresponding to construction process of the company’s construction activity. The process plants are identified by the process of the plant, and the process provides the scope of work and erection sequence required to install the scope of work in a process plant. The estimator develops the scope of work in the erection sequence to install civil, structural steel, and mechanical work in the field and set up cost codes to identify the construction task. Historical data is collected from field construction, and similarities are compared to actual cost and time spent on work activities with those of the estimate. Historical data collected for civil, mechanical, and boiler construction based on cost code/type for each task is averaged and summarized into a spreadsheet, and the productivity rate is determined. The rate is used for future man-hour analysis and estimating jobs that are similar. Productivity rates are entered into a craft labor database (man-hour tables), and the craft labor hours have been verified by graphic and regression analysis. Industrial contractors develop their own specialized cost codes for material and labor cost expressed in unit of man-hours.

1.8.2 Table—jJob cost by cost code and type—HRSG RP piping and supports Cost code XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX

1.9

Type

MH

RP-50 RH desuperheater spray water RP-51 reheater 1 to 2 drain 1.5v RP-50 CRH boot drain HRH boot drain Preheater drains

116.2 66.8 105.4 35.5 35.5 244.7

Productivity measurement

Historical records provide the direct craft man-hour data for field installation of civil and mechanical work. Two methods for the measurement of

Introduction to construction estimating Chapter | 1

7

construction time are used to code, collect, analyze, and compile the actual man-hour data in this manual.

1.9.1

Nonrepetitive one-cycle time study

Normal time is found by multiplying a selected time for the task or cycle by the rating factors. Tn 5 T0 3 RF where Tn is the normal time (hours), T0 is the observed time (hours), and RF is the rating factor and arbitrarily set (number). Normal time does not include factors that affect labor productivity. Allowances for these factors are divided into three components: personal, fatigue, and delay (PF&D) process of timing the cycle: G

G

G

Idle time is excluded; craft takes breaks for coffee and rest room; allowance for personal is 5%. Fatigue is physiological reduction in ability to do work; allowance for fatigue is 5%. Delays beyond the worker’s ability to prevent; allowance for delays is 5%.

Productivity time in the work day is inversely proportional to the amount of PF&D allowance, and the allowance is expressed as a percent of the total work day. PF&D allowance is generally in the range of 10%20%; allowance multiplier: Fa 5 100%/(100% 2 PF&D%)where Fa is the allowance multiplier for PF&D (number), and PF&D is the personal, fatigue, and delay allowance (percentage). Standard productivity is the time required by a trained and motivated worker or workers to perform construction task while working at normal tempo. Hs 5 Tn 3 Fa where Hs is the standard time for a construction task per unit of effort (hour). The allowance for PF&D is 15%, which is an allowance multiplier of 1.176.

1.9.2

Field data report

The field report is collected in the field for similar work, and a spreadsheet is devised for the data. The report is used for time control and to find the number of man-hours for a task. The spreadsheet prepares the data for statistical analysis. The estimator determines the productivity rate, and the rate is used for future cost analysis and estimating similar scopes of work.

8

Industrial Construction Estimating Manual

1.9.3

Table—spreadsheet for field data report

Project: Combined cycle, install HRSG RP piping and supports Foreman: John Smith Date: Craft: PF Cost code

Phase code description

QTY

MH

xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx

RP piping and supports RP-50 RH desuperheater spray water RP-51 reheater 1 to 2 drain 1.5v RP-50 CRH boot drain HRH boot drain Preheater drains

65 40 60 20 20 180

116.2 66.8 105.4 35.5 35.5 244.7

1.10 Detailed estimate The detailed estimate is developed by combining the unit method and historical man-hours into the unit-quantity model to determine the quantities and cost to prepare an accurate and timely estimate. The unit-quantity model has the advantage that the scope and quantity differences can be identified and the impacts estimated.

1.11 Unit method The unit method uses historical man-hours and is defined as the mean, found as Xx x bar 5 x1 1 x2 1 ? 1 xn 5 n The unit method is the average man-hour per quantity ni P MHμ MHa 5 P ni where MHa is the average unit man-hour per quantity ni; MHμ is the quantity ni (unit man-hour); μ is the task 1, 2, k from quantity takeoff associated with construction work; and ni is the task takeoff quantity i, in dimensional units.

1.11.1 Table—calculation HRSG RP piping and supports average man-hour (MHa) HRSG RP piping and supports

Qty ni, lf

RP-50 RH desuperheater spray water

65

MHμ 116.2 (Continued )

Introduction to construction estimating Chapter | 1

9

(Continued) HRSG RP piping and supports

Qty ni, lf

MHμ

RP-51 reheater 1 to 2 drain 1.5v RP-50 CRH boot drain HRH boot drain Preheater drains

40 60 20 20 180 P 5 385.0

66.8 105.4 35.5 35.5 244.7 P 5 604.1

HRSG, Heat recovery steam generator.

P MHμ P 5 1:57 ni

MHa 5 1:57 MH=LF

G

G

G

The unit method is the slope b where a 5 0 or y 5 0 1 bx; MHa is a linear multiplier. When using MHa, the unit method can either overestimate or underestimate MHa. The data is plotted, and the values for y 5 a 1 bx are calculated using linear regression model (Fig. 1.1).

1.11.2 Regression model—unit method The data is plotted, for y 5 a 1 bx, using linear regression:

HRSG RP piping and supports RP-50 RH desuperheater spray water RP-51 reheater 1 to 2 drain 1.5v RP-50 CRH boot drain HRH boot drain Preheater drains

COVAR (R1, R2) VARP (R2) SLOPE (R1, R2) INTERCEPT (R1, R2)

y 5 1.2975x 1 17.428 Quantity, ni, lf

MHμ

x 65 40 60 20 20 180

y 116.2 66.8 105.4 35.5 35.5 244.7

3875.47 2986.81 1.2975 17.428

HRSG, Heat recovery steam generator.

Industrial Construction Estimating Manual

Man-hour, y

10

300.0 Series 1

y = 1.2975x + 17.428 R² = 0.9842

200.0

Linear (Series 1)

100.0 0.0

Linear (Series 1) 0

50

100

150

200

Quantity, x FIGURE 1.1 Unit method MHa 5 ΣMHμ/ni.

1.11.3 Correlation G

G

G

G

G

Measures the strength and direction of a linear relationship between two variables. The value of r is such that (21 # r # 1 1). The 1 and 2 signs are used for positive and negative linear correlations, respectively. Positive correlation: If x and y have a strong positive linear correlation, r is close to 11. An r value exactly 11 indicates a perfect positive fit. Positive values indicate a relationship between X and Y variables such that as values for X increase, values for Y also increase. A perfect correlation of 1 or 21 occurs only when all the data points lie exactly on a straight line. If r 5 11, the slope line is positive. If r 5 21, the slope of this line is negative. A correlation greater than 0.8 is generally described as strong, whereas a correlation less than 0.5 is generally described as weak.

Excel function—CORREL (R1, R2) 5 correlation coefficient of data in arrays R1 and R2 CORREL (R1, R2) 5 correlation coefficient 5 0.9986 CORREL (R1, R2)2 5 coefficient determination 5 0.9842 The coefficient of determination is R2 5 0.9842 and the correlation coefficient, R 5 0.9987 is a strong indication of correlation. A percentage of 99.8 of the total variation on Y can be explained by the linear relationship between X and Y (described by the regression equation; Y 5 1.2975X 1 17.428). The relationship between X and Y variables is such that as X increases, Y increases.

1.12 Unit-quantity model Simplify P the unit P method P and solve for MHμ: P MHμ= ni 5 MHa . Therefore MHμ 5 ni ðMHa Þ (unit-quantity model) The model starts with the quantity takeoff arranged in the erection sequence required to assemble and install the construction task. The estimator selects the task description by defining the work scope for field

Introduction to construction estimating Chapter | 1

11

construction work. Each task is related to and performed by direct craft and divided into one or more subsystems that are further divided into assemblies made up of construction line items. The unit-quantity model is given by: X MHμ 5 ni ðMHa Þ where MHμ is the quantity ni (man-hours for field construction work), ni is the task takeoff quantity i (dimensional units), MHa is the average unit manhour per quantity ni, and μ is the task 1, 2, k from quantity takeoff associated with construction work. The ni quantity is the takeoff for the field scope of work. MHa man-hours are determined from field construction man-hour tables. The unit man-hours were determined from historical data, and they correspond to the labor productivity necessary to install the civil, structural, and mechanical work in an industrial construction facility. The unit-quantity model allows a final cross-check of actual man-hours to estimated man-hours. Factor:MHμ 5 ni ðMHa ÞðfxÞ where fx is the factor percent for productivity loss and alloy weld factor x 5 1, 2, p.

1.12.1 Table—illustration of unit-quantity model HRSG RP piping and supports Scope of work

Quantity ni

Unit

MHa

Unit MH MHμ

RP-50 RH desuperheater spray water RP-51 reheater 1 to 2 drain 1.5v RP-50 CRH boot drain HRH boot drain Preheater drains P MHμ 5 ni(MHa)

65 40 60 20 20 180

lf lf lf lf lf lf

1.57 1.57 1.57 1.57 1.57 1.57

102.05 62.8 94.2 31.4 31.4 282.6 604.5

1.12.2 Regression model—unit-quantity model verification P The data is plotted, for MHμ 5 ni(MHa), using linear regression (Fig. 1.2).

RP-50 RH desuperheater spray water RP-51 reheater 1 to 2 drain

Quantity, ni, lf x

MHμ y

65 40

102 62.8 (Continued )

Industrial Construction Estimating Manual Man-hour, MHμ

12

300

y = 1.57x + 3E-14 R² = 1

200

Series 1

100

Linear (Series 1)

0 0

50

100

150

200

Linear (Series 1)

Quantity, nᵢ FIGURE 1.2 Unit-quantity model MHμ 5 Σni(MHa).

(Continued)

1.5v RP-50 CRH boot drain HRH boot drain Preheater drains COVAR (R1, R2) VARP (R2) SLOPE (R1, R2) INTERCEPT (R1, R2)

Quantity, ni, lf x

MHμ y

60 20 20 180 4689.28 2986.81 1.5700 0.000

94.2 31.4 31.4 283

The coefficient of determination, R2, is exactly 11 and indicates a positive fit. All data points lie exactly on the straight line. The relationship between X and Y variables is such that as X increases, Y also increases. The unit-quantity model improves the accuracy of the historical data.

1.13 Excel estimate spreadsheet for the unit quantity model Estimate sheet—sample form for excel spreadsheet estimate

Historical

Estimate

Description

MH

Qty

Unit

Qty

PF

Facility scope Scope Scope Scope

0 0 0

0 0 0

LF LF LF

0.0 0.0 0.0

0.0 0.0 0.0 0.0

The Excel spreadsheet based on the unit-quantity model to estimate industrial construction has many advantages over other estimating methods: G

G G

The scope of work is defined, and the erection sequence is based on the duplication of design. The unit-quantity model is a balanced unit estimate. The unit-quantity model is a balanced bid strategy.

Introduction to construction estimating Chapter | 1 G

G G

G

13

Standard unit of construction work is completed before construction is started. A detailed work estimate is the most accurate and timely work estimate. Using the duplication of design to define scope reduces the risk of lack of information. Planning occurs when the unit-quantity model is used.

1.14 Elements of construction work G

G

G

The detailed estimate is accurate, reliable, consistent, verifiable, and timely. Estimate consists of direct craft labor, material, equipment, and subcontract material. A chart of elements is included in a construction-work estimate:

Cost construction work

Subcontract material Equipment Material Direct labor

Direct cost

1.15 Computer-aided cost estimation Computerized estimating is a standard tool in the construction industry, which: G G G G G G G G G G G G G G G

reduces the time you spend in estimating, uses functions and formulas to ensure accurate estimates, shows step-by-step how to set up: estimate spreadsheets formulas for construction estimating detail sheets complete estimates in less time improve estimate accuracy organize the following: spreadsheet estimate summary sheet detailed workup sheet formulas that will automatically calculate man-hours and cost sheets containing detail and databases store and analyze data

By comparison, construction-estimating spreadsheets, given historical data from the previous similar work task, can reliably calculate man-hours, material, and labor by category and rapidly produce both summary and detailed man-hour and cost estimates. Manual takeoff with too much details

14

Industrial Construction Estimating Manual

introduces the potential for human error and inaccuracies. Using the unitquantity model, takeoff counts, and measurements can be generated from the model. Therefore data is always consistent with the design. An automation of the tedious task of quantifying allows the estimator to focus on identifying construction assemblies, cost, and factoring risk.

Chapter 2

Construction material 2.1

Overview—introduction

The contractor must make a takeoff of the types and quantities of various materials to complete a construction project. This is to ensure a complete estimate of the cost and material requirements associated with the installation of the materials. This process is the material takeoff (MTO) that is an essential part of the estimation process. The MTO must be an accurate estimate of the cost and materials so the project can run smoother and the craft will have the materials they need. Accurate detailed material estimates are vital to the successful planning and execution of the project. Automation of the takeoff of materials is the quickest, least expensive, and most reliable.

2.2

Material estimate

The material estimate identifies all materials required to complete the project and is derived from the MTO to develop estimating worksheets for each construction activity. Items identified by the MTO are organized, tabulated, and summarized like material items by construction activity, resulting in a material summary list that becomes the material estimate for the project. Steps in creating the material estimate depend on the accuracy of the material estimate derived from the MTO, also known as the quantity takeoff. The takeoff is a count of how much material will be required for the project to complete the scope of work per the specifications provided in the bid package.

2.3

Material takeoff

The construction takeoff is a MTO. l l

l

l

The MTO must list all the materials required to complete the project. The MTO should include any and all raw and prefabricated tools, such as piping, concrete, forms, and structural steel. The MTO needs to specify the type of material, such as type of pipe fittings, valves, pipe supports, structural steel, and concrete. The MTO is used to prepare the bill of materials (BOM) that is used to requisition and procure the necessary materials to complete the project.

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00002-8 © 2020 Elsevier Inc. All rights reserved.

15

16 l l

Industrial Construction Estimating Manual

Cost of material 5 MTO 3 cost/quantity. The unit method is used for material pricing.

2.4

Estimate worksheet

The estimate worksheets illustrated in the sample MTOs are the basis for the MTO and material estimate. The construction estimate worksheet provides a quick, efficient, and comprehensive cost-effective form for estimating and developing the material cost sheets for construction projects.

2.5 Sample estimating worksheets for piping, structural, foundations, and vessels/towers 2.5.1

Power plant piping material takeoff

Project: Combined cycle power plant Start-up/ shutdown (LCL) MTO Revision:

X

Date: x/xx/ xxxx Total

Description A106B std smls pipe 3000# A105 Sol 3000# A105 Sol 3000# A105 Sol 90-degree Elbow LR std A234WPB BW 45-degree Elbow LR std A234WPB BW Straight Tee std Type Strainer Ecco Red std A234WPB BW Ecc Red std A234WPB BW Induction Bend R 5 5 OD 1.5 degrees Induction Bend R 5 5 OD 2.9 degrees 150# RFWN Flange A105 150# Flat Ring Gasket Mineral Fiber Stud Bolt A193 Hot Dip Galv w/2 nuts 4.25 v A106B xs slms pipe 3000# A105 Sol 3000# A105 Sol 45-degree Elbow LR std A234WPB BW 90-degree Elbow LR std A234WPB BW Tee A234WPB std BW

Size 6 631 632 6 3 .75 6 6 6 634 633 6 6 6 6 0.75

Quantity 602 5 2 2 17 2 2 1 2 1 1 5 5 40

Unit lf ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea.

$/Unit 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

$ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

4 431 4 3 0.75 4 4 4

677 5 3 15 20 1

lf ea. ea. ea. ea. ea.

0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00

(Continued )

Construction material Chapter | 2

17

(Continued) Start-up/ shutdown (LCL) MTO Revision:

X

Date: x/xx/ xxxx Total

Conc. Red std A234WPB BW 150# RFWN Flange A105 150# Flat Ring Gasket Mineral Fiber Gate Valve 150# RFWN Flange A105 150# Flat Ring Gasket Mineral Fiber 90-degree Elbow SR std A234WPB BW Expansion joint Stud Bolt A193 Hot Dip Galv w/2 nuts 4.0v A106B xs smls pipe A106B xs smls pipe 90-degree Pipe bend 50 xs Globe valve A106B xs sms pipe Tee 3000# A105 SW 90 Ell 3000# A105 SW A106B xs smls pipe Pipe bend 50 90-degree xs A106B xs sms pipe

2.5.2

432 4 4 4 3 3 3 3 5/8

1 3 3 4 3 3 2 2 48

ea. ea. ea. ea. ea. ea. ea. ea. ea.

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

2 1 1 1 2 2 2 1 1 1.25

2 43 8 5 22 1 5 6 2 16

lf lf ea. ea. lf ea. ea. lf ea. lf

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Power plant structural steel quantity material takeoff

Project: Combined cycle power plant Revision:

Equipment description

Component description

HRSG utility steel bridge Light— 019 lb/ft. Medium— 2039 lb/ft.

X

Date: xx/ xx/xxxx Steel weight

Total steel weight

Quantity

Tons

Tons

186 Lot

204.6 10

11

Lot

30

33

Lot

96

105.6 (Continued )

18

Industrial Construction Estimating Manual

(Continued) Revision:

Equipment description

Component description Heavy— 4079 lb/ft. X heavy— 80120 lb/ft.

X

Date: xx/ xx/xxxx Steel weight

Total steel weight

Quantity

Tons

Tons

Lot

50

55

STG utility bridge steel Light— 019 lb/ft. Medium— 2039 lb/ft. Heavy— 4079 lb/ft. X heavy— 80120 lb/ft.

Lot

7.6

187 8.4

Lot

25.4

27.9

Lot

90

Lot

47

STG utility bridge steel inside enclosure

51.7 37.4

Light— 019 lb/ft. Medium— 2039 lb/ft. Heavy— 4079 lb/ft. X heavy— 80120 lb/ft.

Lot

1.5

1.7

Lot

5.1

5.6

Lot Lot

18 9.4

GSU transformer access platforms

19.8 10.3 13.5

Light and medium

1

12.3

13.5

Light and medium Stair treads Ladders

3

3.2

14.2 10.4

Stair tower and ladders

300 200

Light and medium

2

15

2.3 1.5 33 33

Light and medium

3

10

33 33

Iso phase support steel Dead-end structure 230 kV switchyard structure including bus supports

99

16.5 (Continued )

Construction material Chapter | 2

19

(Continued) Revision:

Equipment description

X

Date: xx/ xx/xxxx Steel weight

Total steel weight Tons

Component description

Quantity

Tons

Light and medium

1

15

Light and medium

6

1

16.5

Transmission line poles

6 6

Grating, handrail, and toe plate

17.1 2v serrated floor grating 1.5v serrated grating Handrail and toe plate

2.5.3

11,200

8.7

4100

3.1

2100

5.3

Power plant foundations quantity material takeoff

Project: Combined cycle power plant Description

Component description

Quantity

Concrete volume (CY)

Total concrete volume (CY)

Total rebar (ton)

50 0 3 2000 3 50 thk

1

1852

1944.6

107

160 3 120 concrete

1

60.4

60.4

3.3

100 3 100 3 2.50 thk

1

9.3

9.3

0.5

120 3 120 3 2.50 thk 190 3 70 3 20 thk

1

13.4

14.7

0.8

1

12.3

14.1

0.8

Boiler-related foundations HRSG stack and heat recovery steam generator HRSG RH blowdown tank and sump foundation HRSG HP blowdown tank foundation CEMS building Air skid foundation

(Continued )

20

Industrial Construction Estimating Manual

(Continued) Description

Component description

Quantity

Concrete volume (CY)

Total concrete volume (CY)

Steam Cycle Chem Feed Area Fdn Boiler feedwater pump Auxiliary boiler foundation

380 3 150 3 20 thk 22.750 3 11.250 thk 300 3 200 3 3.00 thk

Total rebar (ton)

1

46.1

50.7

2.8

2

29.7

65.3

3.6

1

66.7

73.4

4.0

530 3 1030

1

1230.0

1291.5

107.0

250 3 10.50 3 2.50 thk

1

38.2

76.4

4.2

330 3 80 3 20 thk

1

19.6

21.6

1.2

22.30 3 130 3 20 thk 9.50 3 50 3 20 thk

1

21.5

23.7

1.3

1

6.0

6.6

0.4

240 3 80 3 20 thk 180 3 90 3 20 thk

1 1

14.2 12.0

15.6 13.2

0.9 0.7

160 3 60 3 1.50 thk

1

5.3

5.8

0.3

1160 3 630 3 60 thk

1

2510.0

2635.5

145.0

130 3 9.750 3 2.50 thk

2

11.7

26.9

1.5

11.250 3 50 3 30 thk 36.50 3 300 w/ walls

2

6.3

14.4

0.8

1

102.0

117.3

6.5

440 3 270 and 720 3 1200

1

1350.0

1552.5

85.4

510 3 17.50 3 20

1

79.0

90.9

5.0

CTG and CTG-related foundations Combustion turbine and CT generator Gen. circuit breaker foundation Rotor air cooler foundation Excitation skid and transformer VT and surge cubicle foundation Sample panel Compressor wash skid GT water wash tank

STG and STG-related foundations Steam turbine and steam turbine generator Closed cooling water heat exchangers Closed cooling water pumps Cooling Tower chemical feed area Circulating water pump station and cooling tower Sulfuric acid, coagulant tank,

(Continued )

Construction material Chapter | 2

21

(Continued) Description

and pump foundations Condenser polishing unit Condensate extraction pumps Condenser vacuum pumps (2)

2.5.4

Component description

Quantity

140 3 100 3 2.50 thk 150 3 70 3 2.50 thk 160 3 130 3 2.50 thk

Concrete volume (CY)

Total concrete volume (CY)

Total rebar (ton)

1

13.0

15.0

0.8

1

9.7

11.2

0.6

1

19.3

22.2

1.2

Compressor station piping material takeoff

Project: Compressor station Preliminary mechanical MTO list Revision:

X

Quantity

Size

Item

30v

Pipe

400

12v

Pipe

2

30v

5

12v

3

30v

1

30v

90-degree ELL. 90-degree ELL. 45-degree ELL. Tee

2

30v 3 16v

Red tee

10 11

30v 30v

Flange Gasket

600# 600#

4

12v

Gasket

600#

1

16v 3 12v

Reducer

1

16v 3 8v

Reducer

100

0

Date: Sch

XS

XS

Description Pipe, steel, 30.00v OD 3 0.625v wall, DSAW Pipe, steel, 12.00v OD 3 0.500v wall, DSAW Elbow, pipe, W E, 90-degree, L R, 0.625v WT, GR Y60 Elbow, pipe, WE, 90-degree, L R, 0.500v WT, GR Y60 Elbow, pipe, weld ends, 45-degree, long radius, 0.625v Tee, pipe, welding, straight, 0.625v WT, Y60, E B Tee, pipe, welding, Red, 30v 3 16v, 0.625v WT, Y60, E B Flange, welding neck, 1/4v R F, 600# Gasket, G-10 glass epoxy, ANSI 600 LB Class Gasket, G-10 glass epoxy, ANSI 600 LB Class Red, weld ends, concentric, O.500v WT, GR Y60, Red, weld ends, concentric, O.500v WT, GR Y60, (Continued )

22

Industrial Construction Estimating Manual

(Continued) Preliminary mechanical MTO list Revision:

X

Date:

Quantity

Size

Item

1

12v 3 8v

Reducer

1000

42v

Pipe

3900

36v

Pipe

1000

30v

Pipe

160

16v

Pipe

400

12v

Pipe

XS

2

30v

1

16v

5

12v

XS

6

30v

1

42v

90-degree ELL. 90-degree ELL. 90-degree ELL. 45-degree ELL. Tee

6

30v

Tee

3

30v 3 16v

Red Tee

2

36v

Flange

600#

10

30v

Flange

600#

2

36v

Blind flange

600#

2

36v

Gasket

600#

11

30v

Gasket

600#

4

12v

Gasket

600#

1

42v 3 30v

Reducer

1

42v 3 22v

Reducer

Sch

Description Red, weld ends, concentric,O.500v WT, GR Y60, Pipe, steel, 42.00v OD 3 0.875v wall, API-5L, 3 60, DSAW Pipe, steel, 36.00v OD 3 0.750v wall, API-5L, 3 60, DSAW Pipe, steel, 30.00v OD 3 0.625v wall, API-5L, 3 60, DSAW Pipe, steel, 16.00v OD 3 0.500v wall, API-5L, 3 60, DSAW Pipe, steel, 12.00v OD 3 0.500v wall, API-5L, 3 60, DSAW Elbow, Pipe, W E, 90 degrees, L R, 0.625v WT, GR Y60 Elbow, Pipe, W E, 90 degrees, L R, 0.500v WT, GR Y60 Elbow, Pipe, W E, 90 degrees, L R, 0.500v WT, GR Y60 Elbow, Pipe, W E, 45 degrees, L R, 0.625v WT, GR Y60 Tee, Pipe, welding, straight, 0.875v WT, Y60 Tee, Pipe, welding, straight, 0.625v WT, Y60 Tee, Pipe, welding, reducing, 30v 3 16v, 0.625v WT, Y60 Flange, welding neck, 1/4v raised face, Grade F60 Flange, welding neck, 1/4v raised face, Grade F60 Flange, blind, 1/4v raised face, Grade F6

Gasket, G-10 glass epoxy, ANSI 600 LB Class Gasket, G-10 glass epoxy, ANSI 600 LB Class Gasket, G-10 glass epoxy, ANSI 600 LB Class Reducer, weld ends, concentric, O.875v WT, GR Y60, Reducer, weld ends, concentric, O.875v WT, GR Y60 (Continued )

Construction material Chapter | 2

23

(Continued) Preliminary mechanical MTO list Revision:

X

Date:

Quantity

Size

Item

1

22v 3 16v

Reducer

1

16v 3 12v

Reducer

3

16v 3 8v

Reducer

1

12v 3 8v

Reducer

1000

30v

Pipe

400

12v

Pipe

2

30v

5

12v

3

30v

1

30v

90-degree ELL. 90-degree ELL. 45-degree ELL. Tee

2

30v 3 16v

Red tee

10 11

30v 30v

Flange Gasket

600# 600#

4

12v

Gasket

600#

1

16v 3 12v

Reducer

1

16v 3 8v

Reducer

1

12v 3 8v

Reducer

120

36v

Pipe

Sch

XS

XS

Description Reducer, weld ends, concentric, O.500v WT, GR Y60 Reducer, weld ends, concentric, O.500v WT Reducer, weld ends, concentric, O.500v WT, GR Y Reducer, weld ends, concentric, O.500v WT, GR Y60 Pipe, steel, 30.00v OD 3 0.625v wall, API-5L, 3 60, DSAW Pipe, steel, 12.00v OD 3 0.500v wall, API-5L, 3 60, DSA Elbow, Pipe, W E, 90-degree, L R, 0.625v WT, GR Y60 Elbow, Pipe, W E, 90-degree, L R, 0.500v WT, GR Y60 Elbow, Pipe, W E, 45-degree, L R, 0.625v WT, GR Y60 Tee, Pipe, welding, straight, 0.625v WT, Y60 EB Tee, Pipe, welding, Red, 30v 3 16v, 0.625v WT, Y60, E B Flange, welding neck, 1/4v R F, 600# Gasket, G-10 glass epoxy, ANSI 600 LB Class Gasket, G-10 glass epoxy, ANSI 600 LB Class Reducer, W E, concentric, O.500v WT, GR Y60 Reducer, W E, concentric, O.500v WT, GR Y60 Reducer, W E, concentric, O.500v WT, GR Y60 Pipe, steel, 36.00v OD 3 0.750v wall, API-5L, 3 60

24

Industrial Construction Estimating Manual

2.5.5

Vessels/columns material takeoff

Vessels/columns Scope Solvent absorber Unload, handle, haul up to 20000 , rig, set and align, make up foundation AB Install platforms and ladders Remove and replace manway cover (24v 300# Removable-Davit) Install double downflow valve trays (16 trays) Install demisting pads (single grid support, pad, grid top) Vortex breaker Packing (pall rings) Rich solvent flash drum Unload, handle, haul up to 20000 , rig, set and align, make up foundation AB Install platforms and ladders Remove and replace manway cover (24v 300# Hinged) Inlet box Vortex breaker Install demisting pads (single grid support, pad, grid top) Solvent regenerator Unload, handle, haul up to 20000 , rig, set and align, and make up foundation AB Install platforms and ladders Remove and replace manway cover (24v 300# Removable-Davit) Install double downflow valve trays (12 trays) Install demisting pads (single grid support, pad, grid bottom) Vortex breaker Packing (pall rings) Solvent regenerator reflux drum Unload, handle, haul up to 20000 , rig, set and align, make up foundation AB Install platforms and ladders Remove and replace manway cover (24v 300# Hinged) Install demisting pads (single grid support, pad, grid top) Vortex breaker

Diameter

H or L

Volume

Weight

FT-IN

FT-IN

FT^3

Ton

80 6v

690 0v

3915

319.7

70 0v

240 0v

924

14.9

80 0v

720 6v

3644

39.0

50 0v

150 0v

295

2.6

(Continued )

25

Construction material Chapter | 2

(Continued)

Vessels/columns

H or L

Volume

Weight

FT-IN

FT-IN

FT^3

Ton

0

Solvent sump drum Unload, handle, haul up to 20000 , rig, set and align, make up foundation AB Install platforms and ladders Remove and replace manway cover (24v 300# Hinged) Vortex breaker Internal pipe

2.6

Diameter

0

4 0v

12 0v

151

2.2

Combined cycle power plant material takeoff

HRSG vendor piping MTO

2.6.1

LB code piping sheet 1 LB

Line no.

Material

LB

LB

Size Sch/The Pipe BW PWHT Valve Boltup Instrument PS

HP piping and supports—ASME Section 1 HP-03 Econ 1 to SA-106-B 8 HP Econ 2 HP-03 Econ 1 to SA-106-B 6 HP Econ 2 HP-04 Econ 2 to SA-106-B 8 HP Steam Drum HP-04 Econ 2 to SA-106-C 6 HP Steam Drum HP-09 Steam Drum SA-106-B 6 to HP SH 1 HP-10 Steam Drum SA-106-B 6 to HP SH 1 HP-11 Steam Drum SA-106-B 6 to HP SH 1 HP-12 Steam Drum SA-106-B 6 to HP SH 1 HP-13 Steam Drum SA-106-B 6 to HP SH 1 HP-14 Steam Drum SA-106-B 6 to HP SH 1 HP-15 SHTR 1 to SA-335-P91 10 HP SHTR 2 HP-15 SHTR 1 to SA-335-P91 8 HP SHTR 2 HP-15 SHTR 1 to SA-335-P91 3 HP SHTR 2 HP-16 SHTR 1 to SA-335-P91 10 HP SHTR 2

140/0.906 25 160/0.906 42

9

9

9

140/0.812 96

4

4

6

2

160/0.906

3

3

160/0.906 24

4

4

4

1

160/0.906 23

3

3

4

1

160/0.906 23

4

4

4

1

160/0.906 23

3

3

4

1

160/0.906 23

4

4

4

1

160/0.906 23

3

3

4

1

1.25 68

4

4

5

2

2

2

5

2

1

3

1 1.25 68

4

4

(Continued )

26

Industrial Construction Estimating Manual

(Continued) LB Line no. HP-16 SHTR HP SHTR 2 HP-16 SHTR HP SHTR 2 HP-17 SHTR HP SHTR 2 HP-17 SHTR HP SHTR 2 HP-17 SHTR HP SHTR 2

Material

LB

LB

Size Sch/The Pipe BW PWHT Valve Boltup Instrument PS

1 to

SA-335-P91 8

1 to

SA-335-P91 3

1 to

SA-335-P91 10

1 to

SA-335-P91 8

1 to

SA-335-P91 3

1

3

2

2 1

1.25 68 1

3

4

4

2

2

5

2

3

10

1

IP Piping and Supports—ASME Section 1 IP-03 Econ to IP Steam Drum IP-03 Econ to IP Steam Drum IP-06 Drum to IP Superheater 1 IP-06 Drum to IP Superheater 1 IP-09 SH1 to IP SH 2

SA-106-B

4

40

53

9.0

2

SA-106-B

3

40

6

4.0

2

SA-106-B

10

40

42

2.0

SA-106-B

6

40

5

6.0

SA-106-B

10

40

30

2.0

2 4

2

LP Piping and Supports—ASME Section 1 LP-10 Steam Drum to LP SHTR 1 LP-10 Steam Drum to LP SHTR 1 LP-10 Steam Drum to LP SHTR 1 LP-14 SHTR 1 to LP SHTR 2 LP-15 SHTR 1 to LP SHTR 2

SA-106-B

14

std

26

4

SA-106-B

10

40

34

4.0

SA-106-B

8

40

12

3.0

SA-106-B

10

40

32

2.0

2

SA-106-B

10

40

30

2.0

2

RP Piping and Supports—ASME Section 1 RP-03 Reheater 1 to Reheater 2 RP-03 Reheater 1 to Reheater 2 RP-03 Reheater 1 to Reheater 2

SA-335-P91 24

80/1.218 137 4.0 4

SA-335-P91 24

80/0.843

3

2

5.0 5 1

2

Construction material Chapter | 2

2.6.2

27

LB code piping sheet 2 LB

Line no.

Material

LB

LB

Size Sch/The Pipe BW PWHT Valve Boltup Instrument PS

HP piping and supports—ASME B31.1 HP-01 Feedwater Inlet HP-01 Feedwater Inlet HP-01 Feedwater Inlet HP-02-Steam Outlet HP-02-Steam Outlet HP-18 SHP-PSV-104 to SHP-S1002 HP-19 Start-Up Vent Piping HP-20 Sparging Steam Header HP-21 SHP-PSV-112A to SHP-S1-001 (Drum) HP-22 SHP-PSV-112B to SHP-S1-001 (Drum) HP-23 Upper Drain Piping Coll Header HP-23 Upper Drain Piping Coll Header HP-24 Steam Drum Warming Connection HP-25 SHP-PSV-104 Stack Piping HP-25 SHP-PSV-104 Stack Piping HP-26 SHP-PSV-112A Stack Piping HP-26 SHP-PSV-112A Stack Piping HP-27 SHP-PSV-112B Stack Piping HP-27 SHP-PSV-112B Stack Piping

SA-106-C SA-106-C SA-106-C SA-335P91 SA-335P91

10 6 10 14

160/1.125 47 160/0.718 3 1.5 57 1.75 44

2.0 2 3.0 5.0 5 5.0 5

10

1.25 26

6.0 4

1 1

1

5

3 2

3

6 SA-3358 P91 SA-106-B 3

3

1 120/0.718 22

2.0 2

160/0.437 42

5.0

2 3

4

6

2

6

2

SA-106-B 8

40

1

SA-106-B 3

40

66

1.0

SA-106-B 4

160

16

6.0

SA-106-B 14

40

29

1.0

SA-106-B 16

40

1

SA-106-B 18

40

1

SA-106-B 16

40

12

SA-106-B 18

1

SA-106-B 16

12

2.0

40 40 40 std 40

136 10.0 84 2.0 4 4.0 7 3.0 18 3.0

1

2.0

IP Piping and Supports—ASME B31.1 IP-01 Feedwater Inlet IP-02-Steam Outlet IP-02-Steam Outlet IP-10 Pegging Steam IP-10 Pegging Steam IP-11 SIP-PSV-109 to SIP-SI-002 (Stem Out) IP-12 Start-Up to SIP-SI-005 IP-13 SIP-PSV-106 to SIP-SI-001 (Drum)

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

4 10 8 16 6 4

SA-106-B 6 6

40

19

5.0

1 2 1 2 1

2 3 1

9 5

2

1 1

2

(Continued )

28

Industrial Construction Estimating Manual

(Continued) LB

LB

LB

Line no.

Material

Size Sch/The Pipe BW PWHT Valve Boltup Instrument PS

IP-15 Sparging Steam Header IP-16 Intermittent Blow off IP-17 SIP-PSV-109 Stack Piping IP-17 SIP-PSV-109 Stack Piping IP-18 SIP-PSV-106 Stack Piping IP-18 SIP-PSV-106 Stack Piping IP-19 Flash Tank 1 to IP Drum IP-20 F.S. 1 to Blowdown Tank IP-21 BFW-PSV 200 Outlet Piping IP-21 BFW-PSV 200 Outlet Piping

Sa-106-B

3

2.6.3

40

38

5.0

SA-106-B 2.5 80

84

6.0

SA-106-B 10

40

1

SA-106-B 8

40

20

SA-106-B 12

40

1

SA-106-B 10

40

16

1.0

SA-106-B 2.5 80

18

2.0

SA-106-B 6

1

80

3 6 1

1.0

SA-106-B 2.5 160

102

4.0

1

5

SA-106-B 2.5 160

102

4.0

1

5

LB code piping sheet 3 LB

Line no.

Material

LB

LB

Size Sch/The Pipe BW PWHT Valve Boltup Instrument PS

LP Piping and Supports—ASME B31.1 LP-01 Feedwater Inlet LP-01 Feedwater Inlet LP-02 Steam Outlet LP-02 Steam Outlet LP-02 Steam Outlet LP-02 Steam Outlet LP-03 LP FW Heater Bypass LP-04 FW Heater 1 to FW Heater 2 LP-05 FW Heater 1 to FW Heater 2 LP-06 FW Heater 1 to FW Heater 2 LP-07 FW Heater 2 to LP Steam Drum LP-07 FW Heater 2 to LP Steam Drum LP-16 Boiler Feed Pump Recirc.

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

40 40 std 40 std

65 23 1

SA-106-B

8 6 14 10 8 3 8

109

5.0 2.0 6.0 8.0

1

2

40

3

2.0

SA-106-B

6

40

5

2.0

1

SA-106-B

6

40

5

2.0

1

SA-106-B

6

40

5

2.0

1

SA-106-B

8

40

45

13.0

6

SA-106-B

6

40

6

5.0

1

SA-106-B

6

40

49

3.0

1

2

3

5

6 2

4

1 2

4

2

1

(Continued )

Construction material Chapter | 2

29

(Continued) LB

LB

LB

Line no.

Material

Size Sch/The Pipe BW PWHT Valve Boltup Instrument PS

LP-16 Boiler Feed Pump Recirc. LP-17 Boiler Feed Pump Recirc. LP-17 Boiler Feed Pump Recirc. LP-20 RAC to LP Steam Drum LP-21 SLP-PSV-102 to SLP-SI-002 LP-22 Start-Up Vent to SLP-SI-003 LP-23 SLP-PSV-104A to SLP-SI-001 (Drum) LP-24 SLP-PSV-104B to SLP-SI-001 (Drum) LP-26 Sparging Steam Header LP-27 Intermittent Blow off LP-28 SLP-PSV-102 Stack Piping LP-28 SLP-PSV-102 Stack Piping LP-29 SLP-PSV-104A Stack Piping LP-29 SLP-PSV-104A Stack Piping LP-30 SLP-PSV-104B Stack Piping LP-30 SLP-PSV-104B Stack Piping

SA-106-B

6

1

6

SA-106-B

6

40

43

SA-106-B

6

1

6

SA-106-B

10

40

203

3.0

1

8.0

7

6 SA-106-B

8

1

2 40

19

5.0

6

2

6

2

SA-106-B

3

40

38

5.0

SA-106-B

2.5 80

91

8.0

SA-106-B

10

40

1

SA-106-B

8

40

20

SA-106-B

10

40

1

SA-106-B

8

40

12

SA-106-B

10

40

1

SA-106-B

8

40

11

3

1 5

1.0

2.0

1.0

RP Piping and Supports—ASME B31.1 RP-01 Reheater 1 Inlet RP-01 Reheater 1 Inlet RP-01 Reheater 1 Inlet RP-02 Reheater 3 Outlet RP-02 Reheater 3 Outlet RP-02 Reheater 3 Outlet RP-02 Reheater 3 Outlet RP-09 SIP-PSV-108A to SIP-SI-003(CLD RH) RP-10 SIP-PSV-108B to SIP-SI-003(CLD RH) RP-11 SIP-PSV-105 to SIP-SI-004(RH Out) RP-12 Start-Up Vent RP-13 SIP-PSV-108A Stack Piping

SA-106-B SA-106-B

24 16 6 SA-335-P91 24 SA-335-P91 16 SA-335-P91 10 4 6

60/1.218 60 60/0.843 14

2.0 2 12.0 12

60/1.218 50 60/0.843 24 40 1

2.0 2 6.0 6

2 2 4 3 1 2

6

2

6

2

SA-335-P91 10 SA-106-B 18

3

40 40

27 1

5.0 5

1

(Continued )

30

Industrial Construction Estimating Manual

(Continued) LB Line no.

Material

RP-13 SIP-PSV-108A SA-106-B Stack Piping RP-13 SIP-PSV-108B SA-106-B Stack Piping RP-13 SIP-PSV-108B SA-106-B Stack Piping RP-15 SIP-PSV-105 SA-106-B Stack Piping RP-15 SIP-PSV-105 SA-106-B Stack Piping RP-03 Cooling Air Piping SA-106-B

2.6.4

LB

LB

Size Sch/The Pipe BW PWHT Valve Boltup Instrument PS 16

40

19

1.0

20

40

1

18

40

16

14

40

1

12

40

20

1.0

3

40

28

1.0

1.0

2

1

LB code piping sheet 4 LB

Line no.

LB

LB

Material Size Sch/The Pipe BW PWHT Valve Boltup Instrument PS

Silencer drain piping and supports 14v-RP-03 PRVS-X703B SA-106-B 14 to SIL-X704 10v-RP-05 PRVS-X703A SA-106-B 14 to SIL-X704 10v-RP-10 PRVS-X704 SA-106-B 10 to SIL-X705 12v-RP-08 MOV-X211/ SA-106-B 12 212 SIL-X706 10v-HP-13 PRVS-X802 SA-106-B 10 to SIL-X803 12v-HP-17 PRVS-X801A SA-106-B 12 to SIL-X801 8v-LP-13 PRVS-X602 SA-106-B 8 to SIL-X603 6v-IP-10 PRVS-X702 SA-106-B 6 to SIL-X703 4v-IP-08 MOV-X205/206 SA-106-B 4 to SIL-X702 8v-IP-12 PRVS-701 to SA-106-B 8 SIL-X701 12v-LP-11 MOV-X106/ SA-106-B 12 107 to SIL-X602 8v-LP-15 PRVS-X601A SA-106-B 8 to SIL-X601 8v-LP-17 PRVS-X601B SA-106-B 8 to SIL-X601 12v-HP-15 PRVS-X801B SA-106-B 12 to SIL-X801 6v-IP-11 MOV-X310/ SA-106-B 6 311to SIL-X803 PSV Drip Pan Assembly SA-106-B 6

40

40

2.0

40

40

2.0

40

40

2.0

40

40

6.0

40

40

2.0

40

40

2.0

40

40

2.0

40

40

2.0

40

40

6.0

40

40

2.0

40

40

6.0

40

2.0

40

2.0

40

40

2.0

40

40

7.0

40

140

0

2

2

2

2 13

0

Construction material Chapter | 2

2.6.5

31

Small bore code piping sheet 5 SB

Line no.

Material

SB

Size

Sch/ Thk

Pipe

SW

Valve

ps

SA-106B

2

80

80

41

3

4

SA-106B

2

80

80

34

3

4

SA-106B SA-106B SA-106B

2

80

140

56

7

7

2

80

220

66

11

11

2

80

20

10

2

1

SA-106B SA-106B

2

80

20

8

1

1

2

80

100

20

5

SA-106B

2

80

100

20

5

SA-106B

1.5

80

120

44

8

6

SA-106B

2

80

80

18

2

4

SA-106B

2

80

20

12

2

1

SA-106B SA-106B SA-106B

1

80

140

42

7

7

2

80

120

26

2

6

2

80

20

4

1

1

Instrument

HP piping and supports HP-51 Superheater 2 Drain HP-50 Superheater 1 Drain HP Economizer 1 Drains HP Economizer 2 Drains HP-18-A Sparging Header HP-23-D manifold Drain HP-52 Upper Blowdown Piping HP Upper Drains

IP Piping and Supports IP continuous blowdown to continuous blowdown tank IP-50 SPHTR 1 to SPHTR 2 Drain IP-13-A Sparging Steam Header Drain IP Economizer Drains 2v-IP-51 IP-16-D Drain

4

(Continued )

32

Industrial Construction Estimating Manual

(Continued) SB

SB

Line no.

Material

Size

Sch/ Thk

Pipe

SW

Valve

ps

IP-51 Blowdown Piping IP/RH Upper Drains

SA-106B

2

80

100

20

5

SA-106B

2

80

100

20

5

SA-106B

2

80

140

20

3

7

SA-106B

2

80

20

12

2

1

SA-106B SA-106B SA-106B

2

80

20

14

3

1

2

80

20

16

1

2

80

100

20

5

SA-106B SA-106B

2

80

20

4

1

2

80

100

20

5

SA-106B

1.5

80

65

25

5

3

SA-106B SA-106B SA-106B SA-106B SA-106B

2

80

40

12

2

2

1.5

80

60

19

7

3

2

80

20

4

1

2

80

20

4

1

2

80

180

54

9

9

SA-106B

1.5

80

120

20

2

6

Instrument

LP piping and supports LP-50 SPHTR 1 to SPHTR 2 Drain LP-22-A Sparging Steam Drain LP-22-C Drain LP-26-A Blow off Tank Drain LP-51 Upper Blowdown Piping LP boot drain LP upper drains

RP piping and supports RP-50 RH Desuperheater Spray water RP-51 Reheater 1 to 2 Drain 1-1/2v RP-50 CRH boot drain HRH boot drain Preheater drains Blowdown piping HD-D0 -N Intermittent Blow off

2

(Continued )

33

Construction material Chapter | 2

(Continued) SB

SB

Line no.

Material

Size

Sch/ Thk

Pipe

SW

Valve

ps

Instrument

HD-01-M Cascading Blowdown to IP Drum ID-01-M Intermittent Blow off LD-01-N Intermittent Blow off HD-01-N Intermittent Blow off LD-03-G BD Tank to BD Tank

SA-106B

1.5

80

120

64

11

6

4

SA-106B

1.5

80

120

20

2

6

2

SA-106B

1.5

80

120

20

2

6

2

SA-106B

2

80

100

20

5

SA-106B

2

80

100

20

5

SA-106B

1.5

80

160

384

Instrumentation Casing Instrumentation

2.6.6

96

32

Risers and down comers sheet 6 LB

Line no. HRSG-Risers and Down comers HP Drum Down comer Line no. HP-07 Down comer HP-07 Down comer HP-07 Down comer HP Evap to HP Drum Risers AHR11 AHR12 AHR13 BHR11 BHR12 BHR13

Material

Size

Sch/Thk

Pipe

BW

PWHT

PS

SA-106-B SA-106-C

26 16 4

2.5 2

192 40 10

6 6

6 6

4

SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C

8 8 8 8 8 8

140 140 140 140 140 140

10 10 10 10 10 10

2 2 2 2 2 2

2 2 2 2 2 2 (Continued )

34

Industrial Construction Estimating Manual

(Continued) LB Line no.

Material

Size

Sch/Thk

Pipe

BW

PWHT

CHR11 CHR12 CHR13 AHR21 AHR22 BHR21 BHR22 CHR21 CHR22 AHR31 AHR32 AHR33 BHR31 BHR32 IP Drum IP-05 Down comer IP-05 Down comer IP-05 Down comer IP Evap to IP Drum Risers AIR11 AIR12 BIR11 BIR12 CIR21 CIR22 LP Drum Down comer LP-09 Down comer LP-09 Down comer LP-09 Down comer LP Evap to LP Drum Risers ALR11 ALR12 BLR11 BLR12 CLR11 CLR12

SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C

8 8 8 8 8 8 8 8 8 8 8 8 8 8

140 140 140 140 140 140 140 140 140 140 140 140 140 140

10 10 10 10 10 10 10 10 10 10 10 10 10 10

2 2 2 2 2 2 2 2 2 2 2 2 2 2

2 2 2 2 2 2 2 2 2 2 2 2 2 2

SA-106-B SA-106-B

10 5 4

40 40

114 9 2

3.0 3.0

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

10 10 10 10 10 10

40 40 40 40 40 40

6 6 6 6 6 6

2 2 2 2 2 2

SA-106-B SA-106-B

10 6 4

40 40

110 20 2

3.0 3.0

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

12 12 12 12 12

80 80 80 80 80 80

10 10 10 10 10 10

2 2 2 2 2 2

PS

2

2

Construction material Chapter | 2

2.6.7

35

Heat recovery steam generator—field trim piping sheet 7 SB

SB

Material

Size

Sch/ Thk

Pipe

SW

Valve

Instrument

SA-106B SA-106B

1

80

20

4

2

1

80

20

4

6

SA-106B

1

80

20

4

3

SA-106B

1

80

20

4

2

SA-106B

1

80

20

50

6

SA-106B

1

80

20

42

10

3

SA-106B

1

80

20

16

4

2

SA-106B

1

80

20

12

4

2

HP remote steam drum HD-01-K PI-X305 HD-01-F LG-X301 w/ LT-X301C (Top Conn) HD-01-G LG-X301 w/LT-X301C (Bolt Conn) HD-01-H LG-X301 (Drain) HD-01-A LI-X301 w/ LT-X310A (Top Conn) HD-01-B LI-X301 w/ LT-X301A (Bolt Conn) HD-01-C LI-X301 (Drain) HD-01-D LT-X301B w/PT-X305B (Top Conn) HD-01-E LT-X301B w/PT-X305B (Bolt Conn) IP remote steam drum ID-01-F LG-X201 w/ LT-X201C (Top Conn) ID-01-G LG-X201 w/ LT-X201C (Bolt Conn) ID-01-H LG-X201 (Drain) ID-01-A LI-X201 w/ LT-X210A (Top Conn) ID-01-B LI-X201 w/ LT-X201A (Bolt Conn) ID-01-C LI-X201 (Drain) ID-01-D LT-X201B w/ PT-X203B (Top Conn) ID-01-E LT-X201B w/ PT-X203B (Bolt Conn) ID-01-K PI-X203

(Continued )

36

Industrial Construction Estimating Manual

(Continued) SB

SB

Material

Size

Sch/ Thk

Pipe

SW

Valve

Instrument

SA-106B

1

80

20

50

14

6

SA-106B

1

80

20

42

10

3

SA-106B

1

80

20

16

4

2

SA-106B

1

80

20

12

4

2

SA-106B SA-106B

0.75

80

420

240

70

27

0.75

80

420

260

78

21

0.75

80

400

220

66

25

SA-106B

1

80

20

23

8

6

SA-106B SA-106B

1

80

20

12

4

2

1

80

5

4

SA-106B

1

80

20

23

LP remote steam drum LD-01-F LG-X101 w/ LT-X101C (Top Conn) LD-01-G LG-1201 w/ LT-X101C (Bolt Conn) LD-01-H LG-X101 (Drain) LD-01-A LI-X101 w/ LT-X110A (Top Conn) LD-01-B LI-X101 w/ LT-X101A (Bolt Conn) LD-01-C LI-X101 (Drain) LD-01-D LT-X101B w/PT-X103B (Top Conn) LD-01-E LT-X101B w/ PT-X103B (Bolt Conn) LD-01-N PI-X106 Instrumentation IP Instrumentation HP Instrumentation HP Instrumentation Atmospheric blow off tank LD-04-A LG-X103 (Top Conn) LD-04-B LG-X103 (Bolt Conn) PI-X114 TI-X105

1

Flash separator LD-04-A LG-X103 (Top Conn) LD-04-B LG-X103 (Bolt Conn)

8

6

(Continued )

Construction material Chapter | 2

37

(Continued) SB

PI-X114 TI-X105

2.6.8

SB

Material

Size

Sch/ Thk

Pipe

SW

Valve

Instrument

SA-106B SA-106B

1

80

20

12

4

2

1

80

5

4

1

SP-01 AIG piping sheet 8

SP-01 AIG Manifold Connecting Piping Inner connect pipe SP-02 AIG Piping SP-03 AIG Piping SP-04 AIG Piping SP-05 AIG Piping SP-06 AIG Piping SP-07 AIG Piping SP-08 AIG Piping SP-09 AIG Piping SP-10 AIG Piping SP-11 AIG Piping SP-12 AIG Piping SP-13 AIG Piping SP-14 AIG Piping SP-15 AIG Piping SP-16 AIG Piping SP-17 AIG Piping SP-18 AIG Piping SP-19 AIG Piping SP-20 AIG Piping SP-21 AIG Piping SP-22 AIG Piping SP-23 AIG Piping SP-24 AIG Piping SP-25 AIG Piping SP-26 AIG Piping SP-27 AIG Piping SP-28 AIG Piping

Material

Size

Sch/Thk

LB

BW

BU

PS

SA-106-B

10

40

73

3.0

3

2

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 10

40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40

28 21 15 10 30 37 43 49 56 62 68 75 81 33 27 20 15 36 42 48 55 61 67 74 80 87 39

2.0 2.0 2.0 1.0 2.0 2.0 2.0 2.0 2.0 3.0 4.0 4.0 4.0 2.0 2.0 2.0 1.0 2.0 2.0 2.0 2.0 2.0 3.0 3.0 3.0 4.0 2.0

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1

2 2 1 1 2 3 3 3 4 4 4 5 5 2 2 1 1 2 3 3 3 4 4 4 5 5 2

38

Industrial Construction Estimating Manual

2.7 2.7.1

Combined cycle power plant STG vendor piping STG vendor piping sheet 1 SW

Line no.

Material

Size

Sch/ Thk

Pipe

BW

Valve

Boltup

Instrument

PS

2

80

60

20

1

5

2

140 80 40 40 60 60 40 140 40 140 20 40

30 16 8 11 12 10 12 30 14 42 2 9

1 2 1 2 2 2 1 1 3 1 1 3

15 2 1 1 2

Spray water system Pipe

SA-106B

Gland Steam System (15Mo3) Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe

15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3

6 2.5 5 4 6 2 4 6 6 2 2 2

80 80 80 80 80 80 80 80 80 80 80 80

2 1

2

1

1 21 2 24 3

Leak-Off Steam System (15Mo3) Pipe Pipe Pipe Pipe Pipe Pipe Pipe

15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3

2 2 3 3 4 6 6

80 80 80 80 80 80 80

40 40 100 40 40 40 20

15 15 15 10 8 5 8

1 1

304L SS

6

S10S

20

4

1

304L SS

4

S10S

20

7

1

1

304L SS

2

S40S

40

13

1

1

304L SS

1

S40S

20

17

2

2

1 1

1 16 3 2 7

1

Lube oil supply Pipe304L SS Pipe304L SS Pipe304L SS Pipe304L SS

(Continued )

Construction material Chapter | 2

39

(Continued) SW Line no.

Material

Size

Sch/ Thk

Pipe

BW

Valve

Pipe304L SS Pipe304L SS Pipe304L SS Pipe304L SS Pipe304L SS

304L SS

4

S10S

80

21

1

304L SS

2

S40S

20

9

1

304L SS

2

S40S

20

9

1

304L SS

4

S10S

40

13

304L SS

2

S40S

40

13

2.7.2

STG vendor piping sheet 2

1

Boltup

Instrument

4

1

2

1

4

SW Line no.

Material Size Sch/Thk Pipe BW Valve Boltup Instrument PS

Lube Oil Return Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS

12 6 5 6 5 5 10 5 4 4 2.5

S10S S10S S10S S10S S10S S10S S10S S10S S10S S10S S10S

60 20 20 40 20 20 40 20 20 20 20

9 1 4 3 8 9 10 8 1 2 2 9 9 1

304L SS 1.25 S40S 304L SS 2 S40S 304L SS 2 S40S

40 40 40

20 15 1 4

2

2

1 1 1 1

2 1 2

1 1

1 1

Hydrostatic oil, oil purification Pipe-304L SS Pipe-304L SS Pipe-304L SS

PS

4 2 5 (Continued )

40

Industrial Construction Estimating Manual

(Continued) SW Line no.

Material Size Sch/Thk Pipe BW Valve Boltup Instrument PS

Pipe-304L SS

304L SS 2.5 S10S

80

22

2

17

27 11 24

Jacking oil Pipe-304L SS 304L SS Pipe-304L SS 304L SS Pipe-304L SS 304L SS Oil flushing Rubberized hose 304L SS External hydraulic oil Pipe-SS 304L SS Pipe-SS 304L SS Pipe-SS 304L SS Pipe-SS 304L SS

2.7.3

20 S10S 12 S10S 2.5 S10S

60 15 3 120 8 120 32

2

0.75 S40S

20

26

3 2 2 1.5

220 40 240 200

S10S S40S S40S S40S

60 20 80 60

60 15 60 50

STG vendor piping sheet 3 SW

Line no.

Material Size Sch/Thk Pipe BW Valve Boltup Instrument PS

Condensate Condensate Condensate Condensate Condensate

3 2 1.5 1.5 1.5

std 40 s 80 80 80

60 20 40 40 40

11 8 8 8 8

2

Steam turbine drain Steam drain Low-pressure steam Steam turbine Drain Steam drain Steam drain Steam drain Steam drain Steam drain Steam drain Condensate Boiler feedwater Boiler feedwater Steam drains Steam drains Steam drains Steam drains Steam drains Steam drains Steam drains Steam drains

3 6 1.5 6 6 1 1 1 1 1 3 3 3 6 1 1 1 1 1.5 1.5 1.5

80 std 80 80 std 80 80 80 80 80 std std std std 80 80 80 80 80 80 80

60 40 40 40 40 40 40 40 40 40 80 60 60 60 60 60 60 60 60 60 60

5 2 8 6 6 6 6 6 6 6 16 2 12 2 12 2 10.2 4 10.2 10.2 10.2 10.2 10.2 10.2 10.2

5 1 1 1

1 1 1 1 1

2 1 1 2 2 2 2 2 2 2 10 4 4 10 2 2 2 2 2 2 2

1 1 1 1 1 2 2 2 2 2 2 1 1 2 2 2 2 2 2 2 2

(Continued )

Construction material Chapter | 2

(Continued) SW Line no. Steam drains Trim Condensate Steam drains Low-pressure steam Low-pressure steam Low-pressure steam Low-pressure steam Low-pressure steam Low-pressure steam Low-pressure steam Steam drains Steam drains Steam drains Steam drains Steam turbine drain Steam drains Steam drains Hot reheat steam Hot reheat steam

Material Size Sch/Thk Pipe BW Valve Boltup Instrument PS 1.5 1 1 24 1 1 1.5 1.5 2 1.5 2 2 2 2 2 2 2 2 2 2

80 80 80 std 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80

60 20 60 20 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40

14 10 2 8 8 8 8 8 8 16 8 8 8 8 14 8 8 8 8

2 2

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

2 1 2 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

41

Chapter 3

Construction database system 3.1

Introduction

Estimating data systems uses historical data from quantity takeoff quantities and man-hours for estimating new projects of similar equipment or systems. Equipment in process plants, regardless of manufacturer, has processes similar to previously designed units where only the size and weight change. The duplication of design enables the estimator to set up cost codes, summarize and analyze historical data and trends, and maintain craft man-hour databases. This chapter will enable the estimator to collect, verify, and analyze historical data to develop man-hour tables that can be used to set up and implement a man-hour database system using comparable cost and man-hour data to estimate future projects.

3.2

Construction database

Collection of historical data must be a systematic method of categorizing the information using a standard structure referred to as a code of accounts. Before you can effectively collect and analyze historical data, you must have a coding system in place. The job cost by cost code and type is used to describe the task and cost type to describe the man-hours associated with the task. After historical data has been collected, it must be verified by graphic and statistical analysis. Evaluation of the data reduces inconsistencies within the data and correlation will determine if the data is acceptable. This step is critical in the development of a database. The field provides the field data report and the estimator develops a man-hour database that is used to estimate and validate historical data to estimate future projects.

3.3

Development of industrial construction database

“Construction-based estimating data” is an estimating database that uses historical data from quantity takeoff and direct craft labor man-hours as a tool for bidding new projects of similarly designed equipment or systems. Most equipment and systems in industrial process plants have designs similar to

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00003-X © 2020 Elsevier Inc. All rights reserved.

43

44

Industrial Construction Estimating Manual

previously designed systems except for size and weight. This duplication of design enables the estimator to cost code, collect, summarize, and verify field data to develop a man-hour database to estimate new projects of similar design. Development of construction-based estimating database for industrial process plants: l

l

l

l

l

l l l

The quantity takeoff is developed during the bid preparation and quantifies the materials. The scope of work is defined and the erection sequence is based on the duplication of design. Cost codes are used to describe the task and cost type to describe task man-hours. Two methods for the measurement of construction time are used to compile the man-hour data l nonrepetitive one-cycle time study l field data report. The detailed estimate is prepared by combining the unit method and unit quantity method unit method unit quantity model. Excel estimate spreadsheet, based on the Unit Quantity Model, calculates the craft labor.

3.3.1

Benefits of unit man-hour database

The database creates efficiency, quality, and speed and with software is accessible to everyone. l

l l

l

l

l l

l

It uses historical data from field civil, structural, piping, and mechanical work. It develops historical data from material takeoff quantities. It keeps accurate records of man-hour labor productivity and revises the database constantly. It uses labor man-hours as a tool for estimating new projects of similar mechanical and civil systems. It compares data similarities to actual cost and time spent on work activities with those of the estimate. It provides an accurate basis for determining labor productivity. It tracks field-labor productivity for civil, structural, piping, and mechanical to build a historical database. It tracks the cost basis that provides transparency for change orders eliminating disputes.

Construction database system Chapter | 3 l

45

It publishes company man-hour tables that must be validated and clarified using statistical analysis.

3.4

Piping man-hour database

The development of underground cast iron piping database for industrial process plants: The historical data is collected on site every day and summarized in a spreadsheet to be verified by regression analysis. Based on data collected in the field on Project X, the unit rate summary for pipe set and align CI Pipe is summarized in the next.

3.4.1

Pipe set and align, cast iron—lead and mechanical joint

Facility—industrial plant (underground drainage piping) Pipe size (in.)

Pipe set and align (MH/lf)

4 6 8 10 12 16 18 20 24

0.12 0.18 0.24 0.30 0.36 0.48 0.54 0.60 0.72

Pipe man-hours include handle, haul, place, and align in trench

3.4.2

Verify historical data for cast iron pipe—pipe set and align

Facility—industrial plant (underground drainage piping) Data for input: Pipe set and align, cast iron—lead and mechanical joint Man-hour (Y): R1 5 0.12, 0.18, 0.24, 0.30, 0.36, 0.48, 0.54, 0.60, 0.72 Pipe size, inches (X): R2 5 4, 6, 8, 10, 12, 16, 18, 20, 24 Man-hour per lf (Fig. 3.1)

MH/lf, Y

1 0.5 0

Series1

Y = 0.03× R² = 1

0

Linear (Series1)

10

20 Pipe size, X

FIGURE 3.1 Pipe set and align, cast iron.

30

Linear (Series1)

46

Industrial Construction Estimating Manual

X

Y

Pipe size

MH/lf

4 6 8 10 12 16 18 20 24

0.12 0.18 0.24 0.30 0.36 0.48 0.54 0.60 0.72

Covar (R1, R2) Varp (R2) Slope (R1, R2) Intercept (R1, R2)

1.23 0.04 0.0300 0.0000

The coefficient of determination, R2, is exactly 11 and indicates a positive fit. All data points lie exactly on the straight line. The relationship between X and Y variables is such that as X increases, Y also increases.

3.4.3 joint

Mechanical joint MH/JT, cast iron—lead and mechanical

Facility—industrial plant (underground drainage piping) Pipe size (in.)

Mechanical joint (MH/JT)

4 6 8 10 12 16 18 20 24

0.80 1.20 1.60 2.00 2.40 3.20 3.60 4.00 4.80

Pipe man-hours include handle, haul, place, and align in trench

Construction database system Chapter | 3

47

3.4.4 Verify historical data for cast iron pipe—mechanical joint MH/JT Facility—industrial plant (underground drainage piping) Data for Input: Mechanical joint MH/JT, cast iron—lead and mechanical joint Man-hour (Y): R1 5 0.80, 1.20, 1.60, 2.00, 2.40, 3.20, 3.60, 4.00, 4.80 Pipe size, inches (X): R2 5 4, 6, 8, 10, 12, 16, 18, 20, 24 Man-hour per lf (Fig. 3.2) X

Y

Pipe size

MH/JT

4 6 8 10 12 16 18 20 24

0.80 1.20 1.60 2.00 2.40 3.20 3.60 4.00 4.80

Covar (R1, R2) Varp (R2) Slope (R1, R2) Intercept (R1, R2)

8.20 1.64 0.2000 0.0000

The coefficient of determination, R2, is exactly 11 and indicates a positive fit. All data points lie exactly on the straight line. The relationship between X and Y variables is such that as X increases, Y also increases.

MH/JT, Y

6 2 0

Series1

Y = 0.2×-2E-15 R² = 1

4

0

10

Linear (Series1) 20

Pipe size, X FIGURE 3.2 Mechanical joint, cast iron.

30

Linear (Series1)

48

Industrial Construction Estimating Manual

3.4.5 joint

Handle and install fitting, cast iron—lead and mechanical

Facility—industrial plant (underground drainage piping) Pipe size (in.)

Handle install fitting (MH/ea.)

4 6 8 10 12 16 18 20 24

0.24 0.36 0.48 0.60 0.72 0.96 1.08 1.20 1.44

Pipe man-hours include handle, haul, place, and align in trench

3.4.6 Verify historical data for cast iron pipe—handle and install fitting Facility—industrial plant (underground drainage piping) Data for input: Handle and install fitting, cast iron—lead and mechanical joint Man-hour (Y): R1 5 0.24, 0.36, 0.48, 0.60, 0.72, 0.96, 1.08, 1.20, 1.44 Pipe size, inches (X): R2 5 4, 6, 8, 10, 12, 16, 18, 20, 24 Man-hour per lf (Fig. 3.3) X

Y

Pipe size

MH/ea.

4 6 8 10 12

0.24 0.36 0.48 0.60 0.72

MH/ea. Y

(Continued )

2 1 0

Series1

Y = 0.06× R² = 1 0

Linear (Series1)

10

20

Pipe size, X FIGURE 3.3 Handle and install fitting, cast iron.

30

Linear (Series1)

Construction database system Chapter | 3

49

(Continued) X

Y

Pipe size

MH/ea.

16 18 20 24

0.96 1.08 1.20 1.44

Covar (R1, R2) Varp (R2) Slope (R1, R2) Intercept (R1, R2)

2.46 0.15 0.0600 0.0000

The coefficient of determination, R2, is exactly 11 and indicates a positive fit. All data points lie exactly on the straight line. The relationship between X and Y variables is such that as X increases, Y also increases.

3.4.7 Verification of cast iron underground piping by regression analysis l l l

Pipe set and align, MH/lf; R2 5 1 Mechanical joint, MH/JT; R2 5 1 Handle and install fitting, MH/ea.; R2 5 1

R2 5 1 indicates the model and fits the data. The historical data collected, summarized, and analyzed using the regression model is verified and the estimator sets up the unit man-hour table, for cast iron piping, to include in the piping database.

3.4.8

Handle and install pipe, cast iron—lead and mechanical joint

Facility—industrial plant (underground drainage piping) Pipe size (in.)

Pipe set and align (MH/lf)

Lead and mechanical joint (MH/JT)

Handle install fitting (MH/ea.)

4 6 8 10 12 16 18

0.12 0.18 0.24 0.30 0.36 0.48 0.54

0.80 1.20 1.60 2.00 2.40 3.20 3.60

0.24 0.36 0.48 0.60 0.72 0.96 1.08 (Continued )

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Industrial Construction Estimating Manual

(Continued) Pipe size (in.)

Pipe set and align (MH/lf)

Lead and mechanical joint (MH/JT)

Handle install fitting (MH/ea.)

20 24

0.60 0.72

4.00 4.80

1.20 1.44

Pipe man-hours include handle, haul, place, and align in trench

3.5 Illustrative examples of database for civil, structural and miscellaneous steel, and pipeline 3.5.1

Civil database for hydrogen plant

Facility: Hydrogen plant—earthwork Earthwork Mass machine excavation—depth to 60 Machine excavation for single foundations Mass machine backfill Machine backfill foundations Dispose of surplus material Finished grading with 6v thick gravel Access roads heavy substructure and 6v thick gravel Ground water lowering Facility: Hydrogen plant—concrete works Concrete works Blinding concrete Foundation slabs—4000PSI Footing concrete—4000PSI Pier concrete—4000PSI Elevated floor slab concrete Concrete walls Thk. 8v10v Reinforcement bars PVC membrane, 0.2 mm Formwork Extra over for formwork Anchor bolts 6/8 to 2v hot-dip galv. Nonshrink grout (cementitious) Epoxy grout, high strength Exp joints Water stop Embedded items Extra over for compressive strength Templates for columns and vessels Compressor concrete Compressor Rebar

MH 0.339 0.400 0.470 0.737 0.355 0.050 0.084 0.028

Unit cy cy cy cy cy sf sf sf

MH 0.013 1.831 2.310 2.751 3.850 3.852 0.007 0.002 0.187 0.088 0.088 0.242 0.827 0.109 0.110 0.088 0.088 0.088 1.955 13.800

Unit sf cy cy cy cy cy lb sf sf sf lb CF CF lf lf lb cy lb cy ton

Construction database system Chapter | 3

Facility: Hydrogen plant—miscellaneous Miscellaneous PVC cable conduits d 5 6v, underground Sewer system, PVC pipe d 5 6v/8v Fencing 80 high with five lines of barbed wire and one 200 wide gate Gates for access roads Fencing for transformer bays, including two doors, framed wire mesh Oil-resistant paint Storm water U/G RCP 12v diameter Storm water U/G RCP 18v diameter Manholes, cast-in-place Catch basins, cast-in-place Outlet structure, cast-in-place

3.5.2

MH 1.1 1.1 0.198 25.5 0.715 0.053 1 1.5 8 12 240

51

Unit lf lf lf ea. lf sf lf lf ea. ea. ea.

Facility—industrial plant (simple foundation) MH/ cy

Structure excavation—backhoe Structure excavation—hand Structure backfill and compact— loader and Wacker Structure backfill and compact— hand Edge forms—slabs and foundations Fabricate, install, strip foundation forms—1 use Fabricate, install, strip pedestal forms—1 use Fabricate, install, strip wall forms—1 use Fabricate and install reinforcing steel Layout templates and set anchor bolts Set embedded steel—curb angle, etc. Place concrete—from truck below grade Place concrete—slabs at grade Place concrete—pedestals and walls Finish flat concrete Patch and sack concrete Install mesh

MH/ sf

MH/ lf

MH/ lb

MH/diameter in. ft.

0.20 2.80 0.60 3.00 0.10 0.30 0.25 0.20 0.03 0.25 0.04 0.80 1.00 2.00 0.12 0.05 0.02

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Industrial Construction Estimating Manual

3.5.3 Structural and miscellaneous steel database for combined cycle power plant Facility: Combined cycle power plant—structural steel HRSG utility steel bridge

MH

Unit

Light—019 lb/ft.; # 20 ton 28.0 ton Medium—2039 lb/ft.; $ 20 ton 18.0 ton Heavy—4079 lb/ft.; .100 ton 13.2 ton X heavy—80120 lb/ft.; $ 20 ton 12.0 ton STG utility bridge steel Light—019 lb/ft.; # 20 ton 28.0 ton Medium—2039 lb/ft.; $ 20 ton 18.0 ton Medium—2039 lb/ft.; $ 20 ton 18.0 ton X heavy—80120 lb/ft.; $ 20 ton 12.0 ton STG utility bridge steel inside enclosure Light—019 lb/ft.; # 20 ton 28.0 ton Medium—2039 lb/ft.; # 20 ton 18.0 ton Heavy—4079 lb/ft.; . 100 ton 13.2 ton X heavy—80120 lb/ft.; # 20 ton 12.0 ton GSU transformer access platforms Light and medium 26.0 ton Stair tower and ladders Light and medium 26.0 ton Stair treads 0.85 ea. Caged ladders 0.35 lf Iso phase support steel Light and medium 26.0 ton Dead end structure Light and medium 26.0 ton 230 kV switchyard structure including bus supports Light and medium 26.0 ton Transmission line poles Light and medium 26.0 ton Grating, handrail, and toe plate 2v serrated floor grating 0.20 sf 1.5v serrated floor grating 0.20 sf Handrail and toe plate 0.25 lf

3.5.4

Pipeline database

Underground piping labor units

Labor

Minimum

C.S.B. weld to 0.500 Thk. Handling Tape wrap welds Boltups Valves and specialties

0.35 MH/diameter in. 0.012 MH/diameter in. ft. 0.10 MH/diameter in. 0.15 MH/bolt 0.20 MH/diameter in.

1.00 MH/weld 0.08 MH/lf 0.50 MH/JT 0.60 MH/boltup 0.20 MH/valve (Continued )

Construction database system Chapter | 3

53

(Continued) Underground piping labor units Above ground piping labor units C.S.B. weld to 0.500 Thk. Handling Boltups Valves and specialties 150# and 300# Valves and specialties 600# and 900# O-lets and nozzles Tie-Ins Socket welds Screwed joints Trench work for piping Excavation: Large trenches (75 1 cy per location) Intermediate trenches (2074 cy per location) Small trenches (less than 20 cy per location) Backfill and compaction: Large volume (75 1 cy per location) Intermediate volume (2074 cy per location) Small trenches (less than 20 cy per location) Load, haul, and dump: Dump site within 30 min of job Sand bedding and cover

3.5.5

Labor

Minimum

0.40 MH/diameter in. 0.02 MH/diameter in. ft. 0.20 MH/bolt 0.20 MH/diameter in. 0.40 MH/diameter in. 2.0 3 butt weld 3.0 3 butt weld 0.50 MH/diameter in. 0.20 MH/diameter in. Labor man-hours

1.00 MH/weld 0.08 MH/lf 0.80 MH/boltup 0.20 MH/valve 0.40 MH/valve

0.80 MH each 0.20 MH/JT

0.04 MH/cy 0.25 MH/cy 0.50 MH/cy

0.04 MH/cy 0.40 MH/cy 0.67 MH/cy

0.04 MH/cy 0.25 MH/cy

Schedule A—combined cycle power plant piping

Standard labor estimating units Facility—combined cycle power plant

Large bore piping

Small bore piping

Unit of measure

Unit of measure

Description

Man-hours per unit

Man-hours per unit

Handle and install pipe, carbon steel, welded joint WT # 0.375v 0.406v # WT # 0.500v 0.562v # WT # 0.688v 0.718v # WT # 0.938v 1.031v # WT # 1.219v

Diameter inch feet

MH/lf

0.07 0.09 0.11 0.14 0.20

0.18 0.23 0.28 0.35 0.50 (Continued )

54

Industrial Construction Estimating Manual

(Continued) Standard labor estimating units Facility—combined cycle power plant

Large bore piping

Small bore piping

Unit of measure

Unit of measure

Description

Man-hours per unit

Man-hours per unit

1.250v # WT # 1.312v Welding butt welds, carbon steel, Arc-uphill WT # 0.375v 0.406v $ WT # 0.500v 0.562v $ WT # 0.688v 0.718v $ WT # 0.938v (PWHT) 1.031v $ WT # 1.219v (PWHT) 1.250v # WT # 1.312v (PWHT) Olet—SOL, TOL, WOL Stub in Socketweld PWHT craft support labor Boltup of flanged joints by weight class 150#/300# boltup 600#/900# boltup 1500#/2500# boltup Handle valves by weight class 150# and 300# manual valves 600# and 900# manual valves Heavier manual valve $ 1500#

0.25 Diameter inch 0.50 0.55 1.05 1.20 1.45 2.20 2 3 BW 1.5 3 BW

0.75 MH/ea. 1.10 1.20 2.20 2.45 2.70 4.40 2 3 BW 1.5 3 BW Per SW table 1.00 MH/ea. 1.00 1.20 1.60 MH/ea. 1.00 1.80 2.00

3.6 3.6.1

0.45 Diameter inch 0.40 0.50 0.65 Diameter inch 0.45 0.90 1.80

Balance of plant equipment estimating database Set, align, couple, and grout pumps Description

MH

Unit

Pumps—set, align, couple, and grout Motor horsepower less than 15 Motor horsepower 1530 Motor horsepower 3150 Motor horsepower 51100 Motor horsepower 101125 Motor horsepower 126300 Motor horsepower 301500 Motor horsepower more than 500 Vacuum pumps—motor horsepower 030

20.00 2.10 1.80 1.60 1.40 1.30 1.00 0.80 1.00

ea. HP HP HP HP HP HP HP HP

(Continued )

Construction database system Chapter | 3

(Continued) Description Table-Rig, set, and align, weld tanks and vessels Horizontal tanks and vessels Weight range tons 05 Weight range tons 610 Weight range tons 1120 Table-Rig, set, and align factory assembled skids Skid-mounted unit weight (lb) 03000 Skid-mounted unit weight (lb) 30016000 Skid-mounted unit weight (lb) 600115,000 Table-Rig, set, and align heater Preheater and heater weight (lb) 0500 Preheater and heater weight (lb) 5011500 Preheater and heater weight (lb) 15012000 Table-Rig, set, and align compressors Fuel gas compressor 500 HP, weight 45,000 lb Gas compressor cooler-package unit 1 and 2 02000 lb Air compressor A/B 05000 lb Table-Rig, set, and align heat exchangers Closed cooling water heat exchanger A/B/C Tale-Rig, set, and align eyewash/shower Eyewash/shower

MH

Unit

60 90 140

ea. ea. ea.

28 40 60

ea. ea. ea.

30 50 80

ea. ea. ea.

27.6 60 100

ton ea. ea.

60

ea.

32

ea.

55

Chapter 4

Construction labor estimate 4.1

Introduction

This chapter presents the principles of the labor estimate. Labor, material, and equipment cost are the basis for the detailed labor estimate, and these elements must be determined efficiently. Detailed labor estimates determine the direct craft labor and man power requirements for the project. The initial labor estimate is the basis for the estimator to obtain the project schedules. Estimators use statistical and mathematical equations, and construction databases, which are entered into the computer, that model the work of construction. The estimator must set up cost codes, summarize, and analyze labor productivity and trends, and compare data similarities to actual cost and time spent on work activities with those of the estimate. Construction-work estimating data sets, or books, for construction analysis and cost estimating are popular sources of information. With all the combinations of construction and engineering design, labor skill, material, construction equipment, and methods and procedures, the contractor should develop and maintain their own data sets. Estimating data must be verified by statistical analysis, field data reports and the data must be updated and maintained. Construction-work estimating references are useful as a secondary resource if the data is verified by analysis and the work scope is comparable to future content.

4.2 l

l l l

l

l

Elements of construction-work estimate

The quantity takeoff: It is developed during the bid preparation and quantifies the materials required to complete the project. Labor hour: This basic unit is defined as one worker working for 1 hour. Labor cost: Man-hour 3 labor rate. Material cost: It is to ensure a complete cost of material requirements associated with the installation of the materials. Equipment cost: Cost for rental rates for third party equipment and company-owned equipment. Subcontractor quotes: Cost for subcontractors to complete parts of the construction.

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00004-1 © 2020 Elsevier Inc. All rights reserved.

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58

4.3

Industrial Construction Estimating Manual

Construction-work estimating

The work estimate is created using construction-work elements identified in the project material estimate. Estimating worksheets are used to develop the labor estimate. Unit-quantity method—model for estimating The model for detailed estimating based on the unit-quantity method: X The unit-quantity model is given by: MHµ 5 ni ðMHa Þ where MHµ is the quantity ni, unit man-hours for field construction work; ni is the task takeoff quantity I, in dimensional units; MHa is the average unit man-hour per quantity ni; µ is the Task 1, 2, k from quantity takeoff associated w/construction work. The ni quantity is the takeoff for the field scope of work. MHa man-hours are determined from field construction man-hour tables. The model focuses on the quantity ni. MHa is the required unit man-hour to install takeoff field task determined from field construction labor tables. Many different work variations can be illustrated with the unit-quantity method.

4.4 Four scopes of work illustrate estimate worksheets using the unit-quantity model 4.4.1 Combined cycle power plant; boiler foundations—HRSG Stack and HRSG Size

Quantity

Unit MH

Total MH

Work; material takeoff

L

W

H

ni

Unit

MHa

ni MHa

Excavation Forms Rebar Concrete Mud mat Backfill, compact Column total

200 204

50 55

5 5

200 204

50 54

5 0.33

2037.0 2580.0 107.0 1944.4 136.0 80.0

cy sf ton cy cy cy

0.400 0.350 14.0 2.0 0.500 0.631

814.7 903.0 1498.0 3888.9 68.0 50.5 7223.1

Construction labor estimate Chapter | 4

4.4.2 steel

59

Combined cycle power plant—structural and miscellaneous

Unit MH

Total MH

Description

ni

Unit

HRSG utility steel bridge Light—019 lb/ft. Medium—2039 lb/ft. Heavy—4079 lb/ft. X heavy—80120 lb/ft. STG utility bridge steel Light—019 lb/ft. Medium—2039 lb/ft. Heavy—4079 lb/ft. X heavy—80120 lb/ft. STG utility bridge steel inside enclosure Light—019 lb/ft. Medium—2039 lb/ft. Heavy—4079 lb/ft. X heavy—80120 lb/ft. GSU transformer access platforms Light and medium Stair tower and ladders Light and medium Stair treads Ladders Iso-phase support steel Light and medium Dead-end structure Light and medium 230 kV Switchyard structure including bus supports Light and medium Transmission line poles Light and medium Grating, handrail, and toe plate 2v serrated floor grating 1.5v serrated floor grating Handrail and toe plate Total structural and miscellaneous steel MH/ton

204.6 11.0 33.0 105.6 55.0 187.0 8.4 27.9 99.0 51.7 37.4 1.7 5.6 19.8 10.3 13.5 13.5 14.2 10.4 300.0 200.0 33.0 33.0 33.0 33.0 16.5

ton ton ton ton ton ton ton ton ton ton ton ton ton ton ton ton ton ton ton ea. lf ton ton ton ton ton

16.5 6.0 6.0 17.1 11,200.0 4100.0 2100.0 562.2 21.1

ton ton ton ton sf sf sf ton

MHa 24 23 18 16 24 23 18 16 24 23 18 16 23 23 0.55 0.30 23 23

23 23 0.05 0.05 0.15

ni MHa 3803.8 264 759 1900.8 880 3452.5 201.6 641.7 1782 827.2 690.8 40.8 128.8 356.4 164.8 310.5 310.5 464.2 239.2 165 60 759 759 759 759 379.5 379.5 138 138 1080 560 205 315 11,837.3

GSU, Generator step-up transformer; HRSG, Heat recovery steam generator; STG, steam turbine generator.

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Industrial Construction Estimating Manual

4.4.3

Refinery—vessels/columns Quantity

Unit MH

Total MH ni MHa

Description

ni

Unit

MHa

Solvent absorber 80 2 6v D 3 690 2 0v, 319.7 ton Unload, handle, haul up to 20000 , rig, set and align, make up Fdn AB Install platforms Install caged ladders Remove and replace manway cover (24v 300# Removable-Davit) Install double downflow valve trays (16 trays) Install demisting pads (single grid-support, pad, grid-top) Vortex breaker Packing (pall rings) Rich solvent flash drum 70 2 0v D 3 240 2 0v; 14.9 ton Unload, handle, haul up to 20000 , rig, set and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300# Hinged) Inlet box Vortex breaker Install demisting pads (single grid-support, pad, grid-top) Solvent regenerator 80 2 0v D 3 720 2 6v; 39 ton Unload, handle, haul up to 20000 , rig, set and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300# Removable-Davit) Install double downflow valve trays (12 trays) Install demisting pads (single grid-support, pad, grid-bottom) Vortex breaker Packing (pall rings) Solvent regenerator reflux drum 50 2 0v D 3 150 2 0v; 2.6 ton Unload, handle, haul up to 20000 , rig, set and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300# Hinged)

319.7 319.7

ton ton

1.9

1839 600

12 100 1

ea. lf ea.

32 0.35 40

384 35 40

16 1

ea. ea.

40 60

640 60

1 1 14.9

ea. lot ton

32 48

32 48 416

14.9

ton

10.8

160

2 1

ea. ea.

32 40

64 40

1 1 1

ea. ea. ea.

60 32 60

60 32 60

39 39.0

ton ton

8.2

1140 320

5 1

ea. ea.

32 40

160 40

12 1

ea. ea.

40 60

480 60

1 1 2.6

ea. lot ton

32 48

32 48 276

2.6

ton

30.6

80

2 1

ea. ea.

32 40

64 40

1

ea.

60

60 (Continued )

Construction labor estimate Chapter | 4

61

(Continued) Quantity

Unit MH

Total MH

Description

ni

Unit

MHa

ni MHa

Install demisting pads (single grid-support, pad, grid-top) Vortex breaker Total vessels/columns MH/ton

1 376.2 9.8

ea. ton

32

32 3671

4.4.4

Gasifier—Feedstock Bunker A and B Quantity

Description Feedstock Bunker A and B Feedstock Bunker A 400 D 3 1010 Receive, transport material, lift, and set Handle sheets per ring 6 ea. 3 400 3 8 2 30 total 9 rings 3 6 sheets 5 54 sheets Fit and weld vertical 0.75v WT CS 6 3 80 2 3v 3 9 rings 448 weld DI Fit and weld horizontal 0.75v WT CS 8 3 251.30 2011 weld DI Overlay stainless steel liner Feedstock Bunker B 400 D 3 1010 Receive, transport material, lift, and set Handle sheets per ring 6 ea. 3 400 3 8 2 30 total 9 rings 3 6 sheets 5 54 sheets Fit and weld vertical 0.75v WT CS 6 3 80 2 3v 3 9 rings 448 weld DI Fit and weld horizontal 0.75v WT CS 8 3 251.30 2011 weld DI Overlay stainless steel liner

4.5 4.5.1

Unit MH

Total MH

MHa

ni MHa

ni

Unit

231 231 54

ton ton ea.

1.4 12

7449 3724 320 648

448

DI

1.1

504

2011

DI

0.35

704

1 231 231 54

job ton ton ea.

1548 1.4 12

1548 3724 320 648

448

DI

1.1

504

2011

DI

0.35

704

1

job

1548

1548

Typical process piping estimate Field Erect-HRSG HP piping and supports

Facility—Combined cycle power plant Triple-pressure w/Reheat for F-Class GT-Three Wide

62

Industrial Construction Estimating Manual

4.5.2 Estimate sheet—Handle and install pipe-welded joint Pipe handle Description

Size

lf

HP piping and supports Sch 140/ 8 25 0.906v, SA106 B, HP03 Econ 1 to HP Econ 2 Sch 160/ 6 42 0.906v, SA106 B, HP03 Econ 1 to HP Econ 2 Sch 140/ 8 96 0.812v, SA106 B, HP04 Econ 2 to HP steam drum Sch 160/ 6 1 0.906v, SA106 C, HP04 Econ 2 to HP steam drum Sch 160/ 6 24 0.906v, SA106 B, HP09 steam drum to HP SH 1 6 23 Sch 160/ 0.906v, SA106 B, HP10 steam drum to HP SH 1 6 23 Sch 160/ 0.906v, SA106 B, HP11 steam drum to HP SH 1 6 23

PF

Hydro

PF

Total

DIF

MH/ DIF

MH

DIF

MH/ DIF

MH

MH

200

0.14

28

200

0.134

27

55

252

0.14

35

252

0.101

25

61

768

0.14

108

768

0.134

103

211

6

0.14

1

6

0.101

1

1

144

0.14

20

144

0.101

15

35

138

0.14

19

138

0.101

14

33

138

0.14

19

138

0.101

14

33

138

0.14

19

138

0.101

14

33

(Continued )

63

Construction labor estimate Chapter | 4

(Continued) Pipe handle Description Sch 160/ 0.906v, SA106 B, HP12 steam drum to HP SH 1 Sch 160/ 0.906v, SA106 B, HP13 steam drum to HP SH 1 Sch 160/ 0.906v, SA106 B, HP14 steam drum to HP SH 1 1.25v WT, SA-335 P91, HP-15 SHTR 1 to HP SHTR 2 1.031v WT, SA-335 P91, HP-15 SHTR 1 to HP SHTR 2 SA-335 P91, HP-15 SHTR 1 to HP SHTR 2 1.25v WT, SA-335 P91, HP-16 SHTR 1 to HP SHTR2 1.032v WT, SA-335 P91, HP-16 SHTR 1 to HP SHTR 2

PF

Hydro

PF

Total

Size

lf

DIF

MH/ DIF

MH

DIF

MH/ DIF

MH

MH

6

23

138

0.14

19

138

0.101

14

33

6

23

138

0.14

19

138

0.101

14

33

10

68

680

0.25

170

680

0.240

163

333

8

3

24

0.20

5

24

0.192

5

9

3

1

3

0.20

1

3

0

1

10

68

680

0.25

170

680

0.240

163

333

8

3

24

0.20

5

24

0.192

5

9

3

1

3

0.20

1

3

0

1

(Continued )

64

Industrial Construction Estimating Manual

(Continued) Pipe handle Description SA-335 P91, HP-16 SHTR 1 to HP SHTR 2 1.25v WT, SA-335 P91, HP-17 SHTR 1 to HP SHTR 2 1.031v WT, SA-335 P91, HP-17 SHTR 1 to HP SHTR 2 SA-335 P91, HP-17 SHTR 1 to HP SHTR 2 Column total

PF

Hydro

PF

Total

Size

lf

DIF

MH/ DIF

MH

DIF

MH/ DIF

MH

MH

10

68

680

0.25

170

680

0.240

163

333

8

3

24

0.20

5

24

0.192

5

9

3

1

3

0.20

1

3

0

1

519

4181

815

4181

744

1558

Facility—Combined cycle power plant Triple-pressure w/Reheat for F-Class GT-Three Wide

4.5.3 Estimate sheet 2—Welding: BW, SW, PWHT arc-uphill

Description

Size

HP piping and supports Sch 140/ 8 0.906v, SA106 B, HP-03 Econ 1 to HP Econ 2 6 Sch 160/ 0.906v, SA106 B, HP-03 Econ 1 to HP Econ 2

BW

SW

JT

JT

9

9

BW

SW

PWHT

PF

DI

MH/ DI

MH/ JT

Factor

MH/ JT

MH

0

1.20

1.4

1.0

0

0

54

1.20

1.4

1.0

0.5

102

(Continued )

Construction labor estimate Chapter | 4

65

(Continued) BW

SW

BW

SW

PWHT

PF

Description

Size

JT

JT

DI

MH/ DI

MH/ JT

Factor

MH/ JT

MH

Sch 140/ 0.812v, SA106 B, HP-04 Econ 2 to HP steam drum Sch 160/ 0.906v, SA106 C, HP-04 Econ 2 to HP steam drum Sch 160/ 0.906v, SA106 B, HP-09 steam drum to HP SH 1 Sch 160/ 0.906v, SA106 B, HP-10 steam drum to HP SH 1 Sch 160/ 0.906v, SA106 B, HP-11 steam drum to HP SH 1 Sch 160/ 0.906v, SA106 B, HP-12 steam drum to HP SH 1 Sch 160/ 0.906v, SA106 B, HP-13 steam drum to HP SH 1 Sch 160/ 0.906v, SA106 B, HP-14 steam drum to HP SH 1 1.25v WT, SA335 P91, HP15 SHTR 1 to HP SHTR 2

8

4

6

32

1.20

1.4

1.0

0.5

61

6

3

18

1.20

1.4

1.0

0.5

30

6

4

4

24

1.20

1.4

1.0

0.5

45

6

3

4

18

1.20

1.4

1.0

0.5

35

6

4

4

24

1.20

1.4

1.0

0.5

45

6

3

4

18

1.20

1.4

1.0

0.5

35

6

4

4

24

1.20

1.4

1.0

0.5

45

6

3

4

18

1.20

1.4

1.0

0.5

35

10

4

5

40

2.2

1.4

2.8

0.5

279

(Continued )

66

Industrial Construction Estimating Manual

(Continued) BW

SW JT

Description

Size

JT

1.031v WT, SA-335 P91, HP-15 SHTR 1 to HP SHTR 2 SA-335 P91, HP-15 SHTR 1 to HP SHTR 2 1.25v WT, SA335 P91, HP16 SHTR 1 to HP SHTR 2 1.032v WT, SA-335 P91, HP-16 SHTR 1 to HP SHTR 2 SA-335 P91, HP-16 SHTR 1 to HP SHTR 2 1.25v WT, SA335 P91, HP17 SHTR 1 to HP SHTR 2 1.031v WT, SA-335 P91, HP-17 SHTR 1 to HP SHTR 2 SA-335 P91, HP-17 SHTR 1 to HP SHTR 2 Column total

8

2

3

5

BW

SW

PWHT

PF

DI

MH/ DI

MH/ JT

Factor

MH/ JT

MH

16

1.45

1.4

2.5

0.5

65

0

0

1.4

1.495

0

0

40

2.2

1.4

2.8

0.5

279

16

1.45

1.4

2.5

0.5

65

10

4

8

2

3

0

0

0

1.20

1.4

1.495

10

4

5

40

2.2

1.4

2.8

0.5

279

8

2

16

1.45

1.4

2.5

0.5

65

3

0

55

54

0

1.495

398

Facility—Combined cycle power plant Equipment—Triple-pressure w/Reheat for F-Class GT-Three Wide

0

1467

Construction labor estimate Chapter | 4

67

4.5.4 Estimate sheet 3—Boltup of flanged joint by weight class

Description

Size

150#/ 300#

600#/ 900#

1500#/ 2500#

Boltup

Boltup

Boltup

DI

MH/ DI

MH/ DI

MH/ DI

MH

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

0

0

0

0.40

0.50

0.65

0

HP piping and supports HP-03 Econ 8 0 1 to HP Econ 2 HP-03 Econ 6 0 1 to HP Econ 2 8 0 HP-04 Econ 2 to HP steam drum HP-04 Econ 6 0 2 to HP steam drum HP-09 6 0 steam drum to HP SH 1 HP-10 6 0 steam drum to HP SH 1 HP-11 6 0 steam drum to HP SH 1 HP-12 6 0 steam drum to HP SH 1 HP-13 6 0 steam drum to HP SH 1 HP-14 6 0 steam drum to HP SH 1 HP-15 SHTR 10 0 1 to HP SHTR 2 HP-15 SHTR 8 0 1 to HP SHTR 2 HP-15 SHTR 3 0 1 to HP SHTR 2

PF

(Continued )

68

Industrial Construction Estimating Manual

(Continued) 150#/ 300#

600#/ 900#

1500#/ 2500#

PF

Description

Size

Boltup

Boltup

Boltup

DI

MH/ DI

MH/ DI

MH/ DI

MH

HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 Column total

10

0

0

0

0

0.40

0.50

0.65

0

8

0

0

0

0

0.40

0.50

0.65

0

3

0

0

0

0

0.40

0.50

0.65

0

10

0

0

0

0

0.40

0.50

0.65

0

8

0

0

0

0

0.40

0.50

0.65

0

3

0

0

0

0

0.40

0.50

0.65

0

0

0

Facility—Combined cycle power plant Equipment—Triple-pressure w/Reheat for F-Class GT-Three Wide

4.5.5 Estimate sheet 4—Handle valves by weight class Description HP piping and supports

Size

150#/ 300#

600#/ 900#

1500#/ 2500#

Valve

Valve

Valve

DI

MH/ DI

MH/ DI

MH/ DI

MH

0

0

0

0.45

0.90

1.8

0

0

0

0

0.45

0.90

1.8

0

HP-03 Econ 1 to HP Econ 2 HP-03 Econ 1 8 0 to HP Econ 2 HP-04 Econ 2 6 0 to HP steam drum

PF

(Continued )

Construction labor estimate Chapter | 4

69

(Continued) Description

150#/ 300#

600#/ 900#

1500#/ 2500#

PF

HP piping and supports

Size

Valve

Valve

Valve

DI

MH/ DI

MH/ DI

MH/ DI

MH

HP-04 Econ 2 to HP steam drum HP-09 steam drum to HP SH 1 HP-10 steam drum to HP SH 1 HP-11 steam drum to HP SH 1 HP-12 steam drum to HP SH 1 HP-13 steam drum to HP SH 1 HP-14 steam drum to HP SH 1 HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2

8

0

0

0

0

0.45

0.90

1.8

0

6

0

0

0

0

0.45

0.90

1.8

0

6

0

0

0

0

0.45

0.90

1.8

0

6

0

0

0

0

0.45

0.90

1.8

0

6

0

0

0

0

0.45

0.90

1.8

0

6

0

0

0

0

0.45

0.90

1.8

0

6

0

0

0

0

0.45

0.90

1.8

0

6

0

0

0

0

0.45

0.90

1.8

0

10

0

0

0

0

0.45

0.90

1.8

0

8

0

0

0

0

0.45

0.90

1.8

0

3

0

0

0

0

0.45

0.90

1.8

0

10

0

0

0

0

0.45

0.90

1.8

0

8

0

0

0

0

0.45

0.90

1.8

0

3

0

0

0

0

0.45

0.90

1.8

0

(Continued )

70

Industrial Construction Estimating Manual

(Continued) Description

150#/ 300#

600#/ 900#

1500#/ 2500#

PF

HP piping and supports

Size

Valve

Valve

Valve

DI

MH/ DI

MH/ DI

MH/ DI

MH

HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2

10

0

0

0

0

0.45

0.90

1.8

0

8

0

0

0

0

0.45

0.90

1.8

0

3

0

0

0

0 0

0.45

0.90

1.8

0 0

Column total

Facility—Combined cycle power plant Equipment—Triple-pressure w/Reheat for F-Class GT-Three Wide

4.5.6 Estimate sheet 5—Pipe supports Pipe Description

Material

HP piping and supports HP-03 Econ 1 to SA-106-B HP Econ 2 HP-03 Econ 1 to SA-106-B HP Econ 2 HP-04 Econ 2 to SA-106-B HP steam drum HP-04 Econ 2 to SA-106-C HP steam drum HP-09 steam drum SA-106-B to HP SH 1 HP-10 steam drum SA-106-B to HP SH 1 HP-11 steam drum SA-106-B to HP SH 1 HP-12 steam drum SA-106-B to HP SH 1 HP-13 steam drum SA-106-B to HP SH 1 HP-14 steam drum SA-106-B to HP SH 1 HP-15 SHTR 1 SA-335-P91 to HP SHTR 2

Size

Sch/Thk

8

Support

PF DI

MH/DI

MH

140/.906

0

1.00

0

6

160/.906

0

1.00

0

8

140/.812

16

1.00

16

6

160/.906

0

1.00

0

6

160/.906

1

6

1.00

6

6

160/.906

1

6

1.00

6

6

160/.906

1

6

1.00

6

6

160/.906

1

6

1.00

6

6

160/.906

1

6

1.00

6

6

160/.906

1

6

1.00

6

10

1.25

2

20

1.00

20

2

(Continued )

71

Construction labor estimate Chapter | 4

(Continued) Pipe Description

Material

Size

Sch/Thk

HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 Column total

SA-335-P91

8

1.031

SA-335-P91

3

SA-335-P91

10

SA-335-P91

8

SA-335-P91

3

SA-335-P91

10

1.25

SA-335-P91

8

1.031

SA-335-P91

3

Support

PF DI

MH/DI

MH

0

1.00

0

0

1.00

0

1.25

0

1.00

0

1.031

0

1.00

0

0

1.00

0

20

1.00

20

0

1.00

0

0

1.00

0

2

12

92

92

Facility—Combined cycle power plant Equipment—Triple-pressure w/Reheat for F-Class GT-Three Wide

4.5.7 Estimate sheet 6—Instrument PF Description

Material

HP piping and supports HP-03 Econ 1 to SA-106-B HP Econ 2 HP-03 Econ 1 to SA-106-B HP Econ 2 HP-04 Econ 2 to SA-106-B HP steam drum HP-04 Econ 2 to SA-106-C HP steam drum HP-09 steam drum SA-106-B to HP SH 1 HP-10 steam drum SA-106-B to HP SH 1 HP-11 steam drum SA-106-B to HP SH 1 HP-12 steam drum SA-106-B to HP SH 1

Size

Sch/The

8

140/.906

6

160/.906

8

140/.812

6

160/.906

6

160/.906

6

Instrument

MH/ea.

MH

1.20

0

9

1.20

10.8

6

1.20

7.2

1.20

0

4

1.20

4.8

160/.906

4

1.20

4.8

6

160/.906

4

1.20

4.8

6

160/.906

4

1.20

4.8

(Continued )

72

Industrial Construction Estimating Manual

(Continued) PF Description

Material

Size

Sch/The

Instrument

MH/ea.

MH

HP-13 steam drum to HP SH 1 HP-14 steam drum to HP SH 1 HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 Column total

SA-106-B

6

160/.906

4

1.20

4.8

SA-106-B

6

160/.906

4

1.20

4.8

SA-335-P91

10

1.25

5

1.20

6

SA-335-P91

8

1.031

1.20

0

SA-335-P91

3

1.20

0

SA-335-P91

10

1.25

1.20

6

SA-335-P91

8

1.031

1.20

0

SA-335-P91

3

1.20

0

SA-335-P91

10

1.25

1.20

6

SA-335-P91

8

1.031

1.20

0

SA-335-P91

3

1.20

0

5

5

54

64.8

Facility—Combined cycle power plant Equipment—Triple-pressure w/Reheat for F-Class GT-Three Wide

4.5.8 Estimate sheet 7—Summary HP piping and supports PF Description

MH

Estimate sheet 1—Handle and install pipe-welded joint Estimate sheet 2—Welding: BW, SW, PWHT arc-uphill Estimate sheet 3—Boltup of flanged joint by weight class Estimate sheet 4—Handle valves by weight class Estimate sheet 5—Pipe supports Estimate sheet 6—Instrument Column total

1558 1467 0 0 92 65 3182

MH/lf

6.1

Construction labor estimate Chapter | 4

4.6

73

Piping summary converted to MH/lf

HP piping and supports

Pipe

Pipe Hdl

Welding

PS

Instrument

MH

MH/ lf

HP-03 Econ 1 to HP Econ 2 HP-03 Econ 1 to HP Econ 2 HP-04 Econ 2 to HP steam drum HP-04 Econ 2 to HP steam drum HP-09 steam drum to HP SH 1 HP-10 steam drum to HP SH 1 HP-11 steam drum to HP SH 1 HP-12 steam drum to HP SH 1 HP-13 steam drum to HP SH 1 HP-14 steam drum to HP SH 1 HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 Column total

25

55

0

0

0

55

2.2

42

61

102

0

10.8

173

4.1

96

211

61

16

7.2

295

3.1

1

1

30

0

0

31

31.1

24

35

45

6

4.8

91

3.8

23

33

35

6

4.8

79

3.4

23

33

45

6

4.8

89

3.9

23

33

35

6

4.8

79

3.4

23

33

45

6

4.8

89

3.9

23

33

35

6

4.8

79

3.4

68

333

279

20

6

638

9.4

3

9

65

0

0

75

24.9

1

1

0

0

0

1

0.6

68

333

279

0

6

618

9.1

3

9

65

0

0

75

24.9

1

1

0

0

0

1

0.6

68

333

279

20

6

638

9.4

3

9

65

0

0

75

24.9

1

1

0

0

0

1

0.6

519

1558

1467

92

65

3182

6.1

Chapter 5

Computer-aided estimation 5.1

Introduction

Computerized estimating is a standard tool in the construction industry to automate and control estimating spreadsheets used to estimate more effectively and efficiently. Estimates are prepared with greater accuracy, more rapidly, and with less effort. The computer stores, retrieves, and provides history of comparable historical data for civil, structural steel, piping, process equipment, pipeline, and storage tanks to produce detailed process plant estimates. The computer when given historical data, from a database of previous similar work task, can reliably calculate material cost and labor by category and rapidly produce both summary and detailed man-hour and cost estimates. Engineers and estimators use Microsoft Excel spreadsheets to calculate craft labor. The qualitative techniques are primarily based on comparisons of similarities between new and actual field data. Quantitative techniques are based on detailed analysis of historical data and construction activities. Quantitative technique is activity-based costing using formulas to calculate the amount of time it takes to do a task, referred to as cycle time. The estimator must make the right assumptions to derive the cycle time for a task. Level of expertise of the estimator has an influence on the accuracy of the cost estimate.

5.2 l l l l l

l l

Benefits of computer-aided estimating

System effectively provides a history of labor hours and cost. System has accuracy of estimates and consistency between estimators. It provides history of comparable historical data. System draws from the database. Database for worker labor and wage rates, equipment rental, and material cost. Process plant construction database for work scope and labor hours. Everyone in the company can access and use the database.

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00005-3 © 2020 Elsevier Inc. All rights reserved.

75

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Industrial Construction Estimating Manual

5.3 l

Computer Excel estimate spreadsheets

Step-by-step how to set up and organize estimate spreadsheets 1. Quantity takeoff—detailed work-up sheet The quantity takeoff identifies through interpretation of the drawings, specifications, work scope, and erection sequence, the direct craft labor, and material that will be required to complete the project. 2. Labor rates and cost—calculation of labor cost Labor rates and cost—calculation of labor cost direct and indirect craft 3. Labor rates and cost—calculation of labor cost craft supervision 4. Labor rates and cost—calculation of labor cost project staff 5. General conditions’ (GC’s) cost Rates for materials, rentals Rates for equipment—company and third party 6. Material cost 7. Subcontractor cost 8. Estimate summary Direct craft labor Indirect craft labor Craft supervision Project on-site staff Subtotal—labor Site GC—materials Site GC—rentals Equipment rentals—contractor Equipment rentals—third party Subtotal—equipment and GC Project materials Sales tax Subcontractors Special services Subtotal—materials and subcontractors Subtotal—job cost Fee on labor Fee on equipment and GCs Fee on material and subcontractors Total fee Subtotal—job cost 1 fee Bond on contractor Contingency Gross receipts tax Quoted price

Computer-aided estimation Chapter | 5

5.4 5.4.1

Illustration computer Excel estimate spreadsheet forms Quantity takeoff—detailed work-up sheet 1 (civil) Historical

Description

MH

Estimate Qty

Unit

Qty

Unit

Historical

Carpenter

IW

Laborer

0 0 0 0

0 0 0 0

0 0 0 0

0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0

Estimate

Scope 0 0 0 Historical Scope

Estimate 0 0 0 0 0 0 0 0 0 0

5.4.2

77

Labor rates and cost—calculation of labor cost sheet 2

Direct craft

Labor cost—ST

Craft

Man-hours Rate ($/h) Amount MH Rate ($/h) Amount Rate ($/h) Amount ($)

Boilermaker 0 Ironworker 0 Millwright 0 Pipefitter 0 Carpenter 0 Laborer 0 Total direct MH 0 Subtotal

0.00 0.00 0.00 0.00 0.00 0.00

Labor cost—OT premium Subsistence

0 0 0 0 0 0

0 0 0 0 0 0

0.00 0.00 0.00 0.00 0.00 0.00

0

Travel Show up time Labor escalation Total to summary

0 0 0 0 0 0 0

0

$0.00

$0 $0

0.00 0.00 0.00 0.00 0.00 0.00

0 0 0 0 0 0 0

78

Industrial Construction Estimating Manual

Indirect craft Labor cost—ST

Labor cost—OT Subsistence premium

Activity

Manhours

Rate Amount MH ($/h) ($)

Rate ($/h)

Amount Rate Amount ($) ($/h) ($)

Mobe/ demobe Cleanup laborer Crane operator Teamster— warehouse Truck driver Firewatch laborer Fire blanketing laborer Safety training Welder certification Safety drug testing Total indirect MH Subtotal

0

0.00

0

0

0.00

0

0.00

0

0.00

0

0

0.00

0

0.00

0

0.00

0

0

0.00

0

0.00

0

0.00

0

0

0.00

0

0.00

0 0

0.00 0.00

0 0

0 0

0.00 0.00

0 0

0.00 0.00

0

0.00

0

0

0.00

0

0.00

0 0

0.00 0.00

0 0

0 0

0.00 0.00

0 0

0.00 0.00

0

0.00

0

0

0.00

0

0.00

0

0 0

0

Travel Show up time Labor escalation Total to summary

0

$0.00

$0 $0

5.4.3 Labor rates and cost—calculation of labor cost craft supervision sheet 3 Craft supervision labor and cost Man-hours Craft

Direct MH

Foreman

Boilermaker Ironworker Millwright Pipefitter Carpenter Laborer

0 0 0 0 0 0

0 0 0 0 0 0

GF

0 0

0

Computer-aided estimation Chapter | 5

Labor cost—ST

Labor cost—OT premium

Craft

MH

ST rate ($/h)

Amount MH OT rate ($) ($/h)

Boilermaker GF Boilermaker F Ironworker GF Ironworker F Millwright GF Millwright F Pipefitter GF Pipefitter F Carpenter GF Carpenter F Laborer F Total craft supervision MH Subtotal Total craft supervision labor Total OT premium Subsistence Travel Labor escalation Show up time Total to summary

0 0 0 0 0 0 0 0 0 0 0 0

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0

Subsistence

Amount Rate ($/h) ($)

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0 0 0 0 0 0 0 0 0 0 0

0

79

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Amount ($) 0 0 0 0 0 0 0 0 0 0 0

0

0

0 0 0 0 0 0 0

Calculate Calculate Calculate

5.4.4 Labor rates and cost—calculation of labor cost project staff sheet 4 Project on-site staff

Labor cost—ST

Labor cost—OT premium

Salaried

Manhours

ST rate ($/h)

Amount MH OT rate ($) ($/h)

Construction manager Project engineer Field engineer Safety/QC engineer Scheduler Quality control Office manager Cost engineer Secretarial Material control Purchasing

0

0.00

0

0 0 0

0.00 0.00 0.00

0 0 0 0 0 0 0 0

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Subsistence

Amount Rate ($/h) ($)

Amount ($)

0.00

0

0.00

0

0 0 0

0.00 0.00 0.00

0 0 0

0.00 0.00 0.00

0 0 0

0 0 0 0 0 0 0 0

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0 0 0 0 0 0 0 0

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0 0 0 0 0 0 0 0

(Continued )

80

Industrial Construction Estimating Manual

(Continued) Project on-site staff

Labor cost—ST

Salaried

Manhours

General superintendent Total staff MH Subtotal Total staff MH Total OT premium Subsistence Travel Homeoffice travel Staff housing Total to summary

5.4.5

ST rate ($/h)

Labor cost—OT premium

Subsistence

Amount MH OT rate ($) ($/h)

Amount Rate ($/h) ($)

Amount ($)

0 0 0 0 0 0

0

0

0

Calculate Calculate Calculate

0 0

General conditions’ cost sheet 5

Site general conditions

Materials

Description

Duration Rate ($)

Cost ($)

Description

Duration Rate ($)

Cost ($)

Electrical—hookup Electrical—power/ monthly Telephone—hookup Telephone—monthly Office furniture Office supplies Fax machine Copier Drinking water Plan reproduction Project safety billboard

0 0

0 0

0 0

Office trailer Office trailer—setup

0.0 0

0 0

0 0

0 0.0 0.0 0.0 0 0 0.0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0.0 0 0.0 0 0.0

0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

Permits

0

0

0

Change trailers Change trailers—setup Tool trailers Sanitary facilities Dumpsters Temporary fencing Security Cargo containers Construction water hookup Temporary air/water piping Total to summary

0

0

0

Total to summary

Rentals

0

0

81

Computer-aided estimation Chapter | 5

Equipment rentals Company owned

Third party

Description

Duration Rate Cost Description ($) ($)

Duration Rate Cost ($) ($)

3/4 ton pickup

0

0

0

0

0

0

Job site pickup

0.0

0

0

0

0

0

2 ton flatbed truck

0

0

0

0.0

0

0

Forklift, over 8000#

0

0

0

0

0

0

Reachlift,8000#10,000# Hydraulic crane, 10 ton Hydraulic crane, 60 ton Hydraulic crane, 80 ton Truck crane, 8 ton

0.0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

Electric welder, 8 Pak

0

0

0

0

0

0

Industrial welding generator Air compressor, 175475 CFM Generator, 60100 kW Hydrostatic test pump, 4 GPM Fusion machine, 6v8v

0.0

0

0

Manitowoc 2250/Maxer w/ 2200 Boom Assembly/mobe/tear down/ demobe 200 ton crawler crane w/ 2100 Boom Assembly/mobe/tear down/ demobe 90 ton rough terrain crane Mobe/demobe 60 ton rough terrain crane Mobe/demobe Engineering (HRSG erection) Ten (10) 9 ton deadman—5 loads Freight per load

0

0

0

0

0

0

Crane mats (per sf)

0

0

0

0.0 0.0

0 0

0 0

Freight per load Technician

0 0

0 0

0 0

0

0

0

0.0

0

0

0 0 0 0 0 0

0 0 0 0 0 0 0

Crane fuel and maintenance 500 ton gantry Mobe/demobe Prime mover Mobe/demobe Barge ramp Mobe/demobe Total to summary

0 0 0 0

0 0 0 0 0 0

0 0 0 0 0 0 0

Fusion machine, 10v18v Trailer, Pipe Dolly Zoom Boom, 600 Zoom Boom, 400 Van, 8 Passenger Light tower Total to summary

5.4.6

0.0 0 0 0

Material cost sheet 6

Project material Description

Qty

$/Qty

Amount ($)

Weld test coupons Safety items Fire blankets Nomex suits Steel toe shoes Fuel for equipment Special tools H2S monitor

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 (Continued )

82

Industrial Construction Estimating Manual

(Continued) Description

Qty

$/Qty

Amount ($)

Pipe supports Bolt and gasket sets Plate Grout Fill oil

0 0 0 0 0

0 0 0 0 0

0.00% 0.00%

% %

0.00%

% Material/sales tax

0 0 0 0 0 0 0 0 0 0 0 0

Subtotal Escalation Freight Subtotal Sales tax

5.4.7

Subcontractor cost sheet 7

Subcontractors Subcontractor

Type

TBD

Scaffold

MH

Amount ($)

Service

0

Deputy inspector— civil Deputy inspector— structural Welding inspector Weld testing Concrete testing Welder certification lab fees Outside engineering Survey and layout Third-party inspector Soil monitoring/ testing Hot tapping Drug testing laboratory

Insulation

TBD

Painting

0

Electrical

TBD

NDE

0

Lead abatement

TBD

PWHT

0

Millwright

0

Vendor

Amount ($)

TBD

0

TBD

0

TBD

0 0

(Continued )

Computer-aided estimation Chapter | 5

83

(Continued) Subcontractor

Type

MH

Total to summary

5.4.8

Amount ($)

Service

Vendor

0

Total to summary

Amount ($) 0

Estimate summary sheet 8

Estimate summary Account description

Manhours

Cost ($)

Adjustment ($)

Final cost ($)

Direct craft labor Indirect craft labor Union rebate Craft supervision Project on-site Staff Subtotal—labor Site GC—materials Site GC—Rentals Equipment rentals— Equipment rentals—third party Subtotal—equipment and GC Project materials

0 0

0 0

0 0

0 0 0

0 0 0 0 0 0 0 0 Amount ($) 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0

0 0 0 0

0 0 0 0

0 % % %

0

0 0 0 0

Sales tax Subcontractors Special services Subtotal—materials and subcontractors Subtotal—job cost Fee on labor Fee on equipment and GCs Fee on material and subcontractors Total fee Subtotal—job cost 1 fee Bond on ARB Contingency Gross receipts tax Quoted price

0 0 0

0.00

%

0.00

%

0 0 0

0

0 0

84

Industrial Construction Estimating Manual

5.5 Sample cost estimate: Simple cycle power plant SCR Foundation estimate 5.5.1

Quantity takeoff detailed work-up sheet

Install drilled piers and place SCR Foundation estimate sheet 1 Description

Historical

MH

Qty

Estimate

Unit Qty

Historical Drilled piers 20 drilled piers Fabricate and install rebar cage 4000# PSI concrete piers 8 year/ day/ea

480.00 24.00 4.00

1.00 22.00 22.00

Carpenter IW Laborer

Estimate job ea ea

Historical SCR Foundation (300 0v 3 400 0v) Structure excavation—SCR 0.60 177.78 Foundation Fabricate, install, strip foundation 0.35 140.00 forms (one use) Fabricate and install rebar 65.00 4.40 Place concrete slab 2.50 250.00 Layout, templates, and set anchor 1.20 88.00 bolts Set embedded steel 0.06 500.00 Finish flat concrete 0.15 1200.00 Structure backfill and compact— 0.60 71.11 loader and Wacker Cleanup and grade area w/skip 320.00 1.00 loader Haul spoils to location 80.00 1.00

Unit

1.00 ea 22.00 ea 22.00 ea

568 480

528 0 0 528

88

Estimate 407 cy

177.78 cy

lf

140.00 lf

ton cy ea

4.40 ton 250.00 ea 88.00 ea

lb sf cy

500.00 lb 1200.00 sf 71.11 cy

393 1025 107

49 286 625 106 30 180 43

job

1.00 job

320

job

1.00 job

80

Actual

Estimated

Facility—simple cycle power plant

MH

Carpenter

IW

Laborer

MH

Drilled Piers SCR Foundation (300 0v 3 400 0v)

1020 1820

568 407

528 393

0 1025

1096 1825

5.5.2 Labor rates and cost—calculation of labor cost direct and indirect craft sheet 2 Estimate no. Project Direct craft

Start date Completion date Calendar days 64

Computer-aided estimation Chapter | 5

Labor cost—ST

Labor cost—OT premium

Subsistence

85

Craft

Manhours

Rate ($/h)

Amount ($)

Man-hours Rate ($/h)

Amount Rate ($) ($/h)

Amount ($)

Carpenter Ironworker Millwright Pipefitter Carpenter Laborer Total direct MH Subtotal Travel Show up time Labor escalation Total to summary

975 921 0 0 0 1025 2921

78.56 84.94 0.00 0.00 0.00 68.84

76,617 78,201 0 0 0 70,561

0 0 0 0 0 0

0 0 0 0 0 0

0 0 0 0 0 0

32.80 28.84 0.00 0.00 0.00 26.45

225,379 0

0.00

0

0.00

0

0

225,379

Indirect craft Labor cost—ST Activity

Manhours

Mobe/demobe 320 Cleanup laborer 0 Crane operator 320 Oiler 0 Truck driver 80 Firewatchlaborer 0 Fire blanketing 0 laborer Safety training 20 Welder 0 certification Safety drug testing 20 Total indirect MH 760 Subtotal Travel Show up time 0 Labor escalation Total to summary

Labor cost— OT premium

Subsistence

Rate ($/h)

Amount ($)

Manhours Rate Amount Rate Amount ($/h) ($) ($/h) ($)

85.11 0.00 93.21 0.00 71.54 0.00 0.00

27,234 0 29,827 0 5723 0 0

33.75 0.00 33.40 0.00 23.19 0.00 0.00

0 0 0 0 0 0 0

85.11 1702 0.00 0

0.00 0

85.11 1702

33.75 0

66,188 85.11 0 66,188

0

0

86

Industrial Construction Estimating Manual

5.5.3 Labor rates and cost—calculation of labor cost craft supervision sheet 3 Project Supervision Total work days Hours per work day Months

Calendar days

64

46 8 2.1

Craft supervision man-hours Man-hours Craft

Direct MH

Foreman

Gen Foreman

Carpenter Ironworker Millwright Pipefitter Carpenter Laborer

975 921 0 0 0 1025

0 120 0 0 0 128

368 0 0 0 0 0

Labor cost—ST

Labor cost—OT Subsistence premium

Craft

Manhours

Rate ($/h)

Amount ($)

Boilermaker GF Boilermaker F Ironworker GF Ironworker F Millwright GF Millwright F Pipefitter GF Pipefitter F Carpenter GF Carpenter F Laborer F Total craft supervision MH Subtotal Total craft supervision labor Total OT premium Subsistence Travel Labor escalation Show up time Total to summary

0 0 0 120 0 0 0 0 368 0 128 616

0.00 0.00 0.00 90.14 0.00 0.00 0.00 0.00 86.96 0.00 77.59

0 0 0 10,817 0 0 0 0 32,001 0 9932

52,750 52,750 0

Calculate Calculate Calculate

0 0 0 0 52,750

Manhours Rate Amount Rate Amount ($/h) ($) ($/h) ($)

0 0

0.00 0.00 0.00 31.45 0.00 0.00 0.00 0.00 37.00 0.00 30.82

0 0 0 0 0 0 0 0 0 0 0

0

0.00 0.00

0 0 0 0 0 0 0 0 0 0 0

0

Computer-aided estimation Chapter | 5

87

5.5.4 Labor rates and cost—calculation of labor cost project staff sheet 4 Estimate no. Project Project on-site staff Total work days Hours per work day Total work hours Months

Labor cost—ST Manhours

Rate Amount ($) ($/H)

Construction manager Project engineer Field engineer Safety/QC engineer Scheduler Quality control Office manager Cost engineer Secretarial Material control Purchasing General superintendent Total staff MH Subtotal Total staff MH Total OT premium Subsistence Travel Homeoffice travel Staff housing

366

135.00 49,371

183 0 0 0 0 0 366 0 0 0

46 8 366 2.1

Labor cost—OT Subsistence premium

Salaried

0

Start date Completion date Calendar days 64

0.00 0 80.00 14,629 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 35.00 12,800 0.00 0 0.00 0 0.00 0

Man-hours Rate Amount Rate Amount ($/H) ($) ($/H) ($) 135.00 0

16.50 6034

0.00 0

0.00 0

80.00 0 0.00 0

0.00 0 0.00 0

0.00 0 0.00 0 0.00 0

0.00 0 0.00 0 0.00 0

0.00 0 35.00 0 0.00 0

0.00 0 0.00 0 0.00 0

0.00 0 0.00 0

0.00 0 0.00 0

914 76,800 76,800 0

Calculate Calculate

6034 0 0

Calculate

0

0

6034

88

Industrial Construction Estimating Manual

5.5.5

General conditions’ cost sheet 5 Estimate no. Project Site GC Total work days Months

Start date Completion date Calendar days

64

46 2.1

Materials

Rentals

Description

Duration Rate ($)

Cost ($)

Description

Duration Rate ($)

Cost ($)

Electrical—hookup Electrical—power/ monthly Telephone—hookup Telephone—monthly Office furniture Office supplies Fax machine Copier Drinking water Plan reproduction Project safety billboard

0 0

0.00 0.00

0 0

Office trailer Office trailer—setup

2.1 1

1000 250

2133 250

0 0.0 2.1 2.1 0 0 2.1 0 0

0.00 0.00 1500 2000 0.00 0.00 2500 0.00 0.00

0 0 3200 4267 0 0 5333 0 0

2.1 1 2.1 4 2.1

200 250 200 200 1500

0 1

0.00 5000

427 250 427 800 3200 0 0 0 5000

Permits

0

0.00

0

0.00

0

Total to summary

Change trailers Change trailers—setup Tool trailers Sanitary facilities Dumpsters Temporary fencing Security Cargo containers Construction water hookup 0 Temporary air/water piping 12,800 Total to summary

12,487

Equipment rentals Company owned

Third party

Description

Duration Rate ($)

Cost ($)

Description

Duration Rate Cost ($) ($)

3/4 ton pickup

2.1

2838

6054

0

0.00 0

Job site pickup

2.1

2838

6054

0

0.00 0

2 ton flatbed truck

0

0.00

0

0.0

0.00 0

Forklift, over 8000#

0

0.00

0

Manitowoc 2250/Maxer w/ 220’ Boom Assembly/mobe/tear down/ demobe 200 ton crawler crane w/ 210’ Boom Assembly/mobe/tear down/ demobe 90 ton rough terrain crane Mobe/demobe 60 ton rough terrain crane Mobe/demobe Engineering (HRSG erection)

0

0.00 0

0 0 0 0 0

0.00 0.00 0.00 0.00 0.00

Reachlift,8000#10,000# 0.0 Hydraulic crane, 10 ton Hydraulic crane, 60 ton Hydraulic crane, 80 ton Truck crane, 8 ton 0

4000 0 7482 0 17,200 0 21,500 0 0.00 0

0 0 0 0 0

(Continued )

89

Computer-aided estimation Chapter | 5

(Continued) Company owned

Third party

Description

Duration Rate ($)

Cost ($)

Description

Electric welder, 8 pack

0

0.00

0

0.00 0

Industrial welding generator Air compressor, 175475 CFM Generator, 60100 kW Hydrostatic test pump, 4 GPM Cat Backhoe 305

0.0

0.00

0

Ten (10) 9 ton deadman—5 0 loads Freight per load 0

2.1

900

1920

Crane mats (per sf)

0

0.00 0

0.0

0.00 1000

0 0

Freight per load Bigge Technician

0 0

0.00 0 0.00 0

2.1

5676

0.0

0.00 0

0.47 0.0 1.1 1.1 2.1 0

8686 0.00 5676 1462 430 0.00

12,109 Crane fuel and maintenance 4040 500 ton gantry 0 Mobe/demobe 5960 Prime mover 1608 Mobe/demobe 903 Barge ramp 0 Mobe/demobe 38,649 Total to summary

0 0 0 0

0.00 0.00 0.00 0.00 0.00 0.00

Dump truck 10 year/day Trailer, Pipe Dolly Mini Excavator 305 Compactor Concrete vibrator Light tower Total to summary

5.5.6

Duration Rate Cost ($) ($)

Material cost sheet 6 Estimate no. Total work days Months Project material

Start date Completion date Calendar days

64

46 2.1

Description

Qty

$/Qty

Amount ($)

Weld test coupons Safety items: Fire blankets Nomex Suits Steel toe shoes Fuel for equipment Special tools Concrete (4000# PSI) Anchor bolts/rebar (lb)

0 8 0 0 8 0 0 426 3408 0 0 0 0 1

0 0 0 0 0 0 0 124 9 0 0 0

0 0 0 0 0 0 0 52,824 28,968 0 0 0 0 0

Piping Grout, steel, etc. Oil fill Miscellaneous

0

(Continued )

0.00 0

0 0 0 0 0 0 0

90

Industrial Construction Estimating Manual

(Continued) Description

Qty

Subtotal Escalation Freight Subtotal California sales tax

5.5.7

$/Qty

Amount ($)

0.00% 0.00%

% %

9.75%

%

0 81,792 0 0 81,792 7975

Subcontractor cost sheet 7 Estimate no. Project Total work days Months Subcontractors

Subcontractor

Start date Completion date Calendar days

46 2.1

Special services

Type

MH

Amount ($)

Service

Scaffold

0

0

Deputy inspector— civil Deputy inspector— structural Welding inspector Weld testing Concrete testing Welder certification lab fees Outside engineering Survey and layout Third-party inspector Soil monitoring/ testing Hot tapping Drug testing laboratory

Insulation

Redwood

Painting

0

Electrical

TBD

NDE

PCI

Lead abatement

Superheat

PWHT

64

0

Vendor

Amount ($)

1800

18,000

0

0

0

0 0 (Continued )

Computer-aided estimation Chapter | 5

91

(Continued) Subcontractor

Lube oil flush Drilling contractor Total to summary

5.5.8

Type

MH

Amount ($)

Supervisor 2- to 6way consoles

0

0

To be determined

Service

Vendor

Amount ($)

20,000 20,000

Total to summary

18,000

Estimate summary sheet 8 Estimate no. Bid date

Start date Completion date Calendar days Total work days

64 46

Estimate summary

Account description

Man-hours

Cost ($)

Adjustment ($)

Final cost ($)

Direct craft labor Indirect craft labor Union rebate Craft supervision Project on-site staff Subtotal—labor

2921 760

225,379 66,188

0 0

616 914 5211

52,750 82,834 427,151

0 0 0

225,379 66,188 0 52,750 82,834 427,151

Site GC—materials ($) Site GC—rentals ($) Equipment rentals—ARB Inc. ($) Equipment rentals—third-party ($) Special services ($) Subtotal—equipment and GC ($)

12,800 12,487 38,649 0 63,935

Project materials ($) Sales tax ($) Subcontractors ($) Special services ($) Subtotal—materials and subcontractors ($) Subtotal—job cost ($)

0 0 0 0 0 0

81,792 7975 20,000 18,000 127,767 618,853

12,800 12,487 38,649 0 0 63,935

0 0 0 0 0 0

81,792 7975 20,000 18,000 127,767 618,853

92

Industrial Construction Estimating Manual

Fee on labor Fee on equipment and GCs Fee on material and subcontractors Total fee Subtotal—job cost 1 fee Bond on ARB Contingency Gross receipts tax Quoted price

5.5.9

25.00% 10.00% 0.00% 15.46%

% % %

0.00% 10.00% 0.00%

% % $154.52

$106,788 $6,394 $0 $113,181 $732,035 $0 $73,203 $0 $805,238

SCR Foundation—bid breakdown sheet 9

Item Description

Unit $/MH

Manhours

Labor ($)

1.00 Drilled piers 2.00 SCR Foundation (300 0v 3 400 0v) 16.00 Craft supervision 17.00 Material 18.00 Sub-bond costs 19.00 Sales tax 20.00 Construction equipment rentals 21.00 Subcontractors 22.00 Overtime/shift work/ productivity 23.00 Indirect and project field staff 24.00 Contingency, home office (G&A), and profit 25.00 Total direct labor man-hours 26.00 Averaged burdened labor rate

LS LS

1096 1825

89,470 135,909

LS LS LS LS LS

616

52,750

Material Total Comments ($) Dollars ($) 89,470 135,909

81,792 7975 63,935

LS MH MH

38,000

1674

LS

52,750 81,792 0 7975 63,935 38,000 0

149,022

149,022

186,385

186,385

MH 2921 $/MH $154.52 5211

613,536 191,702 805,238

5.5.10 Estimate analysis sheet 10 Estimate no. Bid date Calendar days Total work days

64 46

Computer-aided estimation Chapter | 5

Project crew, supervision, and staff

Man-hours

Manpower

Direct craft Indirect craft Craft supervision Staff Total site man power

2921 760 616 914 5211

8 2 2 3 15

93

Ratio analysis Supervision percent of craft labor (%) Staff percent of craft labor (%) Indirect craft percent of craft labor (%)

21.09 31.30 26.02

Fee loading Fee on labor (%) Fee percent of cost (%) Fee percent of price (%)

25.00 18.29 14.06

Piping analysis Pipe labor MH/lf Pipe welding MH/DI Supports percent of craft labor Testing percent of craft labor

0.00 0.00 0.00 0.00

SCR Foundation Scope of work Direct craft

Drilled piers SCR Foundation (300 0v 3 400 0v)

8

Total MH 2921 1096 1825

8

64 46 Total Manpower h/ h/ Work day day days 8 8 64 46 8 8 64 17 8 8 64 29

2921

9.1

Manhours 2921 1096 1825

Weeks Days Months 9.1 3.4 5.7

64

64 24 40

2.1

2.1 0.8 1.3

Chapter 6

Combined cycle power plant (1 3 1) labor estimate 6.1

Introduction

Natural gas combined cycle power plants play an important role in the construction industry. These power plants are the most efficient power plants operating on the power grid with an efficiency between 45% and 57%. Natural gas power plants are attractive to the power industry because of the following advantages: G

G G G G

It has efficiency between 45% and 57%, highest efficiency for a power plant type. It has a small footprint compared to other power plant types. Construction time is short compared to other types of power plants. Capital cost is lower than other types of power plants. Gaseous emissions are very low; plants emit far less carbon dioxide than other types of power plants.

This chapter focuses on detailed labor estimates to determine direct craft man-hours to erect a 1 3 1 combined cycle power plant. The man-hour estimate provides the basis for the project schedule. The estimator uses the labor estimate to determine crew craft and make up requirements, project duration and to develop Level I and II schedules for the project.

6.2

Detailed estimating unit-quantity model

Combined cycle power plant estimate consists of the following work estimates: G G

G G G G

Foundations Mechanical equipment [CTG, STG, heat recovery steam generator (HRSG)] includes vendor piping BOP equipment Structural steel Underground piping Aboveground piping

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00006-5 © 2020 Elsevier Inc. All rights reserved.

95

96

6.3

Industrial Construction Estimating Manual

Combine cycle power plant foundation summary Carpenter

Laborer

IW

Total MH

28,741.0

5102.6

17,350.9

6287.4

28,741.0

Boiler foundations

7347.1

1137.7

4550.4

1659.0

7347.1

Estimate sheet—HRSG and stack foundation Estimate sheet—HRSG RH blowdown tank foundation Estimate sheet—CEMS building foundation Estimate sheet—steam cycle chemistry feed area foundation Estimate sheet—boiler feedwater pump foundation (2 ea.) Estimate sheet—auxiliary boiler foundation

6276.9

774.0

4004.9

1498.0

6276.9

93.6

42.0

44.6

7.0

93.6

112.8

48.0

53.6

11.2

112.8

249.6

84.2

129.0

36.4

249.6

270.9

81.7

138.9

50.4

270.9

343.3

107.9

179.4

56.0

343.3

CTG and CTG-related foundations

5528.5

1025.5

3329.8

1173.2

5528.5

Estimate sheet— combustion turbine and CTG generator Estimate sheet—generator circuit breaker foundation (2 ea.) Estimate sheet—fuel gas performance heater foundation Estimate sheet—rotor air cooler foundation Estimate sheet—excitation skid and transformer foundation Estimate sheet—VT and surge cubicle foundation Estimate sheet—sample panel foundation Estimate sheet— compressor wash skid foundation Estimate sheet—GT water wash tank foundation

4280.5

600.2

2686.2

994.0

4280.5

6.3.1 Estimate summary— power island equipment foundations

321.1

74.25

188.05

58.8

321.1

297.7

80.7

163.8

53.2

297.7

138.6

58.8

63.0

16.8

138.6

144.2

58.8

67.15

18.2

144.2

69.7

31.2

32.85

5.6

69.7

116.6

50.4

53.61

12.6

116.6

102.2

44.1

48.31

9.8

102.2

27

26.85

4.2

58.1

58.1

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

97

(Continued) IW

Total MH

15,865.3

2939.5

Carpenter

9470.7

3455.2

15,865.3

Estimate—steam turbine and steam turbine generator Estimate—closed cooling water heat exchangers (2 ea.) Estimate—closed cooling water pumps (2 ea.) Estimate—cooling tower chemical feed area Estimate—circulating water pump station and cooling tower Estimate—circulating water pump station and cooling tower Estimate—sulfuric acid, coagulant tank, and pump foundations Estimate—condenser polishing unit Estimate—condenser extraction pumps Estimate—condenser vacuum pumps

8498.4

1043.5

5424.9

2030.0

8498.4

21

215.8

11.2

186.0

Plant mechanical systemrelated foundations

STG and STG-related foundations

Estimate sheet— potable water skid Estimate sheet— demineralized storage tank Estimate sheet—oilwater separator (process drain) foundation Estimate sheet—oilwater separator (storm drain) foundation Estimate sheet— demineralized water forwarding pump skid Estimate sheet—injection water storage tank

Laborer

215.8

92.25

102.5

186.0

87.3

87.5

468.5

111.75

265.7

91

468.5

582.6

142.2

328.4

112

582.6

2912.6

1084

5196.2

70

390.2

5196.2

1200

390.2

114

206.15

103.4

48

44.15

11.2

103.4

91.5

45

38.1

8.4

91.5

133.0

55.5

60.7

16.8

133.0

7160.7

2046.3

3962.2

1152.2

7160.7

132.3

54

64.3

14

132.3

297.8

87

160.35

50.4

297.8

91.9

42

42.9

7

91.9

144.5

54.45

70.4

19.6

144.5

64.4

29.7

33.25

1.4

64.4

323.9

88.5

50.4

323.9

185.0

(Continued )

98

Industrial Construction Estimating Manual

(Continued) Carpenter Estimate sheet—STIG wastewater injection pump skid Estimate sheet—clarifier (2 ea.) Estimate sheet—clarified water storage tank Estimate sheet—clarified water forwarding pump Estimate sheet—gas compressors (2 ea.) Estimate sheet—STIG plant gas compressor Estimate sheet—gas compressor filter foundation Estimate sheet—fuel gas filter separator foundation Estimate sheet—control oil skid foundation Estimate sheet—STG plant heat exchanger Estimate sheet—dry lime silos (5 ea.) Estimate sheet—air compressors (2 ea.) Estimate sheet— compressed air dryer Estimate sheet— compressed air receiver Estimate sheet—clarified water and solids holding tanks (3 ea.) Estimate sheet—waste solids and recycle solids pump skid (2 ea.) Estimate sheet—clarified water pump skid foundation Estimate sheet—eyewash, showers, heaters (3 ea.)

64.4

381.0

29.7

135

Laborer

IW

Total MH

33.3

1.4

64.4

192.8

53.2

381.0

1630.9

599.2

2552.6

2552.6

322.5

104.6

45

49.8

9.8

104.6

492.7

168

250.45

74.2

492.7

260.0

88.8

130.55

40.6

260.0

136.0

54.75

65.8

15.4

136.0

75.8

33.6

36.6

5.6

75.8

86.3

36.6

41.25

8.4

86.3

195.9

63.3

101.8

30.8

195.9

228.2

39.2

477.4

477.4

210

175.9

79.5

83.8

12.6

175.9

77.5

36.0

37.3

4.2

77.5

77.5

36.0

37.3

4.2

77.5

452.1

170.1

226.0

56.0

452.1

219.7

58.5

123.4

37.8

219.7

104.6

45.0

49.8

9.8

104.6

108.1

48.6

53.9

5.6

108.1

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

6.3.2 Utility distribution plant electrical controls foundations

17,628.3

5932.4

Excel estimate HRSG utility bridge foundations (4 ea.) Excel estimate STG utility bridge foundations (4 ea.) Excel estimate stair towers and ladders (4 ea.) Excel estimate stair towers and ladders (4 ea.) Excel estimate miscellaneous pipe support foundation (100 ea.) Excel estimate miscellaneous concrete paving (100 ea.) Excel estimate CTG iso-phase bus duct Foundation (16 ea.) Excel estimate STG iso-phase bus duct foundation (16 ea.) Excel estimate CTG step-up transformer foundation (16 ea.) Excel estimate STG main step-up transformer foundation (16 ea.) Excel estimate auxiliary transformer (16 ea.) Excel estimate SUS transformer (5 ea.) Excel estimate CTG PDC Excel estimate STG/HRSG PDC Excel estimate miscellaneous cable tray supports and fdn. (5 ea.) Excel estimate transmission towers (6 ea.) Excel estimate takeoff towers (7 ea.) Excel estimate disconnect switch Excel estimate circuit breaker Excel estimate pole supports (14 ea.) Excel estimate miscellaneous small foundations (10 ea.) Excel estimate electrical manholes (7 ea.) Excel estimate transmission towers (6 ea.) Excel estimate transmission towers (6 ea.) Excel estimate trenches, curbs, equip pads, piers, etc.

1777.8

99

8138.5

3557.4

17,628.3

504.0

961.6

312.2

1777.8

1315.0

453.6

622.0

239.4

1315.0

199.3

96.0

97.7

5.6

199.3

130.0

57.6

65.4

7.0

130.0

416.7

288.0

86.7

42.0

416.7

253.9

32.4

172.5

49.0

253.9

265.6

120.0

106.4

39.2

265.6

265.6

120.0

106.4

39.2

265.6

1322.2

453.6

605.4

263.2

1322.2

1322.2

453.6

605.4

263.2

1322.2

1303.3

645.0

446.9

211.4

1303.3

404.6

202.5

168.5

33.6

404.6

429.5 488.1 247.4

133.5 126.0 192.0

206.4 251.5 45.6

89.6 110.6 9.8

429.5 488.1 247.4

412.2

210.6

151.2

50.4

412.2

406.4 131.2 143.5 136.2

239.4 51.6 63.0 75.6

123.6 62.8 67.9 46.6

43.4 16.8 12.6 14.0

406.4 131.2 143.5 136.2

298.8

216.0

64.6

18.2

298.8

1679.2

861.8

562.6

254.8

1679.2

412.2

210.6

151.2

50.4

412.2

846.1

126.0

360.3

359.8

846.1

3021.8

0.0

1999.8

1022.0

3021.8

100

Industrial Construction Estimating Manual

6.4 Work estimates are illustrated with the unit-quantity model 6.4.1

Estimate—power island equipment foundations

Excel estimate spreadsheet for boiler foundations Historical Description

MH

Qty

MHa

ni

Estimate Unit Qty ni

Estimate sheet—HRSG and stack foundation Excavation (bathtub) Forms (2040 3 540 3 50 ) Rebar Concrete (2000 3 500 3 50 ) Mud mat (2040 3 540 3 0.330 ) Backfill, compact Estimate sheet—HRSG RH blowdown tank foundation Excavation (bathtub) Forms (160 3 160 3 2.50 ) Rebar Concrete (100 3 100 3 2.50 ) Mud mat (140 3 140 3 0.330 ) Backfill, compact Estimate sheet—CEMS building foundation Excavation (bathtub) Forms (140 3 140 3 2.50 ) Rebar Concrete (120 3 120 3 2.50 ) Mud mat (160 3 160 3 0.330 ) Backfill, compact Estimate sheet—steam cycle chemistry feed area foundation Excavation (bathtub) Forms (420 3 190 3 3.30 ) Rebar Concrete (380 3 150 3 2.30 ) Mud mat (420 3 190 3 0.330 ) Backfill, compact Estimate sheet—boiler feedwater pump foundation (2 ea.) Excavation (bathtub) Forms (26.750 3 15.250 3 2.50 ) Rebar

Carpenter Labor IW ni MHa 6276.9

0.400 0.0 0.300 2580 14.0 107 2.0 1944.4 0.500 136.0 0.600 80.0

0.400 0.300 14.0 2.0 0.500 0.600

0.400 0.300 14.0 2.0 0.500 0.600

0.400 0.300 14.0 2.0 0.500 0.600

0.400 0.300 14.0

0.0 140 0.5 9.7 2.4 40.0

0.0 160 0.8 14.0 3.2 40.0

0.0 280.6 2.6 51.0 9.9 36.8

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

0.0 cy 272.2 sf 3.6 ton

0.0 2580.0 107.0 1944.4 136.0 80.0

0.0 140.0 0.5 9.7 2.4 40.0

0.0 160.0 0.8 14.0 3.2 40.0

0.0 280.6 2.6 51.0 9.9 36.8

0.0 272.2 3.6

0.0 774.0 1498.0 3888.9 68.0 48.0 93.6 0.0 42.0 7.0 19.4 1.2 24.0 112.8 0.0 48.0 11.2 28.0 1.6 24.0 249.6

0.0 84.2 36.4 102.0 5.0 22.1 270.9

0.0 81.7 50.4

774.0

4004.9 1498.0

774.0 1498.0

42.0

3888.9 68.0 48.0 44.6

7.0

42.0 7.0

48.0

19.4 1.2 24.0 53.6

11.2

48.0 11.2

84.2

28.0 1.6 24.0 129.0

36.4

84.2 36.4

81.7

102.0 5.0 22.1 138.9

50.4

81.7 50.4

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

101

(Continued) Historical Description

Estimate

MH

Qty

MHa

ni

Unit Qty

Carpenter Labor IW

ni

ni MHa

Estimate sheet—HRSG and stack foundation Concrete (22.750 3 11.250 3 3.30 ) Mud mat (26.750 3 15.250 3 0.330 ) Backfill, compact Estimate sheet—auxiliary boiler foundation Excavation (bathtub) Forms (340 3 240 3 3.10 ) Rebar Concrete (300 3 200 3 3.10 ) Mud mat (340 3 240 3 0.330 ) Backfill, compact

6276.9 2.0

774.0

4004.9 1498.0

52.4 cy

52.4

104.7

104.7

0.500

5.0 cy

5.0

2.5

2.5

0.600

52.8 cy

52.8

31.7 343.3

0.400 0.0 cy 0.300 359.6 sf 14.0 4 ton 2.0 72.3 cy 0.500 10.1 cy 0.600 49.6 cy

0.0 359.6 4.0 72.3 10.1 49.6

0.0 107.9 56.0 144.6 5.1 29.8

107.9

31.7 179.4

56.0

107.9 56.0 144.6 5.1 29.8

6.4.2 CTG and CTG-related foundations sheet 1 Historical Description

MH

Qty

MHa

ni

Estimate Unit Qty ni

ni MHa

Estimate sheet— combustion turbine and CTG generator Excavation (bathtub) 0.400 0.0 Forms (570 3 1070 3 6.10 ) 0.300 2000.8 Rebar 14.0 71 Concrete (530 3 1030 3 6.10 ) 2.0 1295.0 Mud mat 0.500 75.3 (570 3 1070 3 0.330 ) Backfill, compact 0.600 97.6 Estimate sheet—generator circuit breaker foundation (2 ea.) Excavation (bathtub) 0.400 0.0 0.300 247.5 Forms (290 3 20.50 3 2.50 ) Rebar 14.0 4.2 2.0 80.2 Concrete (250 3 16.50 3 2.50 ) 0.500 7.3 Mud mat (290 3 20.50 3 0.330 ) Backfill, compact 0.600 40.0

Carpenter Labor IW

4280.5

cy sf ton cy cy cy

cy sf ton cy

0.0 2000.8 71.0 1295.0 75.3

0.0 600.2 994.0 2590.0 37.7

97.6

58.6 321.1

0.0 247.5 4.2 80.2

0.0 74.3 58.8 160.4

cy

7.3

3.7

cy

40.0

24.0 297.7

600.2

2686.2 994.0

600.2 994.0 2590.0 37.7

74.3

58.6 188.1

58.8

74.3 58.8 160.4 3.7

80.7

24.0 163.8

53.2

(Continued )

102

Industrial Construction Estimating Manual

(Continued) Historical Description

MH

Qty

MHa

ni

Estimate Unit Qty ni

Carpenter Labor IW ni MHa

Estimate sheet— combustion turbine and CTG generator

4280.5

Estimate sheet—fuel gas performance heater foundation Excavation (bathtub) 0.400 0.0 Forms (570 3 24.50 3 1.70 ) 0.300 268.9 Rebar 14.0 3.8 2.0 69.7 Concrete 0 0 0 (53 3 20.5 3 1.7 ) 0.500 17.2 Mud mat (570 3 24.50 3 0.330 ) Backfill, compact 0.600 26.4 Estimate sheet—rotor air cooler foundation Excavation (bathtub) 0.400 0.0 0.300 196 Forms (330 3 120 3 20 ) Rebar 14.0 1.2 Concrete (330 3 80 3 20 ) 2.0 20.5 5.5 Mud mat (370 3 120 3 0.330 ) 0.500 Backfill, compact 0.600 32.0 Estimate sheet—excitation skid and transformer foundation Excavation (bathtub) 0.400 0.0 Forms (26.330 3 170 3 20 ) 0.300 196 Rebar 14.0 1.3 Concrete (22.30 3 130 3 20 ) 2.0 22.6 0.500 5.5 Mud mat (26.330 3 170 3 0.330 ) Backfill, compact 0.600 32.0

cy sf ton cy

0.0 268.9 3.8 69.7

0.0 80.7 53.2 139.4

cy

17.2

8.6

cy

26.4

15.8 138.6

cy sf ton cy cy cy

0.0 196.0 1.2 20.5 5.5 32.0

600.2

0.0 58.8 16.8 41.0 2.8 19.2 144.2

cy sf ton cy cy

0.0 196.0 1.3 22.6 5.5

0.0 58.8 18.2 45.2 2.8

cy

32.0

19.2

2686.2 994.0

80.7 53.2 139.4 8.6

58.8

15.8 63.0

16.8

58.8 16.8

58.8

41.0 2.8 19.2 67.2

18.2

58.8 18.2 45.2 2.8 19.2

6.4.3 CTG and CTG-related foundations sheet 2 Historical Description

Estimate

MH

Qty

MHa

ni

Unit Qty ni

Estimate sheet—VT and surge cubicle foundation Excavation (bathtub) Forms (13.50 3 12.50 3 20 ) Rebar

Carpenter Labor IW ni MHa 69.7

0.400 0.300 14.0

0.0 cy 104 sf 0.4 ton

0.0 104.0 0.4

0.0 31.2 5.6

31.2

32.9

5.6

31.2 5.6

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

103

(Continued) Historical Description

Estimate

MH

Qty

MHa

ni

Unit Qty ni

ni MHa

Estimate sheet—VT and surge cubicle foundation

Concrete (9.50 3 8.50 3 20 ) Mud mat (13.50 3 12.50 3 0.330 ) Backfill, compact Estimate sheet—sample panel foundation Excavation (bathtub) Forms (380 3 120 3 2.10 ) Rebar Concrete (240 3 80 3 2.10 ) Mud mat (280 3 120 3 0.330 ) Backfill, compact Estimate sheet—compressor wash skid foundation Excavation (bathtub) Forms (220 3 130 3 2.10 ) Rebar Concrete (180 3 90 3 2.10 ) Mud mat (220 3 130 3 0.330 ) Backfill, compact Estimate sheet—GT water wash tank foundation Excavation (bathtub) Forms (200 3 100 3 1.50 ) Rebar Concrete (160 3 60 3 1.50 ) Mud mat (200 3 100 3 0.330 ) Backfill, compact

Carpenter Labor IW

69.7 2.0 0.500

6.3 cy 2.1 cy

6.3 2.1

12.6 1.1

0.600

32.0 cy

32.0

19.2 116.6

0.400 0.300 14.0 2.0 0.500 0.600

0.0 168 0.9 15.7 4.1 33.6

0.400 0.300 14.0 2.0 0.500 0.600

0.0 147 0.7 13.2 3.5 33.6

0.400 0.300 14.0 2.0 0.500 0.600

0.0 90 0.3 5.6 2.5 24.0

cy sf ton cy cy cy

cy sf ton cy cy cy

0.0 168.0 0.9 15.7 4.1 33.6

0.0 147.0 0.7 13.2 3.5 33.6

cy sf ton cy cy cy

0.0 90.0 0.3 5.6 2.5 24.0

0.0 50.4 12.6 31.4 2.1 20.2 102.2 0.0 44.1 9.8 26.4 1.8 20.2 58.1 0.0 27.0 4.2 11.2 1.3 14.4

31.2

32.9

5.6

12.6 1.1

50.4

19.2 53.6

12.6

50.4 12.6

44.1

31.4 2.1 20.2 48.3

9.8

44.1 9.8

27.0

26.4 1.8 20.2 26.9

4.2

27.0 4.2 11.2 1.3 14.4

6.4.4 STG and STG-related foundations sheet 3 Historical Description

MH

Qty

MHa

ni

Estimate Unit Qty ni

Estimate—steam turbine and steam turbine generator Excavation (bathtub) Forms (1200 3 670 3 9.30 ) Rebar Concrete (1160 3 630 3 9.30 )

Carpenter Labor IW ni MHa 8498.4

0.400 0.0 cy 0.300 3478.2 sf 14.0 145 ton 2.0 2643.0 cy

0.0 3478.2 145.0 2643.0

0.0 1043.5 2030.0 5286.0

1043.5

5424.9 2030.0

1043.5 2030.0 5286.0

(Continued )

104

Industrial Construction Estimating Manual

(Continued) Historical Description

Estimate

MH

Qty

MHa

ni

Unit Qty ni

ni MHa

Estimate—steam turbine and steam turbine generator

Mud mat (1200 3 670 3 0.330 ) Backfill, compact Estimate—closed cooling water heat exchangers (2 ea.) Excavation (bathtub) Forms (170 3 13.750 3 2.50 ) Rebar Concrete (130 3 9.750 3 2.50 ) Mud mat (170 3 13.750 3 0.330 ) Backfill, compact Estimate—closed cooling water pumps (2 ea.) Excavation (bathtub) Forms (150 3 90 3 30 ) Rebar Concrete (11.250 3 50 3 30 ) Mud mat (150 3 90 3 0.330 ) Backfill, compact Estimate—cooling tower chemical feed area Excavation (bathtub) Forms (410 3 340 3 2.50 ) Rebar Concrete (36.50 3 300 3 2.50 ) Mud mat (410 3 340 3 0.330 ) Backfill, compact Estimate—circulating water pump station and cooling tower Excavation (bathtub) Forms (480 3 310 3 30 ) Rebar Concrete (440 3 270 3 30 ) Mud mat (480 3 310 3 0.330 ) Backfill, compact

Carpenter Labor IW

8498.4

0.500 0.600

0.400 0.300 14.0 2.0 0.500 0.600

0.400 0.300 14.0 2.0 0.500 0.600

0.400 0.300 14.0 2.0 0.500 0.600

99.3 cy 148.8 cy

0.0 307.5 1.5 25.8 5.8

cy sf ton cy cy

80.0 cy

0.0 291 0.8 14.1 3.4 96.0

0.0 372.5 6.5 116.6 17.0 40.0

0.400 0.0 0.300 474 14.0 8 2.0 145.2 0.500 18.4 0.600 48.0

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

99.3 148.8

49.7 89.3 215.8

0.0 307.5 1.5 25.8 5.8

0.0 92.3 21.0 51.6 2.9

80.0

48.0 186.0

0.0 291.0 0.8 14.1 3.4 96.0

0.0 372.5 6.5 116.6 17.0 40.0

0.0 474.0 8.0 145.2 18.4 48.0

0.0 87.3 11.2 28.2 1.7 57.6 468.5 0.0 111.8 91.0 233.2 8.5 24.0 582.6

0.0 142.2 112.0 290.4 9.2 28.8

1043.5

92.3

5424.9 2030.0

49.7 89.3 102.5

21.0

92.3 21.0 51.6 2.9

87.3

48.0 87.5

11.2

87.3 11.2

111.8

28.2 1.7 57.6 265.7

91.0

111.8 91.0

142.2

233.2 8.5 24.0 328.4

112.0

142.2 112.0 290.4 9.2 28.8

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

105

6.4.5 Circulating water pump station and cooling tower Circulating water pump station and cooling tower Excavation (bathtub) Forms (760 3 1240 3 40 ) Rebar Concrete (720 3 1200 3 40 ) Mud mat (760 3 1240 3 0.330 ) Backfill, compact Estimate—sulfuric acid, coagulant tank, and pump foundations Excavation (bathtub) Forms (550 3 210 3 2.50 ) Rebar Concrete (510 3 170 3 2.50 ) Mud mat (550 3 210 3 0.330 ) Backfill, compact Estimate—condenser polishing unit Excavation (bathtub) Forms (180 3 140 3 2.50 ) Rebar Concrete (140 3 100 3 2.50 ) Mud mat (180 3 140 3 0.330 ) Backfill, compact Estimate—condenser extraction pumps Excavation (bathtub) Forms (190 3 110 3 2.50 ) Rebar Concrete (150 3 70 3 2.50 ) Mud mat (190 3 110 3 0.330 ) Backfill, compact Estimate—condenser vacuum pumps Excavation (bathtub) Forms (200 3 170 3 2.50 ) Rebar Concrete (160 3 130 3 2.50 ) Mud mat (190 3 170 3 0.330 ) Backfill, compact

5196.2 1200.0 2912.6 1083.6

0.400 0.0 0.300 4000 14.0 77.4 2.0 1408.0 0.500 116.3 0.600 64.0

cy 0.0 0.0 sf 4000.0 1200.0 1200.0 ton 77.4 1083.6 1083.6 cy 1408.0 2816.0 2816.0 cy 116.3 58.2 58.2 cy 64.0 38.4 38.4 390.2 114.0 206.2 70.0

0.400 0.300 14.0 2.0 0.500 0.600

0.0 380 5 92.3 14.3 24.0

cy sf ton cy cy cy

0.0 380.0 5.0 92.3 14.3 24.0

0.400 0.300 14.0 2.0 0.500 0.600

0.0 160 0.8 14.1 3.1 24.0

cy sf ton cy cy cy

0.0 160.0 0.8 14.1 3.1 24.0

0.400 0.300 14.0 2.0 0.500 0.600

0.0 150 0.6 11.2 2.6 24.0

cy sf ton cy cy cy

0.0 150.0 0.6 11.2 2.6 24.0

0.400 0.0 cy 0.300 185 sf 14.0 1.2 ton 2.0 22.1 cy 0.500 4.2 cy 0.600 24.0 cy

0.0 185.0 1.2 22.1 4.2 24.0

0.0 114.0 70.0 184.6 7.2 14.4 103.4 0.0 48.0 11.2 28.2 1.6 14.4 91.5 0.0 45.0 8.4 22.4 1.3 14.4 133.0 0.0 55.5 16.8 44.2 2.1 14.4

114.0 70.0

48.0

184.6 7.2 14.4 44.2

11.2

48.0 11.2

45.0

28.2 1.6 14.4 38.1

8.4

45.0 8.4

55.5

22.4 1.3 14.4 60.7

16.8

55.5 16.8 44.2 2.1 14.4

106

Industrial Construction Estimating Manual

6.4.6 Plant mechanical systemrelated foundations sheet 1 Historical Description

Estimate—Plant mechanical systemrelated foundations Estimate sheet—potable water skid Excavation (bathtub) Forms (220 3 140 3 2.50 ) Rebar Concrete (180 3 100 3 2.50 ) Mud mat (220 3 140 3 0.330 ) Backfill, compact Estimate sheet—demineralized storage tank Excavation (bathtub) Forms (320 3 260 3 2.50 ) Rebar Concrete (280 3 220 3 2.50 ) Mud mat (320 3 260 3 0.330 ) Backfill, compact Estimate sheet—oilwater separator (process drain) foundation Excavation (bathtub) Forms (180 3 100 3 2.50 ) Rebar Concrete (140 3 60 3 2.50 ) Mud mat (180 3 100 3 0.330 ) Backfill, compact Estimate sheet—oilwater separator (storm drain) foundation Excavation (bathtub) Forms (47 3 140 3 1.50 ) Rebar Concrete (42.50 3 100 3 1.50 ) Mud mat (470 3 140 3 0.330 ) Backfill, compact Estimate sheet—demineralized water forwarding pump skid Excavation (bathtub) Forms (6.5 3 100 3 30 ) Rebar Concrete (2.50 3 60 3 30 )

MH

Qty

MHa

ni

0.400 0.0 0.300 180 14.0 1 2.0 19.2 0.500 3.8 0.600 40.0

0.400 0.0 0.300 290 14.0 3.6 2.0 65.6 0.500 10.3 0.600 40.0

0.400 0.0 0.300 140 14.0 0.5 2.0 8.9 0.500 2.2 0.600 40.0

Estimate Unit Qty ni

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

0.400 0.0 cy 0.300 181.5 sf 14.0 1.4 ton 2.0 26.0 cy 0.500 8.0 cy 0.600 24.0 cy

0.400 0.300 14.0 2.0

0.0 99 0.1 1.8

cy sf ton cy

0.0 180.0 1.0 19.2 3.8 40.0

0.0 290.0 3.6 65.6 10.3 40.0

0.0 140.0 0.5 8.9 2.2 40.0

0.0 181.5 1.4 26.0 8.0 24.0

0.0 99.0 0.1 1.8

Carpenter Labor IW ni MHa 3165.5

355.7

132.3

54.0

0.0 54.0 14.0 38.4 1.9 24.0 297.8 0.0 87.0 50.4 131.2 5.2 24.0 91.9

0.0 42.0 7.0 17.8 1.1 24.0 144.5

0.0 54.5 19.6 52.0 4.0 14.4 64.4 0.0 29.7 1.4 3.6

2667.0 142.8 64.3

14.0

54.0 14.0

87.0

38.4 1.9 24.0 160.4

50.4

87.0 50.4

42.0

131.2 5.2 24.0 42.9

7.0

42.0 7.0

54.5

17.8 1.1 24.0 70.4

19.6

54.5 19.6

29.7

52.0 4.0 14.4 33.3

1.4

29.7 1.4 3.6

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

107

(Continued) Historical Description

MH

Qty

MHa

ni

Mud mat (6.50 3 100 3 0.330 ) 0.500 1.7 Backfill, compact 0.600 48.0 Estimate sheet—injection water storage tank Excavation (bathtub) 0.400 0.0 Forms (32 3 270 3 2.50 ) 0.300 295 Rebar 14.0 3.6 Concrete (280 3 230 3 2.50 ) 2.0 65.6 0 0 0 0.500 59.6 Mud mat (32 3 27 3 0.33 ) Backfill, compact 0.600 40.0

Estimate Unit Qty ni cy cy

cy sf ton cy cy cy

1.7 48.0

0.0 295.0 3.6 65.6 59.6 40.0

Carpenter Labor IW ni MHa 0.9 28.8 323.9 0.0 88.5 50.4 131.2 29.8 24.0

0.9 28.8 185.0

88.5

50.4

88.5 50.4 131.2 29.8 24.0

6.4.7 Plant mechanical systemrelated foundations sheet 2 Historical Estimate sheet—injection water forwarding pump Excavation (bathtub) Forms (6.5 3 100 3 30 ) Rebar Concrete (2.50 3 60 3 30 ) Mud mat (6.50 3 100 3 0.330 ) Backfill, compact Estimate sheet—STIG wastewater injection pump skid Excavation (bathtub) Forms (6.5 3 100 3 30 ) Rebar Concrete (2.50 3 60 3 30 ) Mud mat (6.50 3 100 3 0.330 ) Backfill, compact Estimate sheet—clarifier (2 ea.) Excavation (bathtub) Forms (24 3 210 3 2.50 ) Rebar Concrete (200 3 170 3 2.50 ) Mud mat (240 3 210 3 0.330 ) Backfill, compact

Estimate 64.4

0.400 0.300 14.0 2.0 0.500 0.600

99

0.0 cy sf 0.1 ton 1.8 cy 1.7 cy 48.0 cy

0.0 99.0 0.1 1.8 1.7 48.0

0.400 0.300 14.0 2.0 0.500 0.600

0.0 99 0.1 1.8 1.7 48.0

cy sf ton cy cy cy

0.0 99.0 0.1 1.8 1.7 48.0

0.400 0.300 14.0 2.0 0.500 0.600

0.0 450 3.8 69.3 12.4 80.0

cy sf ton cy cy cy

0.0 450.0 3.8 69.3 12.4 80.0

0.0 29.7 1.4 3.6 0.9 28.8 64.4

29.7

33.3

1.4

29.7 1.4

29.7

0.0 29.7 29.7 1.4 3.6 0.9 28.8 381.0 135.0 0.0 135.0 135.0 53.2 138.6 6.2 48.0

3.6 0.9 28.8 33.3

1.4

1.4 3.6 0.9 28.8 192.8

53.2

53.2 138.6 6.2 48.0

(Continued )

108

Industrial Construction Estimating Manual

(Continued) Historical Estimate sheet—clarified water storage tank Excavation (bathtub) Forms (52 3 1630 3 2.50 ) Rebar Concrete (480 3 1590 3 2.50 ) Mud mat (520 3 1630 3 0.330 ) Backfill, compact Estimate sheet—clarified water forwarding pump Excavation (bathtub) Forms (16 3 140 3 2.50 ) Rebar Concrete (120 3 100 3 2.50 ) Mud mat (160 3 140 3 0.330 ) Backfill, compact Estimate sheet—gas compressors (2 ea.) Excavation (bathtub) Forms (38 3 180 3 2.50 ) Rebar Concrete (340 3 140 3 2.50 ) Mud mat (380 3 180 3 0.330 ) Backfill, compact

Estimate 2552.6 322.5 1630.9 599.2

0.400 0.300 14.0 2.0 0.500 0.600

0.0 1075 42.8 777.3 104.6 40.0

0.400 0.300 14.0 2.0 0.500 0.600

0.0 150 0.7 12.2 2.8 40.0

0.400 0.300 14.0 2.0 0.500 0.600

0.0 560 5.3 97.0 16.9 80.0

cy 0.0 sf 1075.0 ton 42.8 cy 777.3 cy 104.6 cy 40.0

cy sf ton cy cy cy

cy sf ton cy cy cy

0.0 150.0 0.7 12.2 2.8 40.0

0.0 560.0 5.3 97.0 16.9 80.0

0.0 322.5 322.5 599.2 599.2 1554.6 1554.6 52.3 52.3 24.0 24.0 104.6 45.0 49.8 9.8 0.0 45.0 45.0 9.8 24.4 1.4 24.0 492.7 168.0

24.4 1.4 24.0 250.5

0.0 168.0 168.0 74.2 194.0 8.5 48.0

194.0 8.5 48.0

9.8

74.2

74.2

6.4.8 Plant mechanical systemrelated foundations sheet 3 Historical Estimate sheet—STIG plant gas compressor Excavation (bathtub) Forms (58 3 160 3 20 ) Rebar Concrete (540 3 120 3 20 ) Mud mat (580 3 160 3 0.330 ) Backfill, compact Estimate sheet—gas compressor filter foundation Excavation (bathtub) Forms (21 3 15.50 3 2.50 ) Rebar Concrete (170 3 11.50 3 2.50 ) Mud mat (210 3 15.50 3 0.330 ) Backfill, compact

Estimate 260.0

0.400 0.0 0.300 296 14.0 2.9 2.0 52.8 0.500 11.5 0.600 32.0

cy 0.0 sf 296.0 ton 2.9 cy 52.8 cy 11.5 cy 32.0

0.0 88.8 40.6 105.6 5.8 19.2 136.0

0.400 0.0 0.300 182.5 14.0 1.1 2.0 19.9 0.500 4.0 0.600 40.0

cy 0.0 sf 182.5 ton 1.1 cy 19.9 cy 4.0 cy 40.0

0.0 54.8 15.4 39.8 2.0 24.0

88.8 130.6 40.6

88.8 40.6 105.6 5.8 19.2 54.8 65.8 15.4

54.8 15.4 39.8 2.0 24.0

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

109

(Continued) Historical Estimate sheet—fuel gas filter separator foundation Excavation (bathtub) Forms (15 3 130 3 20 ) Rebar Concrete (110 3 90 3 20 ) Mud mat (150 3 130 3 0.330 ) Backfill, compact Estimate sheet—control oil skid foundation Excavation (bathtub) Forms (16 3 14.50 3 20 ) Rebar Concrete (120 3 10.50 3 20 ) Mud mat (160 3 14.50 3 0.330 ) Backfill, compact Estimate sheet—STG plant heat exchanger Excavation (bathtub) Forms (31.5 3 21.50 3 20 ) Rebar Concrete (27.50 3 17.50 3 20 ) Mud mat (31.50 3 21.50 3 0.330 ) Backfill, compact Estimate sheet—dry lime silos (5 ea.) Excavation (bathtub) Forms (15 3 130 3 2.50 ) Rebar Concrete (110 3 90 3 2.50 ) Mud mat (150 3 130 3 0.330 ) Backfill, compact

Estimate 75.8

0.400 0.0 0.300 112 14.0 0.4 2.0 8.1 0.500 2.4 0.600 32.0

cy 0.0 sf 112.0 ton 0.4 cy 8.1 cy 2.4 cy 32.0

0.0 33.6 5.6 16.2 1.2 19.2 86.3

33.6

36.6

5.6

33.6 5.6

36.6

16.2 1.2 19.2 41.3

8.4

0.400 0.0 0.300 122 14.0 0.6 2.0 10.3 0.500 2.9 0.600 32.0

cy 0.0 sf 122.0 ton 0.6 cy 10.3 cy 2.9 cy 32.0

0.0 36.6 8.4 20.6 1.5 19.2 195.9

0.400 0.0 0.300 211 14.0 2.2 2.0 39.2 0.500 8.4 0.600 32.0

cy 0.0 sf 211.0 ton 2.2 cy 39.2 cy 8.4 cy 32.0

0.400 0.0 0.300 700 14.0 2.8 2.0 51.1 0.500 12.0 0.600 200.0

cy 0.0 sf 700.0 ton 2.8 cy 51.1 cy 12.0 cy 200.0

0.0 63.3 63.3 30.8 30.8 78.4 78.4 4.2 4.2 19.2 19.2 477.4 210.0 228.2 39.2 0.0 210.0 210.0 39.2 39.2 102.2 102.2 6.0 6.0 120.0 120.0

36.6 8.4 20.6 1.5 19.2 63.3 101.8 30.8

6.4.9 Plant mechanical systemrelated foundations sheet 4 Historical Estimate sheet—air compressors (2 ea.) Excavation (bathtub) Forms (15 3 11.50 3 2.50 ) Rebar Concrete (110 3 7.50 3 2.50 ) Mud mat (150 3 11.50 3 0.330 ) Backfill, compact Estimate sheet—compressed air dryer Excavation (bathtub) Forms (12 3 120 3 2.50 ) Rebar Concrete (80 3 80 3 2.50 ) Mud mat (120 3 120 3 0.330 ) Backfill, compact

Estimate 175.9

0.400 0.0 0.300 265 14.0 0.9 2.0 16.8 0.500 4.3 0.600 80.0

cy 0.0 sf 265.0 ton 0.9 cy 16.8 cy 4.3 cy 80.0

0.400 0.0 0.300 120 14.0 0.3 2.0 6.2 0.500 1.8 0.600 40.0

cy 0.0 sf 120.0 ton 0.3 cy 6.2 cy 1.8 cy 40.0

0.0 79.5 12.6 33.6 2.2 48.0 77.5 0.0 36.0 4.2 12.4 0.9 24.0

79.5

83.8 12.6

79.5 12.6

36.0

33.6 2.2 48.0 37.3

4.2

36.0 4.2 12.4 0.9 24.0

(Continued )

110

Industrial Construction Estimating Manual

(Continued) Historical Estimate sheet—compressed air receiver Excavation (bathtub) Forms (12 3 120 3 2.50 ) Rebar Concrete (80 3 80 3 2.50 ) Mud mat (120 3 120 3 0.330 ) Backfill, compact Estimate sheet—clarified water and solids holding tanks (3 ea.) Excavation (bathtub) Forms (21 3 16.80 3 2.50 ) Rebar Concrete (170 3 12.80 3 2.50 ) Mud mat (210 3 16.80 3 0.330 ) Backfill, compact Estimate sheet—waste solids and recycle solids pump skid (2 ea.) Excavation (bathtub) Forms (21 3 180 3 2.50 ) Rebar Concrete (170 3 140 3 2.50 ) Mud mat (210 3 180 3 0.330 ) Backfill, compact Estimate sheet—clarified water pump skid foundation Excavation (bathtub) Forms (16 3 140 3 2.50 ) Rebar Concrete (120 3 100 3 2.50 ) Mud mat (160 3 140 3 0.330 ) Backfill, compact Estimate sheet—eyewash, showers, heaters (3 ea.) Excavation (bathtub) Forms (9 3 90 3 1.50 ) Rebar Concrete (50 3 50 3 1.50 ) Mud mat (90 3 90 3 0.330 ) Backfill, compact

Estimate 78.9

36.0

37.3

5.6

0.400 0.0 0.300 120 14.0 0.4 2.0 6.2 0.500 1.8 0.600 40.0

cy 0.0 sf 120.0 ton 0.4 cy 6.2 cy 1.8 cy 40.0

0.0 36.0 36.0 5.6 5.6 12.4 12.4 0.9 0.9 24.0 24.0 452.1 170.1 226.0 56.0

0.400 0.0 0.300 567 14.0 4 2.0 73.7 0.500 13.1 0.600 120.0

cy 0.0 sf 567.0 ton 4.0 cy 73.7 cy 13.1 cy 120.0

0.0 170.1 170.1 56.0 56.0 147.4 147.4 6.6 6.6 72.0 72.0 219.7 58.5 123.4 37.8

0.400 0.0 0.300 195 14.0 2.7 2.0 48.5 0.500 4.7 0.600 40.0

cy 0.0 sf 195.0 ton 2.7 cy 48.5 cy 4.7 cy 40.0

0.0 58.5 37.8 97.0 2.4 24.0 104.6

0.400 0.0 0.300 150 14.0 0.7 2.0 12.2 0.500 2.8 0.600 40.0

0.400 0.0 0.300 162 14.0 0.4 2.0 4.6 0.500 3.0 0.600 72.0

cy 0.0 sf 150.0 ton 0.7 cy 12.2 cy 2.8 cy 40.0

cy 0.0 sf 162.0 ton 0.4 cy 4.6 cy 3.0 cy 72.0

0.0 45.0 9.8 24.4 1.4 24.0 108.1 0.0 48.6 5.6 9.2 1.5 43.2

58.5 37.8

45.0

97.0 2.4 24.0 49.8

9.8

45.0 9.8

48.6

24.4 1.4 24.0 53.9

5.6

48.6 5.6 9.2 1.5 43.2

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

111

6.4.10 Utility distribution plant electrical controls sheet 1 foundations Historical Description

Excel estimate HRSG utility bridge foundations (4 ea.) Excavation (bathtub) Forms (29 3 310 3 3.50 ) Rebar Concrete (250 3 270 3 3.50 ) Mud mat (290 3 310 3 0.330 ) Backfill, compact Excel estimate STG utility bridge foundations (4 ea.) Excavation (bathtub) Forms (25 3 290 3 3.50 ) Rebar Concrete (210 3 250 3 3.50 ) Mud mat (250 3 290 3 0.330 ) Backfill, compact Excel estimate stair towers and ladders (4 ea.) Excavation (bathtub) Forms (10 3 100 3 20 ) Rebar Concrete (60 3 60 3 20 ) Mud mat (100 3 100 3 0.330 ) Backfill, compact Excel estimate stair towers and ladders (4 ea.) Excavation (bathtub) Forms (8 3 80 3 1.50 ) Rebar Concrete (40 3 40 3 1.50 ) Mud mat (80 3 80 3 0.330 ) Backfill, compact Excel estimate miscellaneous pipe support fen (100 ea.) Excavation (bathtub) Forms (4 3 2 3 1.60 ) Rebar Concrete (40 3 20 3 1.60 ) Mud mat (40 3 20 3 0.330 ) Backfill, compact Excel estimate miscellaneous concrete paving (100 ea.) Excavation (bathtub) Forms (108 3 4.5 3 0.50 )

MH

Qty

MHa

ni

Estimate Unit Qty ni

Carpenter Labor IW ni MHa 1777.8

0.400 0.0 0.300 1680 14.0 22.3 2.0 402.5 0.500 44.4 0.600 224.0

0.400 0.0 0.300 1512 14.0 17.1 1.5 313.1 0.500 35.8 0.600 224.0

0.400 0.0 0.300 320 14.0 0.4 1.5 12.3 0.500 4.9 0.600 128.0

0.400 0.0 0.300 192 14.0 0.5 1.5 4.1 0.500 3.2 0.600 96.0

0.400 0.0 0.300 960 14.0 3 1.5 54.5 0.500 9.9 0.600 0.0

0.400 0.0 0.300 108

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf

0.0 1680.0 22.3 402.5 44.4 224.0

0.0 1512.0 17.1 313.1 35.8 224.0

0.0 320.0 0.4 12.3 4.9 128.0

0.0 192.0 0.5 4.1 3.2 96.0

0.0 960.0 3.0 54.5 9.9 0.0

0.0 108.0

0.0 504.0 312.2 805.0 22.2 134.4 1315.0 0.0 453.6 239.4 469.7 17.9 134.4 199.3 0.0 96.0 5.6 18.5 2.5 76.8 130.0 0.0 57.6 7.0 6.2 1.6 57.6 416.7

0.0 288.0 42.0 81.8 5.0 0.0 253.9

0.0 32.4

504.0

961.6 312.2

504.0

453.6

312.2 805.0 22.2 134.4 622.0 239.4

453.6 239.4

96.0

469.7 17.9 134.4 97.7

5.6

96.0 5.6

57.6

18.5 2.5 76.8 65.4

7.0

57.6 7.0

288.0

6.2 1.6 57.6 86.7

42.0

288.0 42.0

32.4

81.8 5.0 0.0 172.5

49.0

32.4

(Continued )

112

Industrial Construction Estimating Manual

(Continued) Historical Description

MH

Qty

MHa

ni

Rebar 14.0 Concrete (1080 3 0.50 3 0.50 ) 1.5 Mud mat 0.500 (1080 3 4.50 3 0.330 ) Backfill, compact 0.600

Estimate Unit Qty ni

3.5 115.0 0.0 0.0

ton cy cy cy

Carpenter Labor IW ni MHa

3.5 115.0 0.0

49.0 172.5 0.0

172.5 0.0

49.0

0.0

0.0

0.0

6.4.11 Utility distribution plant electrical controls sheet 2 foundations Historical Estimate Excel estimate CTG iso-phase bus duct foundation (16 ea.) Excavation (bathtub) Forms (10 3 10 3 2.50 ) Rebar Concrete (60 3 60 3 2.50 ) Mud mat (100 3 100 3 0.330 ) Backfill, compact Excel estimate STG iso-phase bus duct foundation (16 ea.) Excavation (bathtub) Forms (10 3 10 3 2.50 ) Rebar Concrete (60 3 60 3 2.50 ) Mud mat (100 3 100 3 0.330 ) Backfill, compact Excel estimate CTG step-up transformer foundation (16 ea.) Excavation (bathtub) Forms (44 3 64 3 0.250 ) Rebar Concrete (400 3 600 3 0.250 ) Mud mat (440 3 640 3 0.330 ) Backfill, compact Excel estimate STG main stepup transformer fen (16 ea.) Excavation (bathtub) Forms (44 3 64 3 0.250 ) Rebar Concrete (400 3 600 3 0.250 ) Mud mat (440 3 640 3 0.330 ) Backfill, compact Excel estimate auxiliary transformer (16 ea.) Excavation (bathtub) Forms (34 3 30 3 0.60 )

265.6 120.0 106.4 0.400 0.0 0.300 400 14.0 2.8 1.5 53.3 0.500 4.9 0.600 40.0

cy sf ton cy cy cy

0.0 400.0 2.8 53.3 4.9 40.0

0.0 120.0 120.0 39.2 80.0 80.0 2.5 2.5 24.0 24.0 265.6 120.0 106.4

39.2

39.2

39.2

0.400 0.0 0.300 400 14.0 2.8 1.5 53.3 0.500 4.9 0.600 40.0

cy sf ton cy cy cy

0.0 400.0 2.8 53.3 4.9 40.0

0.0 120.0 120.0 39.2 39.2 80.0 80.0 2.5 2.5 24.0 24.0 1322.2 453.6 605.4 263.2

0.400 0.0 0.300 1512 14.0 18.8 1.5 355.6 0.500 139.1 0.600 4.0

cy sf ton cy cy cy

0.0 1512.0 18.8 355.6 139.1 4.0

0.0 453.6 453.6 263.2 263.2 533.4 533.4 69.6 69.6 2.4 2.4 1322.2 453.6 605.4 263.2

0.400 0.0 0.300 1512 14.0 18.8 1.5 355.6 0.500 139.1 0.600 4.0

cy sf ton cy cy cy

0.0 1512.0 18.8 355.6 139.1 4.0

0.0 453.6 453.6 263.2 263.2 533.4 533.4 69.6 69.6 2.4 2.4 1303.3 645.0 446.9 211.4

0.400 0.0 0.300 2150

cy sf

0.0 2150.0

0.0 645.0 645.0

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

113

(Continued) Historical Estimate Rebar Concrete (300 3 260 3 0.60 ) Mud mat (340 3 300 3 0.330 ) Backfill, compact Excel estimate SUS transformer (5 ea.) Excavation (bathtub) Forms (16 3 11 3 2.50 ) Rebar Concrete (120 3 70 3 2.50 ) Mud mat (160 3 110 3 0.330 ) Backfill, compact

14.0 15.1 1.5 277.3 0.500 50.4 0.600 9.6

ton cy cy cy

15.1 277.3 50.4 9.6

211.4 211.4 416.0 416.0 25.2 25.2 5.8 5.8 404.6 202.5 168.5 33.6

0.400 0.0 0.300 675 14.0 2.4 1.5 44.7 0.500 10.9 0.600 160.0

cy sf ton cy cy cy

0.0 675.0 2.4 44.7 10.9 160.0

0.0 202.5 202.5 33.6 67.1 5.5 96.0

33.6 67.1 5.5 96.0

6.4.12 Utility distribution plant electrical controls sheet 3 foundations Historical Estimate Excel estimate CTG PDC Excavation (bathtub) Forms (22 3 67 3 2.50 ) Rebar Concrete (180 3 630 3 2.50 ) Mud mat (220 3 670 3 0.330 ) Backfill, compact Backfill, compact Excel estimate STG/HRSG PDC Excavation (bathtub) Forms (47 3 37 3 2.50 ) Rebar Concrete (430 3 330 3 2.50 ) Mud mat (470 3 370 3 0.330 ) Backfill, compact Excel estimate miscellaneous cable tray supports and fdn. (5 ea.) Excavation (bathtub) Forms (8 3 6 3 1.60 ) Rebar Concrete (40 3 20 3 1.60 ) Mud mat (80 3 60 3 0.330 ) Backfill, compact Excel estimate transmission towers (6 ea.) Excavation (bathtub) Forms (13 3 10 3 4.50 ) Rebar Concrete (90 3 60 3 4.50 ) Mud mat (130 3 100 3 0.330 ) Backfill, compact

0.400 0.0 0.300 445 14.0 6.4 1.5 115.5 0.500 18.2 0.600 40.0 0.600 160.0

cy sf ton cy cy cy cy

0.400 0.0 0.300 420 14.0 7.9 1.5 144.5 0.500 21.5 0.600 40.0

cy sf ton cy cy cy

0.400 0.0 0.300 640 14.0 0.7 1.5 13.0 0.500 0.6 0.600 25.6

0.400 0.0 0.300 702 14.0 3.6 1.5 64.8 0.500 1.6 0.600 72.0

cy sf ton cy cy cy

cy sf ton cy cy cy

429.5 0.0 0.0 445.0 133.5 6.4 89.6 115.5 173.3 18.2 9.1 40.0 24.0 160.0 96.0 488.1 0.0 0.0 420.0 126.0 7.9 110.6 144.5 216.8 21.5 10.8 40.0 24.0 247.4

133.5 206.4

89.6

133.5 89.6 173.3 9.1 24.0 96.0 126.0 251.5 110.6 126.0 110.6 216.8 10.8 24.0 192.0 45.6

0.0 0.0 640.0 192.0 192.0 0.7 9.8 13.0 19.5 19.5 21.5 10.8 10.8 25.6 15.4 15.4 412.2 210.6 151.2 0.0 0.0 702.0 210.6 210.6 3.6 50.4 64.8 97.2 97.2 21.5 10.8 10.8 72.0 43.2 43.2 406.4 239.4 123.6

9.8

9.8

50.4

50.4

43.4

(Continued )

114

Industrial Construction Estimating Manual

(Continued) Historical Estimate Excel estimate takeoff towers (7 ea.) Excavation (bathtub) Forms (19 3 8 3 30 ) Rebar Concrete (150 3 40 3 30 ) Mud mat (190 3 8v 3 0.330 ) Backfill, compact Excel estimate disconnect switch Excavation (bathtub) Forms (14 3 29 3 20 ) Rebar Concrete (100 3 250 3 20 ) Mud mat (140 3 29v 3 0.330 ) Backfill, compact

0.400 0.0 0.300 798 14.0 3.1 1.5 56.0 0.500 1.9 0.600 48.0

cy sf ton cy cy cy

0.400 0.0 0.300 172 14.0 1.2 1.5 21.9 0.500 5.0 0.600 32.0

cy sf ton cy cy cy

0.0 0.0 798.0 239.4 239.4 3.1 43.4 56.0 84.0 21.5 10.8 48.0 28.8 131.2 51.6 0.0 0.0 172.0 51.6 51.6 1.2 16.8 21.9 32.9 21.5 10.8 32.0 19.2

43.4 84.0 10.8 28.8 62.8

16.8

16.8 32.9 10.8 19.2

6.4.13 Utility distribution plant electrical controls sheet 4 Historical Estimate Excel estimate circuit breaker Excavation (bathtub) Forms (19 3 11 3 3.50 ) Rebar Concrete (150 3 70 3 3.50 ) Mud mat (190 3 110 3 0.330 ) Backfill, compact Excel estimate pole supports (14 ea.) Excavation (bathtub) Forms (9 3 9 3 10 ) Rebar Concrete (50 3 50 3 10 ) Mud mat (90 3 9v 3 0.330 ) Backfill, compact Excel estimate miscellaneous small foundations (10 ea.) Excavation (bathtub) Forms (9 3 9 3 20 ) Rebar Concrete (50 3 50 3 20 ) Mud mat (90 3 9v 3 0.330 ) Backfill, compact Excel estimate electrical manholes (7 ea.) Excavation (bathtub) Forms (19 3 17 3 4.50 ) Rebar Concrete (90 3 60 3 4.50 ) Mud mat (190 3 17v 3 0.330 ) Backfill, compact

0.400 0.0 0.300 210 14.0 0.9 1.5 15.7 0.500 2.6 0.600 56.0

0.400 0.0 0.300 252 14.0 1 1.5 17.5 0.500 1.0 0.600 16.0

0.400 0.0 0.300 720 14.0 1.3 1.5 23.1 0.500 1.0 0.600 32.0

0.400 0.0 0.300 2872.8 14.0 18.2 1.5 331.4 0.500 4.0 0.600 91.2

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

cy sf ton cy cy cy

0.0 210.0 0.9 15.7 21.5 56.0

0.0 252.0 1.0 17.5 21.5 16.0

0.0 720.0 1.3 23.1 21.5 32.0

0.0 2872.8 18.2 331.4 21.5 91.2

143.5 0.0 63.0 12.6 23.6 10.8 33.6 136.2

63.0

67.9

12.6

63.0 12.6

75.6

23.6 10.8 33.6 46.6

0.0 75.6 75.6 14.0 26.3 10.8 9.6 298.8 216.0

26.3 10.8 9.6 64.6

0.0 216.0 216.0 18.2 34.7 10.8 19.2 1679.2 861.8

34.7 10.8 19.2 562.6

0.0 861.8 861.8 254.8 497.1 10.8 54.7

497.1 10.8 54.7

14.0

14.0

18.2

18.2

254.8

254.8

(Continued )

115

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

(Continued) Historical Estimate Excel estimate transmission towers (6 ea.) Excavation (bathtub) Forms (13 3 10 3 4.50 ) Rebar Concrete (90 3 60 3 4.50 ) Mud mat (130 3 10v 3 0.330 ) Backfill, compact Excel estimate transmission towers (6 ea.) Excavation (bathtub) Forms (5 3 7.8 3 70 ) Rebar Concrete (160 3 7.80 3 70 ) Mud mat (50 3 7.8v 3 0.330 ) Backfill, compact Excel estimate trenches, curbs, equip pads, piers, etc. Excavation (bathtub) Forms (5 3 7.8 3 70 ) Rebar Concrete (160 3 7.80 3 70 ) Mud mat (50 3 7.8v 3 0.330 ) Backfill, compact

0.400 0.0 0.300 702 14.0 3.6 1.5 64.8 0.500 1.6 0.600 72.0

cy sf ton cy cy cy

0.400 0.0 0.300 420 14.0 25.7 1.5 233.0 0.500 0.5 0.600 0.0

cy sf ton cy cy cy

0.400 0.0 0.300 0 14.0 73 1.5 1326.0 0.500 0.0 0.600 0.0

cy sf ton cy cy cy

0.0 702.0 3.6 64.8 21.5 72.0

0.0 420.0 25.7 233.0 21.5 0.0

412.2 210.6

151.2

0.0 210.6 210.6 50.4 97.2 10.8 43.2 846.1 126.0

97.2 10.8 43.2 360.3

50.4

50.4

359.8

0.0 126.0 126.0 359.8 359.8 349.5 349.5 10.8 10.8 0.0 0.0 3021.8 0.0 1999.8 1022.0

0.0 0.0 0.0 0.0 73.0 1022.0 1326.0 1989.0 21.5 10.8 0.0 0.0

0.0 1022.0 1989.0 10.8 0.0

6.5 Summary foundation man-hours Direct craft man-hours

Estimate

Scope of work

MH

Carpenter

Labor

IW

Foundations Boiler foundations CTG and CTG-related foundations STG and STG-related foundations Plant mechanical systemrelated foundations Utility distribution plant electrical controls foundations

53,530 7347 5528 15,865 7161

13,081 1138 1025 2939 2046

29,452 4550 3330 9471 3962

10,997 1659 1173 3455 1152

17,628

5932

8138

3557

6.6 Mechanical equipment (CTG, STG, heat recovery steam generator) includes vendor piping 6.7 HRSG triple pressure; three wide-installation man-hours HRSG triple pressure; three wide-installation man-hours Excel spreadsheet summary HRSG vendor piping (PF) Excel spreadsheet summary HRSG equipment (BM)

59,600 35,341 24,258

116

Industrial Construction Estimating Manual

HRSG triple pressure; three wide-installation equipment man-hours

24,258

HRSG—module casing HRSG—ductwork SCR and inlet HRSG—erect gas baffles HRSG—modules HRSG—pressure vessels HRSG—install duct burner assemblies and elements HRSG—steel (ladders, platforms, and grating) HRSG—skids HRSG—stack and breeching HRSG—SCR and CO2 internals

6528 3606 2578 1111 420 1160 4300 240 2898 1417

6.8 Estimate heat recovery steam generator triple pressure; three wide Historical Description

MH

Qty

MHa

ni

Estimate Unit

Qty

BM

ni

ni MHa

Estimate—heat recovery steam generator

24,258

6.8.1 HRSG—module casing

6528

Slide plate assemblies Shim and set slide/base plates (provide shims) Weld shear blocks Grout base plates Anchor bolts Erect casing panels and assemblies Casing assembly—columns, floor beams Roof beam corner angle Bellows Install roof/floor beam assemblies Roof beams assembly Frame connections Moment welds Moment weld-col 13/16v single groove/3/16v fillet Boltup 7/8v diameter 3 2v Fillet weld at web 1/4v Remove lift lug Remove angle clip

1.00

45.0

EA

45.0

45.0

0.50 4.00 0.65

180.0 45.0 180.0

EA EA EA

180.0 45.0 180.0

90.0 180.0 117.0

20.00

35.0

EA

35.0

700.0

4.00 2.60

24.0 40.0

EA EA

24.0 40.0

96.0 104.0

25.00

24.0

EA

24.0

600.0

12.00

128.0

EA

128.0

1536.0

1.00 2.00 0.50 0.50

96.0 64.0 32.0 32.0

EA EA EA EA

96.0 64.0 32.0 32.0

96.0 128.0 16.0 16.0 (Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

117

(Continued) Historical Description

Field seam liners and insulation Install ceramic fiber blanket Install ogee clips, washers, bolt, and weld washer Install mesh SS screen wire Install insulation and liner plates Weld casing seams Casing assembly w/cols Casing assembly w/floor beams Roof casing w/tube bundle assembly Casing panel Fit up

MH

Qty

MHa

ni

Estimate Unit

Qty

BM

ni

ni MHa

0.04 0.25

4663.4 460.0

SF EA

4663.4 460.0

186.5 115.0

0.04 1.00

4663.4 460.0

SF SF

4663.4 460.0

186.5 460.0

0.35 0.35 0.35

1537.0 897.0 1255.8

LF LF LF

1537.0 897.0 1255.8

538.0 314.0 439.5

0.35 0.05

973.6 4663.4

LF LF

973.6 4663.4

340.8 223.8

6.8.2 HRSG—ductwork SCR and inlet Slide plate assemblies (SCR and inlet) Shim and set slide/base plates (provide shims) Weld sheer blocks Grout base plates Anchor bolts Erect casing panels and assemblies Casing assembly, flange assembly, and grid assembly Floor panel Casing assembly w/roof beam Install roof/floor beam assemblies SCR Roof beams assembly Moment welds Frame connection: inlet duct “A,” “B,” “C,” and “D” Moment weld-col 13/16v single groove/3/16v fillet Moment weld-col 9/16v single groove/3/16v fillet Moment weld-col 5/8v single groove/3/16v fillet Boltup 7/8v diameter 3 2v Fillet weld at web 1/4v Remove lift lug Remove angle clip

3606 1.00 0.50 4.00 0.65

12.0 48.0 12.0 48.0

EA EA EA EA

12.0 48.0 12.0 48.0

12.0 24.0 48.0 31.2

10.00

24.0

EA

24.0

240.0

10.00 20.00

8.0 6.0

EA EA

8.0 6.0

80.0 120.0

25.00

6.0

EA

6.0

150.0

12.00

48.0

EA

48.0

576.0

10.00

32.0

EA

32.0

320.0

8.00

16.0

EA

16.0

128.0

1.00 2.00 0.50 0.50

48.0 31.5 32.0 48.0

EA EA EA EA

48.0 31.5 32.0 48.0

48.0 63.0 16.0 24.0

(Continued )

118

Industrial Construction Estimating Manual

(Continued) 6.8.2 HRSG—ductwork SCR and inlet

3606

Field seam liners and insulation Inlet duct Field joint at wall

Install insulation and liner plates 1.00 Install ogee clips, washers, bolt, and weld 0.25 washer Field joint at floor and roof Install insulation and liner plates 1.00 Install ogee clips, washers, bolt, and weld 0.25 washer SCR/CO Insulate and install lower liner plates at field seams Plates 1.00 Insulation 0.04 Weld casing seams Spool duct Casing panel 0.35 Casing panel 0.35 Roof casing w/tube bundle assembly 0.35 SCR Casing assembly w/cols 0.35 Casing assembly w/floor beams 0.35 Roof casing w/tube bundle assembly 0.35 Inlet duct Field joint at wall Seal weld secondary casing to column 0.35 Field joint at floor and roof Seal weld secondary casing to column 0.35 Cover plate-floor/roof 0.35

150.0 150.0

EA EA

150.0 150.0

150.0 37.5

120.0 120.0

EA EA

120.0 120.0

120.0 30.0

400.0 4800.0

EA SF

400.0 4800.0

400.0 192.0

307.4 175.4 175.4

LF LF LF

307.4 175.4 175.4

107.6 61.4 61.4

307.4 165.4 165.4

LF LF LF

307.4 165.4 165.4

107.6 57.9 57.9

440.0

LF

440.0

154.0

270.0 270.0

LF LF

270.0 270.0

94.5 94.5

6.8.3 HRSG—erect gas baffles, pressure vessels, modules, and duct burner Install side wall gas baffles Baffle plates Fillet weld Install upper splice gas baffles Splice plates U-bolt connections Install lower gas baffles Baffle plates U-bolt connections Header/shipping restraints Angle 4 3 4 3 3/4 3 60 -1-5/8v Tube bundle gas baffles Baffle plates

5269

0.75 0.35

880.0 1320.0

EA LF

880.0 1320.0

660.0 462.0

0.75 0.35

647.0 647.0

EA EA

647.0 647.0

485.3 226.5

0.75 0.35

307.0 307.0

EA EA

307.0 307.0

230.3 107.5

1.00

78.0

EA

78.0

78.0

0.75

299.0

EA

299.0

224.3

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

119

(Continued) 6.8.3 HRSG—erect gas baffles, pressure vessels, modules, and duct burner Fillet weld Estimate—modules HRSG—modules Reheater 3 HP superheated 2/reheater 2 HP superheated 1/reheater 1 HP evaporator/IP superheated 2 HP economizer 2/IP superheated 1 HP economizer 1/IP economizer 1/LP evaporator Feedwater heater 2 Feedwater heater 1 Estimate—pressure vessels HRSG—pressure vessels

5269 0.35

299.0

LF

299.0

104.7

2.20 1.80 1.40 1.50 1.50

56.0 65.5 165.5 147.0 138.5

ton ton ton ton ton

56.0 65.5 165.5 147.0 138.5

123.2 117.9 231.7 220.5 207.8

2.20 2.50

55.0 35.5

ton ton

55.0 35.5

121.0 88.8

Set saddle base plates 24.00 Set drum 1.40 IP steam drum Set saddle base plates 24.00 Set drum 2.50 LP steam drum Set saddle base plates 24.00 Set drum 2.20 Flash separator Set saddle base plates 24.00 Set drum 2.50 Estimate—duct burner HRSG—install duct burner assemblies and elements Duct burner assembly 20.00 Scanner, hose, and retainer assembly 10.00 Element support 5.00

1.0 158.0

EA ton

1.0 158.0

24.0 220.4

1.0 9.0

EA ton

1.0 9.0

24.0 22.5

1.0 30.0

EA ton

1.0 30.0

24.0 66.0

1.0 6.0

EA ton

1.0 6.0

24.0 15.0

18.0 55.0 50.0

EA EA EA

18.0 55.0 50.0

360.0 550.0 250.0

HP steam drum

6.8.4 HRSG—steel (ladders, platforms, and grating), skids, SCR, and CO Assemble and install all of the structural steel and platforms Top of HRSG L0 3 W0 0.40 4140.0 HP, IP, LP drums L0 3 W0 0.40 540.0 0.40 1080.0 Top of inlet duct L0 3 W0 Right/left side X EA times (L0 3 W0 ) 0.40 518.4 Stair tower X EA times (L0 3 W0 ) 0.40 384.0 Misc X EA times (L0 3 W0 ) 0.40 216.0 Handrail LF 0.32 714.0 Ladders LF 1.00 360.0 Stair tower structural 32.00 30.0

5957

SF SF SF SF SF SF LF LF ton

4140.0 540.0 1080.0 518.4 384.0 216.0 714.0 360.0 30.0

1656.0 216.0 432.0 207.4 153.6 86.4 228.5 360.0 960.0

(Continued )

120

Industrial Construction Estimating Manual

(Continued) 6.8.4 HRSG—steel (ladders, platforms, and grating), skids, SCR, and CO Estimate—skids HRSG—skids Level and set the AFCU skid Level and set the piping module Level and set the blower skid Estimate—SCR and CO HRSG—SCR and CO2 internals

5957

80.00 80.00 80.00

1.0 1.0 1.0

EA EA EA

1.0 1.0 1.0

80.0 80.0 80.0

1.00 30.00

100.0 2.0

EA EA

100.0 2.0

100.0 60.0

30.00 0.35 0.35

6.0 560.0 18.0

EA LF EA

6.0 560.0 18.0

180.0 196.0 6.3

0.35 0.75 0.35

216.0 216.0 216.0

LF EA EA

216.0 216.0 216.0

75.6 162.0 75.6

2.00 0.35 0.25

62.0 1060.0 265.0

EA LF LF

62.0 1060.0 265.0

124.0 371.0 66.3

Install internal structure

Remove shipping braces Set support structure and cut/weld and grind lifting lugs Set left, middle right internal structure Weld structure bases to each other Insert and weld top and side pins-4v-1/4v fillet weld Catalyst anchor installation Set anchor channel and weld to structure Install T-shaped anchors Make up T-shaped-washer/nut w/jam nut Seal plate installation Install side/top/bottom slide plates Weld seal plates Trim seal plates

6.8.5 HRSG—stack and breeching (XX0-Xv OD 3 XXX0-Xv high) Erect lower stack Seam up shell cans for lower section Set shell cans (field fabrication) 4.00 Weld vertical (shell can to shell can 0.75 w/stiffener splices) Stack shell cans and weld to make up lower sections Set shell cans 4.00 Weld horizontal 0.75 Shoot shim packs, erect lower stack, and grout base ring Shims and bolt to foundation 2.40 Set lower stack section 60.00 Load and haul to erection site 4.00 Erect damper Seam up (2) damper halves Set up damper halves (field fabrication) 10.00 Weld damper halves 0.80

2898

16.0 224.0

EA LF

16.0 224.0

64.0 168.2

16.0 450.0

EA LF

16.0 450.0

64.0 337.5

32.0 1.0 28.0

EA EA EA

32.0 1.0 28.0

76.8 60.0 112.0

2.0 20.0

EA LF

2.0 20.0

20.0 16.0

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

121

(Continued) 6.8.5 HRSG—stack and breeching (XX0-Xv OD 3 XXX0-Xv high) Boltup 0.40 Load and haul dampers to erection site 16.00 Erect upper stack Seam up shell cans for upper section Set shell cans (field fabrication) 4.00 Weld vertical (shell can to shell can 0.75 w/stiffener splices) Stack shell cans and weld to make up upper sections Set shell cans 4.00 Weld horizontal 0.50 Erect upper stack sections Set upper sections 60.00 Weld horizontal 0.75 Load and haul to erection site 4.00 Attach structural steel and platforms 360-Degree platform 0.15 Ladder 0.35 360-Degree platform 0.15 Bridge 0.15 Fit and weld breech sections to stack Set panels 60.00 Weld 0.75 Install expansion joint Expansion joint 60.00 Backup bars 1.00 Boltup 0.25 Expanded metal 1.20

2898 100.0 2.0

EA EA

100.0 2.0

40.0 32.0

14.0 220.0

EA LF

14.0 220.0

56.0 165.2

16.0 460.0

EA LF

16.0 460.0

64.0 230.0

1.0 120.0 20.0

EA LF EA

1.0 120.0 20.0

60.0 90.0 80.0

360.0 132.0 360.0 240.0

EA LF SF SF

360.0 132.0 360.0 240.0

54.0 46.2 54.0 36.0

2.0 330.0

EA LF

2.0 330.0

120.0 247.8

1.0 24.0 1120.0 200.0

EA EA EA EA

1.0 24.0 1120.0 200.0

60.0 24.0 280.0 240.0

6.9 Heat recovery steam generator large bore vendor piping Excel spreadsheet summary HRSG vendor piping

14,145 lf

35,341 2.50

Excel summary HRSG LB and SB vendor piping

7343

20,720 2.82

lf

Qty

HRSG—large bore code piping HP piping and supports—ASME Section 1 IP piping and supports—ASME Section 1 LP piping and supports—ASME Section 1 RP piping and supports—ASME Section 1 HP piping and Supports—ASME B31.1 IP piping and supports—ASME B31.1 LP piping and supports—ASME B31.1 RP piping and supports—ASME B31.1

PF

ni

Unit ni MHa MH/LF

4238 519 136 134 177 504 646 944 438

lf lf lf lf lf lf lf lf lf

15,529 3182 403 300 1548 3031 1022 2051 2191

3.66 3.10 2.96 2.24 8.75 6.01 1.58 2.17 5.00

(Continued )

122

Industrial Construction Estimating Manual

(Continued) Excel spreadsheet summary HRSG vendor piping

14,145 lf

35,341 2.50

Excel summary HRSG LB and SB vendor piping

7343

20,720 2.82

lf

Qty ni Silencer drain piping and supports HRSG—large bore code piping

PF Unit ni MHa MH/LF

740 lf 4238.0 lf

HP piping and supports—ASME Section 1 MH

2.43 15,529.4

519

lf

3182

Qty

Unit Qty

PF

Line no.

Material

Size Sch/Thk

ni

ni MHa

HP-03 econ 1 to HP econ 2 HP-03 econ 1 to HP econ 2 HP-04 econ 2 to HP steam drum HP-04 econ 2 to HP steam drum HP-09 steam drum to HP SH 1 HP-10 steam drum to HP SH 1 HP-11 steam drum to HP SH 1 HP-12 steam drum to HP SH 1 HP-13 steam drum to HP SH 1 HP-14 steam drum to HP SH 1 HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-15 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-16 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 HP-17 SHTR 1 to HP SHTR 2 IP piping and supports—ASME Section 1 IP-03 econ to IP steam drum IP-03 econ to IP steam drum IP-06 drum to IP superheater 1 IP-06 drum to IP superheater 1 IP-09 SH 1 to IP SH 2 LP piping and supports—ASME Section 1 LP-10 steam drum to LP SHTR 1 LP-10 steam drum to LP SHTR 1 LP-10 steam drum to LP SHTR 1 LP-14 SHTR 1 to LP SHTR 2 LP-15 SHTR 1 to LP SHTR 2 RP piping and supports—ASME Section 1 RP-03 reheater 1 to reheater 2 RP-03 reheater 1 to reheater 2 RP-03 reheater 1 to reheater 2

SA-106-B SA-106-B SA-106-B SA-106-C SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-335-P91 SA-335-P91 SA-335-P91 SA-335-P91 SA-335-P91 SA-335-P91 SA-335-P91 SA-335-P91 SA-335-P91

8 6 8 6 6 6 6 6 6 6 10 8 3 10 8 3 10 8 3

140/.906 2.2 160/.906 4.1 140/.812 3.1 160/.906 31.1 160/.906 3.8 160/.906 3.4 160/.906 3.9 160/.906 3.4 160/.906 3.9 160/.906 3.4 1.25 9.4 1 24.9 0.6 1.25 9.1 1 24.9 0.6 1.25 9.4 1 24.9 0.6

25 42 96 1 24 23 23 23 23 23 68 3 1 68 3 1 68 3 1 136.0

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

25 42 96 1 24 23 23 23 23 23 68 3 1 68 3 1 68 3 1

54.9 173.2 295.1 31.1 90.7 79.3 89.2 79.3 89.2 79.3 638.5 74.6 0.6 618.5 74.6 0.6 638.5 74.6 0.6 403.0

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

4 3 10 6 10

40 40 40 40 40

2.48 4.54 2.37 13.37 2.61

53 6 42 5 30 134.0

lf lf lf lf lf lf

53 6 42 5 30

131.2 27.3 99.6 66.9 78.2 300.2

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

14 10 8 10 10

std 40 40 40 40

2.22 2.32 3.11 2.01 2.07

26 34 12 32 30 177.0

lf lf lf lf lf lf

26 34 12 32 30

57.7 78.8 37.3 64.4 62.0 1548.0

lf lf lf

137 20 20

745.5 797.4 5.1

SA-335-P91 24 SA-335-P91 24 3

MHa

1800

ni

80/1.218 5.44 137 80/.843 39.87 20 0.26 20

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

123

6.9.1 Piping and supports—ASME B31.1 sheet 1 HP piping and supports—ASME B31.1 HP-01 feedwater inlet HP-01 feedwater inlet HP-01 feedwater inlet HP-02-steam outlet HP-02-steam outlet HP-18 SHP-PSV-104 to SHP-S1-002 (stm out) HP-19 start-up vent piping HP-20 sparging steam header HP-21 SHP-PSV-112A to SHP-S1-001 (Drum) HP-22 SHP-PSV-112B to SHP-S1-001 (Drum) HP-23 upper drain piping coll header HP-23 upper drain piping coll header HP-24 steam drum warming connection HP-25 SHP-PSV-104 stack piping HP-25 SHP-PSV-104 stack piping HP-26 SHP-PSV-112A stack piping HP-26 SHP-PSV-112A stack piping HP-27 SHP-PSV-112B stack piping HP-27 SHP-PSV-112B stack piping IP piping and supports—ASME B31.1 IP-01 feedwater inlet IP-02-steam outlet IP-02-steam outlet IP-10 pegging steam IP-10 pegging steam IP-11 SIP-PSV-109 to SIP-SI-002 (stm out) IP-12 start-up to SIP-SI-005 IP-13 SIP-PSV-106 to SIP-SI-001 (drum) IP-15 sparging steam header IP-16 intermittent blow off IP-17 SIP-PSV-109 stack piping IP-17 SIP-PSV-109 stack piping IP-18 SIP-PSV-106 stack piping IP-18 SIP-PSV-106 stack piping IP-19 flash tank 1 to IP drum IP-20 F.S. 1 to blowdown tank IP-21 BFW-PSV 200 outlet piping

504.0 lf SA-106-C SA-106-C SA-106-C SA-335-P91 SA-335-P91

10 160/1.125 3.09 47 6 160/.718 9.00 3 10 1.5 5.09 57 14 1.75 11.91 44 10 1.25 8.65 26 6 0.39 20

SA-335-P91 8 SA-106-B 3 6

120/.718 160/.437

6 SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

8 3 4 14 16 18 16 18 16

40 40 160 40 40 40 40 20 12

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

4 10 8 16 6 4 6 6 3 2.5 10 8 12 10 2.5 6 2.5

40 40 40 std 40

SA-106-B Sa-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

40 40 80 40 40 40 40 80 80 160

47 3 57 44 26 20

145.0 27.0 290.0 523.9 224.9 7.8

4.58 22 1.69 42 1.92 20

lf 22 lf 42 lf 20

100.7 71.0 38.4

1.92 20

lf 20

38.4

10.56 0.46 3.12 2.72 21.12 23.76 6.05 4.32 6.88

lf lf lf lf lf lf

3031.4

20 66 16 29 20 20 12

lf lf lf lf lf lf lf lf 20 lf 646.0 lf 1.06 136 lf 1.88 84 lf 11.14 4 lf 18.88 7 lf 2.46 18 lf 0.90 20 lf 3.51 19 lf 1.35 20 lf 0.77 38 lf 0.85 84 lf 7.30 20 lf 1.02 20 lf 0.96 20 lf 1.39 16 lf 0.46 18 lf 0.48 20 lf 0.59 102 lf

20 66 16 29 20 20 12 20 20

211.2 30.2 49.9 78.8 422.4 475.2 72.6 86.4 137.6 1021.7 136 143.9 84 157.7 4 44.6 7 132.2 18 44.3 20 18.0 19 66.7 20 27.0 38 29.2 84 71.6 20 146.0 20 20.4 20 19.2 16 22.3 18 8.4 20 9.6 102 60.7

944.0 lf

2051.1

6.9.2 Piping and supports—ASME B31.1 sheet 2 LP piping and supports—ASME B31.1 LP-01 feedwater inlet LP-01 feedwater inlet LP-02 steam outlet

SA-106-B SA-106-B SA-106-B

8 40 6 40 14 std

1.83 109 2.34 20 3.41 65

lf 109 lf 20 lf 65

199.1 46.8 221.4

(Continued )

124

Industrial Construction Estimating Manual

(Continued) LP piping and supports—ASME B31.1 LP-02 steam outlet LP-02 steam outlet LP-02 steam outlet LP-03 LP FW heater bypass LP-04 FW heater 1 to FW heater 2 LP-05 FW heater 1 to FW heater 2 LP-06 FW heater 1 to FW heater 2 LP-07 FW heater 2 to LP steam drum LP-07 FW heater 2 to LP steam drum LP-16 boiler feed pump recirc. LP-16 boiler feed pump recirc. LP-17 boiler feed pump recirc. LP-17 boiler feed pump recirc. LP-20 RAC to LP steam drum LP-21 SLP-PSV-102 to SLP-SI-002 (stm out) LP-22 start-up vent to SLP-SI-003 LP-23 SLP-PSV-104A to SLP-SI-001 (drum) LP-24 SLP-PSV-104B to SLP-SI-001 (drum) LP-26 sparging steam header LP-27 intermittent blow off LP-28 SLP-PSV-102 stack piping LP-28 SLP-PSV-102 stack piping LP-29 SLP-PSV-104A stack piping LP-29 SLP-PSV-104A stack piping LP-30 SLP-PSV-104B stack piping LP-30 SLP-PSV-104B stack piping RP piping and supports—ASME B31.1 RP-01 reheater 1 inlet RP-01 reheater 1 inlet RP-01 reheater 1 inlet RP-02 reheater 3 outlet RP-02 reheater 3 outlet RP-02 reheater 3 outlet RP-02 reheater 3 outlet RP-09 SIP-PSV-108A to SIP-SI-003 (CLD RH) RP-10 SIP-PSV-108B to SIP-SI-003 (CLD RH) RP-11 SIP-PSV-105 to SIP-SI-004 (RH out) RP-12 start-up vent RP-13 SIP-PSV-108A stack piping RP-13 SIP-PSV-108A stack piping RP-13 SIP-PSV-108B stack piping RP-13 SIP-PSV-108B stack piping RP-15 SIP-PSV-105 stack piping RP-15 SIP-PSV-105 stack piping RP-03 cooling air piping

944.0 lf SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

10 8 3 8 6 6 6 8 6 6 6 6 6 10 6 8 6 6 3 2.5 10 8 10 8 10 8

40 std 40 40 40 40 40 40 40 1 40 1 40 40

40 80 40 40 40 40 40 40

5.76 10.24 0.12 16.77 4.90 4.90 4.90 4.64 7.38 1.11 2.10 1.20 2.10 1.58 1.62 3.71 1.62 1.62 1.04 0.81 0.80 1.50 0.80 2.71 0.80 2.20

60 14 20 50 24 20 20 20

132.4 204.8 2.4 50.3 24.5 24.5 24.5 208.8 44.3 54.5 12.6 51.6 12.6 320.4 32.4 70.4 32.4 32.4 39.5 73.7 16.0 30.0 16.0 32.5 16.0 24.2 2191.4 364.6 369.6 9.6 342.0 346.3 30.0 3.2 32.4

1.62 20

lf 20

32.4

1.62 6.90 2.70 5.01 3.00 6.19 2.10 3.66 0.68

lf lf lf lf lf lf lf lf lf

SA-106-B SA-106-B

24 60/1.218 6.08 16 60/.843 26.40 6 0.48 SA-335-P91 24 60/1.218 6.84 SA-335-P91 16 60/.843 14.43 SA-335-P91 10 40 1.50 4 0.16 6 1.62 6

SA-335-P91 SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

6 10 18 16 20 18 14 12 3

40 40 40 40 40 40 40 40

23 20 20 3 5 5 5 45 6 49 6 43 6 203 20 19 20 20 38 91 20 20 20 12 20 11 438.0 60 14 20 50 24 20 20 20

20 27 20 19 20 16 20 20 28

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

2051.1 23 20 20 3 5 5 5 45 6 49 6 43 6 203 20 19 20 20 38 91 20 20 20 12 20 11

20 27 20 19 20 16 20 20 28

32.4 186.4 54.0 95.2 60.0 99.0 42.0 73.2 19.2

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

125

6.9.3 Piping and supports—ASME B31.1 sheet 3 Silencer drain piping and supports 14v-RP-03 PRVS-X703B to SIL-X704 10v-RP-05 PRVS-X703A to SIL-X704 10v-RP-10 PRVS-X704 to SIL-X705 12v-RP-08 MOV-X211/212 SIL-X706 10v-HP-13 PRVS-X802 to SIL-X803 12v-HP-17 PRVS-X801A to SIL-X801 8v-LP-13 PRVS-X602 to SIL-X603 6v-IP-10 PRVS-X702 to SIL-X703 4v-IP-08 MOV-X205/206 to SIL-X702 8v-IP-12 PRVS-701 to SIL-X701 12v-LP-11 MOV-X106/107 to SIL-X602 8v-LP-15 PRVS-X601A to SIL-X601 8v-LP-17 PRVS-X601B to SIL-X601 12v-HP-15 PRVS-X801B to SIL-X801 6v-IP-11 MOV-X310/311 to SIL-X803 PSV Drip Pan Assembly

740.0 lf SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

14 14 10 12 10 12 8 6 4 8 12 8 8 12 6 6

40 40 40 40 40 40 40 40 40 40 40

3.04 3.04 2.55 4.49 2.17 2.61 1.74 1.30 1.50 1.74 4.49 1.74 1.74 40 2.61 40 2.40 40 2.25

40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 140

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

1800.3 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 140

121.7 121.7 101.9 179.5 86.9 104.3 69.5 52.1 59.8 69.5 179.5 69.5 69.5 104.3 96.0 314.5

6.10 Heat recovery steam generator small bore vendor piping 6.10.1 Excel spreadsheet summary heat recovery steam generator vendor piping Qty

HRSG—small bore code piping HP piping and supports IP piping and supports LP piping and supports RP piping and supports Blowdown piping Instrumentation

PF

ni

Unit

ni MHa

MH/LF

3105 760 700 420 385 680 160

lf lf lf lf lf lf lf

5191 1125 957 580 604 880 1044

1.67 1.48 1.37 1.38 1.57 1.29 6.53

126

Industrial Construction Estimating Manual

6.10.2 Heat recovery steam generator—small bore code piping

HP piping and supports MH

2945 lf

4147

760

1125

Qty Unit Qty PF

Line no.

Material Size Sch/Thk MHa ni

HP-51 superheater 2 drain HP-50 superheater 1 drain HP economizer 1 drain HP economizer 2 drains HP-18-A sparging header HP-23-D manifold drain HP-52 upper blowdown piping HP upper drains IP piping and supports IP continuous blowdown to continuous blowdown tank IP-50 SPHTR 1 to SPHTR 2 drain IP-13-A sparging steam header drain IP economizer drains 2v-IP-51 IP-16-D drain IP-51 blowdown piping IP/RH upper drains LP piping and supports LP-50 SPHTR 1 to SPHTR 2 drain LP-22-A sparging steam drain LP-22-C drain LP-26-A blow off tank drain LP-51 upper blowdown piping LP boot drain LP upper drains RP piping and supports RP-50 RH desuperheater spray water RP-51 reheater 12 drain 1-1/2v RP-50 CRH boot drain HRH boot drain Preheater drains Blowdown piping HD-D0 -N intermittent blow off HD-01-M cascading blowdown to IP drum ID-01-M intermittent blow off LD-01-N intermittent blow off HD-01-N intermittent blow off LD-03-G BD tank to BD tank Instrumentation Casing instrumentation

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

2 2 2 2 2 2 2 2

80 80 80 80 80 80 80 80

lf

1.87 1.69 1.58 1.34 2.57 2.27 1.13 1.13

SA-106-B 1.5

80

80 80 140 220 20 20 100 100 700 1.68 120

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

2 2 1 2 2 2 2

80 80 80 80 80 80 80

1.27 2.76 1.38 1.17 1.87 1.13 1.13

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

2 2 2 2 2 2 2

80 80 80 80 80 80 80

1.02 2.76 3.06 2.96 1.13 1.77 1.13

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

1.5 2 1.5 2 2 2

80 80 80 80 80 80

1.79 1.67 1.76 1.77 1.77 1.36

SA-106-B 1.5 SA-106-B 1.5

80 80

1.13 2.06

SA-106-B SA-106-B SA-106-B SA-106-B

1.5 1.5 2 2

80 80 80 80

1.13 1.13 1.13 1.13

SA-106-B 1.5

80

ni lf lf lf lf lf lf lf lf lf lf

80 20 140 120 20 100 100 420 140 20 20 20 100 20 100 385 65 40 60 20 20 180 680 120 120

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

120 120 100 100 160 6.53 160

lf lf lf lf lf lf

80 80 140 220 20 20 100 100 120 80 20 140 120 20 100 100 140 20 20 20 100 20 100 65 40 60 20 20 180 120 120 120 120 100 100

ni MHa 149.3 135.5 221.6 295.5 51.3 45.4 113.4 113.4 957 201.5 101.8 55.3 193.9 140.7 37.5 113.4 113.4 580 142.4 55.3 61.2 59.2 113.4 35.5 113.4 604 116.2 66.8 105.4 35.5 35.5 244.7 880 135.5 247.0

135.5 135.5 113.4 113.4 1044.0 160 1044.0

127

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

6.11 Heat recovery steam generator—risers and down comers Qty

HP Drum down comer HP evap to HP drum risers IP drum down comer IP evap to IP drum risers LP drum down comer LP evap to LP drum risers 6.11.1 HP, IP, and LP drums risers and down comers

PF

ni

Unit ni MHa MH/LF

795 242 200 125 36 132 60

lf lf lf lf lf lf lf

3827 2115 832 196 216 168 300

4.81 8.74 4.16 1.57 6.00 1.27 5.00

795 lf

3827

242 lf

2115

HP drum Down comer MH Line no.

Material

HP-07 down comer HP-07 down comer HP-07 down comer HP evap to HP drum risers AHR11 AHR12 AHR13 BHR11 BHR12 BHR13 CHR11 CHR12 CHR13 AHR21 AHR22 BHR21 BHR22 CHR21 CHR22 AHR31 AHR32 AHR33 BHR31 BHR32 IP drum IP-05 down comer IP-05 down comer IP-05 down comer IP evap to IP drum risers AIR11 AIR12 BIR11 BIR12

SA-106-B 26 SA-106-C 16 4

2.5 2

SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C SA-106-C

140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140

Qty Unit Qty

Size Sch/Thk MHa ni

8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8

SA-106-B 10 SA-106-B 5 4

40 40

SA-106-B SA-106-B SA-106-B SA-106-B

40 40 40 40

10 10 10 10

9.28 192 lf 7.79 40 lf 2.16 10 lf 200 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 4.16 10 lf 125 lf 1.52 114 lf 1.98 9 lf 2.40 2 lf 36 lf 6.00 6 lf 6.00 6 lf 6.00 6 lf 6.00 6 lf

PF

ni

ni MHa

192 40 10

1782.5 311.4 21.6 832 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 41.6 196 173.3 17.9 4.8 216 36.0 36.0 36.0 36.0

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 114 9 2 6 6 6 6

(Continued )

128

Industrial Construction Estimating Manual

(Continued) Qty

Unit ni MHa MH/LF

ni CIR21 CIR22

SA-106-B 10 SA-106-B 10

40 40

SA-106-B 10 SA-106-B 6 4

40 40

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

80 80 80 80 80 80

LP drum

Down comer LP-09 down comer LP-09 down comer LP-09 down comer LP evap to LP drum risers ALR11 ALR12 BLR11 BLR12 CLR11 CLR12

12 12 12 12 12 12

PF

6.00 6 6.00 6

lf lf

6 6

132 lf 1.24 110 lf 1.34 20 lf 2.40 2 lf 60 lf 5.00 10 lf 5.00 10 lf 5.00 10 lf 5.00 10 lf 5.00 10 lf 5.00 10 lf

36.0 36.0 168.0 136.5 26.7 4.8 300 50.0 50.0 50.0 50.0 50.0 50.0

110 20 2 10 10 10 10 10 10

6.12 Heat recovery steam generator—field trim piping Qty

HP remote steam drum IP remote steam drum LP remote steam drum Instrumentation Atmospheric blow off tank Flash separator

PF

ni

Unit

ni MHa

MH/LF

1570 80 80 80 1240 45 45

lf lf lf lf lf lf lf

3341 392 310 310 2114 128 86

2.1 4.9 3.9 3.9 1.7 2.9 1.9

6.12.1 Heat recovery steam generator field trim piping—HP, IP, LP remote drums MH Line no. HRSG—field trim piping HP remote steam drum HD-01-K PI-X305 HD-01-F LG-X301 w/LT-X301C (top conn) HD-01-G LG-X301 w/LT-X301C (bottom conn) HD-01-H LG-X301 (drain) HD-01-A LI-X301 w/LT-X310A (top conn)

Qty

Unit Qty PF

Material Size Sch/Thk MHa ni

SA-106-B 1 SA-106-B 1

80 80

4.9 4.9

1570 80 20 20

SA-106-B 1

80

4.9

20

ni

ni MHa

lf lf lf lf

20 20

3341 392.0 98.0 98.0

lf

20

98.0

(Continued )

129

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

(Continued) MH Line no. HD-01-B LI-X301 w/LT-X301A (bottom conn) HD-01-C LI-X301 (drain) HD-01-D LT-X301B w/PT-X305B (top conn) HD-01-E LT-X301B w/PT-X305B (bottom conn) IP remote steam drum ID-01-F LG-X201 w/LT-X201C (top conn) ID-01-G LG-X201 w/LT-X201C (bottom conn) ID-01-H LG-X201 (drain) ID-01-A LI-X201 w/LT-X210A (top conn) ID-01-B LI-X201 w/LT-X201A (bottom conn) ID-01-C LI-X201 (drain) ID-01-D LT-X201B w/PT-X203B (top conn) ID-01-E LT-X201B w/PT-X203B (bottom conn) ID-01-K PI-X203 LP remote steam drum LD-01-F LG-X101 w/LT-X101C (top conn) LD-01-G LG-1201 w/LT-X101C (bottom conn) LD-01-H LG-X101 (drain) LD-01-A LI-X101 w/LT-X110A (top conn) LD-01-B LI-X101 w/LT-X101A (bottom conn) LD-01-C LI-X101 (drain) LD-01-D LT-X101B w/PT-X103B (top conn) LD-01-E LT-X101B w/PT-X103B (bottom conn) LD-01-N PI-X106 Instrumentation IP instrumentation HP instrumentation HP instrumentation Atmospheric blow off tank LD-04-A LG-X103 (top conn) LD-04-B LG-X103 (bottom conn) PI-X114 TI-X105 Flash separator LD-04-A LG-X103 (top conn) LD-04-B LG-X103 (bottom conn) PI-X114 TI-X105

Qty

Unit Qty PF

Material Size Sch/Thk MHa ni

ni

ni MHa

SA-106-B 1

80

4.9

20

lf

20

98.0

SA-106-B 1

80

80 6.44 20

lf lf

20

310 128.8

SA-106-B 1

80

4.9

20

lf

20

98.0

SA-106-B 1

80

2.24 20

lf

20

44.8

SA-106-B 1

80 80

lf lf lf

20

SA-106-B 1

1.94 20 80 6.44 20

20

38.8 310 128.8

SA-106-B 1

80

4.9

20

lf

20

98.0

SA-106-B 1

80

2.24 20

lf

20

44.8

SA-106-B 1

80 80 80 80

SA-106-B 1

80

lf lf lf lf lf lf lf

20

SA-106-B 0.8 SA-106-B 0.8 0.8

1.94 20 1240 1.7 420 1.75 420 1.66 400 45 3.91 20

38.8 2114 420 715.0 420 734.6 400 664.2 128 20 78.1

SA-106-B 1 SA-106-B 1

80 80 80

lf lf lf lf

20 5

SA-106-B 1

1.94 20 2.3 5 45 2.61 20

20

38.8 11.5 86 52.2

SA-106-B 1 SA-106-B 1

80 80

1.28 20 1.6 5

lf lf

20 5

25.6 8.0

130

Industrial Construction Estimating Manual

6.13 SP-01 AIG piping Qty

SP-01 AIG manifold connecting piping Inner connect pipe

PF

ni

Unit

ni MHa

MH/LF

1332 73 1259

lf lf lf

2262 119 2143

1.70 1.63 1.70

SP-01 AIG piping

1332 lf MH

Qty

Line no.

Material Size Sch/Thk MHa ni

SP-01 AIG manifold connecting piping Inner connect pipe SP-02 AIG piping SP-03 AIG piping SP-04 AIG piping SP-05 AIG piping SP-06 AIG piping SP-07 AIG piping SP-08 AIG piping SP-09 AIG piping SP-10 AIG piping SP-11 AIG piping SP-12 AIG piping SP-13 AIG piping SP-14 AIG piping SP-15 AIG piping SP-16 AIG piping SP-17 AIG piping SP-18 AIG piping SP-19 AIG piping SP-20 AIG piping SP-21 AIG piping SP-22 AIG piping SP-23 AIG piping SP-24 AIG piping SP-25 AIG piping SP-26 AIG piping SP-27 AIG piping SP-28 AIG piping

SA-106-B 10

40

SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B SA-106-B

40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 10

1.63 73 1259 1.88 28 1.10 21 1.18 15 1.36 10 1.84 30 1.84 37 1.75 43 1.69 49 1.71 56 1.71 62 1.71 68 1.72 75 1.68 81 1.79 33 1.91 27 1.94 20 1.99 15 1.74 36 1.77 42 1.70 48 1.64 55 1.67 61 1.67 67 1.63 74 1.65 80 1.65 87 1.90 39

2262

Unit Qty PF

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

ni

ni MHa

73

118.9 2143 52.8 23.1 17.7 13.6 55.2 68.1 75.4 82.8 95.5 105.7 116.0 128.7 136.2 59.1 51.5 38.9 29.8 62.7 74.1 81.6 90.2 101.9 111.9 120.6 132.0 143.6 74.2

28 21 15 10 30 37 43 49 56 62 68 75 81 33 27 20 15 36 42 48 55 61 67 74 80 87 39

131

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

6.14 Excel double-flow STG installation estimate man-hours

Excel spreadsheet summary STG vendor piping Excel spreadsheet summary STG piping Excel spreadsheet summary STG equipment

MH

BM

IW

MW

PF

23,363 7014

1636

1335

7449

12,943 7014

1636

1335

7449

5928 10,420

5928

6.15 Excel double-flow STG equipment installation estimate ni MHa

BM

IW

MW

Excel double-flow STG installation man-hours Estimate—centerline equipment Estimate HP/IP turbine and front standard Final turbine assembly and alignment Generator acoustic enclosure Generator installation Lube oil system Hydraulic power oil system

10,420 3729 347 2106 1447 1811 400 580

1636 306

1335 195 116

350

504 520

7449 3228 231 2106 593 1291

400 580

6.16 Excel double-flow STG installation estimate Description

MH

Qty

Unit Qty

MHa ni 6.16.1 Estimate—centerline equipment Layout foundations

ni

0.12 3120.0 SF

ni MHa BM IW MW

3729 3120.0 374

306 195 3228 374

Set lower exhaust hood Clean protective coating 0.25 Weld LO supply and drain down comers 6.00 Bolt connections—mid-standard 0.50 Fit mid-standard to sole plates 2.00 Install and grout retaining strips 0.50 Set lower turbine and exhaust hood 1.02 Clean and set turning gear standard 80.00 Move exhaust hood 80.00 Rough alignment 1.42 Seal weld mid-standard 0.50

104.0 2.0 12.0 4.0 104.0 176.9 1.0 1.0 176.9 30.0

LF EA EA EA LF ton EA EA ton LF

104.0 2.0 12.0 4.0 104.0 176.9 1.0 1.0 176.9 30.0

26 12 6 8 52 180 80 80 251 15

26 12 6 8 52 180 80 80 251 15

Install lower inner casing Rig and install inner casing Install lower half packing casing Rough alignment

2.56 20.00 1.42

52.4 ton 2.0 EA 52.4 ton

52.4 134 2.0 40 52.4 74

134 40 74

2.56 0.50 2.10

56.4 ton 112.0 EA 56.4 ton

56.4 144 112.0 56 56.4 118

144 56 118

Install upper inner casing Rig and install upper casing Bolt connection—inner casing Final alignment

(Continued )

132

Industrial Construction Estimating Manual

(Continued) Description

MH

Qty

Unit Qty

MHa ni Crossover flange level check

ni

ni MHa BM IW MW

8.00

1.0 EA

1.0 8

8

2.56 1.42 0.50

77.0 ton 77.0 ton 60.0 EA

77.0 197 77.0 109 60.0 30

197 109 30

0.50 2.10

216.0 EA 176.9 ton

216.0 108 176.9 371

108 371

20.00 10.00

8.0 EA 8.0 EA

8.0 160 8.0 80

160 80

2.10

77.0 ton

77.0 162

162

2.10

52.4 ton

52.4 110

110

1.50 2.10 40.00

104.0 LF 52.4 ton 1.0 EA

104.0 156 52.4 110 1.0 40

16.00

16.0 EA

16.0 256

256

2.10

52.4 ton

52.4 110

110

1.00

40.0 EA

40.0 40

40

10.00

3.0 EA

3.0 30

30

Install upper half exhaust hood Install upper exhaust hood halves Rough alignment Bolt connection—vertical joint

Close exhaust hood Bolt connection—exhaust hood Final alignment

Exhaust hood centerline sole plate Adjust left and right-side anchor blocks Weld anchor blocks exhaust hood

Tops-on exhaust hood alignment Final alignment

Turning gear standard Final alignment

Weld exhaust hood to condenser Weld exhaust hood condenser neck Alignment during welding Install condenser joint shield

156 110 40

Final grout sole plates Clean area and install grout sole plates

Final tops-on alignment Final alignment

Fit exhaust hood keys Fit internal exhaust hood keys

Set and fit bearing rings Set T2, T3, and T4 bearing rings

6.16.2 Estimate HP/IP turbine and front standard

347

116

231

Front standard base plate check Set fixators Clean and set front standard plate

3.50 20.00

4.0 1.0

EA EA

4.0 1.0

14 20

14 20

1.42 2.10

32.0 32.0

ton ton

32.0 32.0

45 67

45 67

Set assembled HP/IP turbine Remove turbine end shipping brace Rough alignment Final turbine assembly and alignment

1.70 4.00 1.42

59.1 4.0 59.1

ton EA ton

59.1 4.0 59.1

100 16 84 2106

Remove dowels from exhaust hood Rig and remove upper exhaust hood

0.55 1.56

216.0 77.0

EA ton

216.0 77.0

120 120

Front standard base plate check Rough alignment Final alignment

Set HP/IP turbine assembly 100 16 84 2106

Upper exhaust hood—inner casing 120 120

Remove upper—inner casing (Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

133

(Continued) 6.16.2 Estimate HP/IP turbine and front standard

347

Loosen and remove dowels and bolts Rig and remove upper inner casing

116

231

0.50

112.0

EA

112.0

56

56

2.56

56.4

ton

56.4

144

144

2.10

13.8

ton

13.8

29

29

0.25 14.00 1.42

79.0 12.0 5.8

LF EA ton

79.0 12.0 5.8

20 168 8

20 168 8

0.25

36.0

LF

36.0

9

9

16.00 16.00 1.42

3.0 3.0 17.0

EA EA ton

3.0 3.0 17.0

48 48 24

48 48 24

0.25 1.65

48.0 84.9

LF ton

48.0 84.9

12 140

12 140

0.25 10.00

36.0 12.0

LF EA

36.0 12.0

9 120

9 120

3.0 600.0

EA LB

3.0 600.0

60 24

60 24

0.25 14.00 1.42

79.0 12.0 5.8

LF EA ton

79.0 12.0 5.8

20 168 8

20 168 8

2.56

56.4

ton

56.4

144

144

0.50 2.10

120.0 56.4

LF ton

120.0 56.4

60 118

60 118

1.56

77.0

ton

77.0

120

120

1.42 0.50 16.00

77.0 60.0 2.0

ton EA EA

77.0 60.0 2.0

109 30 32

109 30 32

20.00 1.60 4.00 20.00 1.42

1.0 20.1 4.0 2.0 20.1

EA ton EA EA ton

1.0 20.1 4.0 2.0 20.1

20 32 16 40 29

20 32 16 40 29

Final tops-off alignment Alignment (T3 and T4 inboard oil deflector)

Lower half low-pressure diaphragms Clam protective coating Rig and install diaphragms Rough alignment

Number 3 and 4 bearings Bearings, bearing rings and standard fits Install bearings Install upper half bearing rings Rough alignment

Low-pressure rotor Clam protective coating Rig and install low-pressure rotor

Install low-pressure oil deflectors Clam protective coating Install lower half oil deflectors

Upper half pressure bearings and rings Install upper half bearings and rings Rough alignment

20.00 0.04

Upper half low-pressure diaphragms Clam protective coating Rig and install diaphragms Rough alignment

Upper half casing Rig and install the upper inner casing Install horizontal joint shields Final alignment

Final turbine assembly and alignment Upper half exhaust casing Rig and install the upper exhaust hood Rough alignment Bolt connection—vertical joint Install atmosphere relief diaphragm

HP/IP—LP assembly Set T2 lower half bearings Rig and lift generator end of rotor Remove shipping brackets Install upper T1 and T2 bearings Rough alignment

134

Industrial Construction Estimating Manual

6.16.3 Generator acoustic enclosure

1447

350

504

593

Front standard base plate Grout front standard base plate

1.40

43.0

SF

43.0

60

60

40.00

1.0

EA

1.0

40

40

2.10

105.0

ton

105.0

220

220

0.25

32.0

LF

32.0

8

8

30.00

1.0

EA

1.0

30

30

1.42 10.00 10.00

0.5 2.0 2.0

ton EA EA

0.5 2.0 2.0

1 20 20

1 20 20

2.58 1.42

40.0 1.0

EA ton

40.0 1.0

103 1

103 1

0.25 20.00

32.0 1.0

LF EA

32.0 1.0

8 20

8 20

1.15

54.0

DI

54.0

62

62

1.15

104.0

DI

104.0

120

120

3.64 0.45

32.0 54.0

LF DI

32.0 54.0

116 24

116 24

40.00 2.10 1.20

1.0 13.7 16.5

EA ton EA

1.0 13.7 16.5

40 29 20

40.00 40.00 40.00 40.00 40.00 8.00 16.00

1.0 1.0 2.0 2.0 1.0 4.0 12.0

EA EA EA EA EA EA EA

1.0 1.0 2.0 2.0 1.0 4.0 12.0

40 40 80 80 40 32 192

Horn drop check Install/remove generator end rotor support

Final alignment HP/IP rotor Final alignment

“A” coupling Clean coupling and associated hardware Assemble, fit, and dowel “A” coupling guard Rough alignment Install and fit “A” coupling covers Install and fit upper half oil deflectors

Install HP/IP centerline keys Machine and install center keys Rough alignment Install crossover Remove shipping skid and coatings Remove expansion joint locking device 54v diameter fit up and weld—HP/ LP turbine 54v diameter fir up and weld— assembly Install 4v diameter crossover pipe 54v diameter flange boltup Install and align turning gear Install turning gear to rotor Final alignment Dowel turning gear to standard

40 29 20

Turbine generator sections Left lower quarter section Right lower quarter section Middle quarter section End half section Bottom plate Doors Field joints

6.16.4 Generator installation Generator terminal compartment Assemble cribbing and set compartment Rigging and moving generator Clean and install trunnions Rough alignment stator

40 40 80 80 40 32 192

1811

520 120

120.0

1.0

EA

1.0

120

10.0

8.0

EA

8.0

80

1291

80

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

135

(Continued) 6.16.4 Generator installation Rig, lift, and move and set generator Remove and install generator outer shields Install generator journal bearings Boltup outer end shield and dowel Install hydrogen seal rings Install and align oil deflectors Set and rough alignment stator Final generator alignment Final alignment Grout sole plate LP turbine generator Install studs and align coupling guard

1811

520

360

360

2.0

40

40

EA EA

4.0 48.0

40 49

40 49

1.0 12.0 185.5

EA EA ton

1.0 12.0 185.5

25 120 263

25 120 263

2.1 16.0

259.5 8.0

ton EA

259.5 8.0

545 128

545 128

40.0

1.0

EA

1.0

40

40

60.0 20.0 2.2 60.0

1.0 3.0 100.0 1.0

EA EA LF EA

1.0 3.0 100.0 1.0

400 60 60 220 60

400 60 60 220 60

1.0 3.0 200.0

EA EA LF

0.0 1.0 3.0 200.0

580 80 60 440

580 80 60 440

1.4

259.5

ton

259.5

20.0

2.0

EA

10.0 1.0

4.0 48.0

25.0 10.0 1.4

Estimate—LO system

Lube oil system Set lube oil tank Align lube oil pumps Install lube oil piping Install lube oil conditioner

Estimate—hydraulic power oil system

Hydraulic power oil system Set hydraulic power unit Align hydraulic power pumps Install hydraulic power piping

80.0 20.0 2.2

6.17 STG vendor piping Qty

Spray water system Gland steam system (15Mo3) Leak off steam system (15Mo3) Lube oil supply Lube oil return Hydrostatic oil, oil purification Jacking oil Oil flushing External hydraulic oil Hydro Clean piping

PF

ni

Unit

ni MHa

MH/LF

3040 60 840 320 300 300 200 300 20 700

lf lf lf lf lf lf lf lf lf lf

7014 75 1369 440 456 633 322 916 20 1003 540 1240

2.3 1.25 1.63 1.37 1.52 2.11 1.61 3.05 1.00 1.43

1291

136

Industrial Construction Estimating Manual

6.17.1 STG—vendor piping sheet 1 3040 lf MH

Qty Unit Qty PF

Line no.

Material Size Sch/Thk MHa ni

Spray water system Gland steam system (15Mo3) Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Pipe Leak off steam system (15Mo3) Pipe Pipe Pipe Pipe Pipe Pipe Pipe Lube oil supply Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

SA-106-B 2

80

15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3

6 2.5 5 4 6 2 4 6 6 2 2 2

80 80 80 80 80 80 80 80 80 80 80 80

15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3 15Mo3

2 2 3 3 4 6 6

80 80 80 80 80 80 80

304L 304L 304L 304L 304L 304L 304L 304L 304L

6 4 2 1 4 2 2 4 2

S10S S10S S40S S40S S10S S40S S40S S10S S40S

SS SS SS SS SS SS SS SS SS

7014

1.25 60 840 1.98 140 1.20 80 1.37 40 1.49 40 1.67 60 1.20 60 1.44 40 2.15 140 2.74 40 1.20 140 1.20 20 1.20 40 320 1.20 40 1.20 40 1.25 100 1.18 40 1.21 40 1.80 40 2.56 20 300 1.83 20 1.82 20 1.27 40 1.19 20 1.48 80 1.58 20 1.58 20 1.73 40 1.45 40

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

ni

ni MHa

60

75 1369 278 96 55 60 100 72 58 302 110 168 24 48 440 48 48 125 47 48 72 51 456 37 36 51 24 119 32 32 69 58

140 80 40 40 60 60 40 140 40 140 20 40 40 40 100 40 40 40 20 20 20 40 20 80 20 20 40 40

6.17.2 STG—vendor piping sheet 2 Lube oil return Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS

12 6 5 6 5 5 10 5

S10S S10S S10S S10S S10S S10S S10S S10S

2.80 1.47 1.02 1.72 2.34 2.74 2.84 1.60

300

lf

60 20 20 40 20 20 40 20

lf lf lf lf lf lf lf lf

633 60 20 20 40 20 20 40 20

168 29 20 69 47 55 114 32

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

137

(Continued) Lube oil return Pipe-304L SS Pipe-304L SS Pipe-304L SS Hydrostatic oil, oil purification Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Jacking oil Pipe-304L SS Pipe-304L SS Pipe-304L SS Oil flushing Rubberized hose External hydraulic oil Pipe-SS Pipe-SS Pipe-SS Pipe-SS Hydro Clean piping

300

lf

304L SS 304L SS 304L SS

4 4 2.5

S10S S10S S10S

1.50 2.07 1.42

20 20 20 200

lf lf lf lf

20 20 20

633 30 41 28 322

304L SS 304L SS 304L SS 304L SS

1.25 2 2 2.5

S40S S40S S40S S10S

1.50 1.65 1.62 1.64

20 12 2.5

S10S S10S S10S

8.19 1.99 1.55

304L SS

0.75

S40S

1.00

304L SS 304L SS 304L SS 304L SS

3 2 2 1.5

S10S S40S S40S S40S

2.01 1.60 1.15 1.11

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

40 40 40 80

304L SS 304L SS 304L SS

40 40 40 80 300 60 120 120 20 20 700 220 40 240 200

60 66 65 131 916 491 238 186 20 20 1003 441 64 276 222 540 1240

60 120 120 20 220 40 240 200

6.18 STG piping Qty

Condensate Auxiliary steam Steam turbine drain Steam drain Low-pressure steam High-pressure steam Hot reheat steam Trim Boiler feedwater

PF

ni

Unit

MHa

ni MHa

MH/LF

3480 340 1100 140 1080 320 280 80 20 120

lf lf lf lf lf lf lf lf lf lf

1.4 1.6 1.5 1.5 1.6 2.2 2.4 1.5 2

5928 476 1760 210 1620 512 616 192 30 240

1.7 1.4 1.6 1.5 1.5 1.6 2.2 2.4 1.5 2

138

Industrial Construction Estimating Manual

6.19 Excel F class CTG installation estimate man-hours

Excel spreadsheet summary CTG equipment Excel spreadsheet summary CTG vendor piping Excel spreadsheet summary CTG equipment and piping

MH

BM

IW

MW

13,260 14,634

7231

3837

2192

27,894

7231

3837

2192

PF 14,634 14,634

6.20 Summary F class CTG installation man-hour estimate

F class CTG equipment installation estimate Estimate—centerline equipment Modules and skids Place equipment Generator terminal enclosure Turbine enclosure, grating, and walkways Turbine load compartment Install enclosure to base Inlet filter house Inlet filter house transition duct Support steel Inlet ductwork Inlet plenum Exhaust duct Exhaust duct/stack

ni MHa

BM

IW

MW

13,260 2463 815 202 180 1891 199 280 1730 337 1247 1311 841 374 1391

7231

3837 271 815 202 180 1891 199 280

2192 2192

1730 337 1247 1311 841 374 1391

6.21 Excel F class CTG installation estimate Description

MH

Qty

Unit Qty

MHa ni 6.21.1 Estimate—centerline equipment Set fixators Grout fixators Rig, lift, and set turbine down onto fixators Install load coupling to turbine Rig, lift, and set generator Install collector assembly Weld radiation shields and install thermocouple Rig and set exhaust diffuser Rough alignment, centerline equipment Generator-turbine final alignment Modules and skids Set accessory package

3.50 9.20 0.50 9.25 0.50 9.25 1.35 9.25 1.42 2.10 3.20

16.0 16.0 188.5 2.5 280.0 10.0 27.0 14.1 495.1 495.1

ni EA EA ton ton ton ton EA ton ton ton

37.5 ton

ni MHa BM IW MW

2463 56 147 94 23 140 93 36 131 703 1040 815 37.5 120

16.0 16.0 188.5 2.5 280.0 10.0 27.0 14.1 495.1 495.1

271 2192 56 147 94 23 140 93 36 131 703 1040 815 120

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

139

(Continued) Description

MH

Qty

Unit Qty

MHa ni Set liquid fuel and atomizing air skid Set electric control compartment Water injection skid Fire protection skid Set water cooling module Set bus accessory compartment Set liquid fuel forwarding skid Air processing skid Set water wash skid Set cooling fan module Place equipment Set hydrogen dryer and purge assembly Set liquid detectors Install batteries (pallet 1, 2, 3) Install air conditioners Set drain collection tank Set load excitation compartment Set DC link reactor Set isolation/excitation transformer

ni

4.80 4.80 4.80 5.20 3.20 5.20 5.20 5.20 4.80 5.20

30.0 23.0 15.0 10.0 49.8 7.5 5.9 1.3 10.9 5.5

ton ton ton ton ton ton ton ton EA lot

30.0 23.0 15.0 10.0 49.8 7.5 5.9 1.3 10.9 5.5

30.00 20.00 20.00 42.00 30.00 20.00 20.00 20.00

1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

lot EA EA EA EA EA EA EA

1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

Enclosures and barriers

Generator terminal enclosure Set generator terminal enclosure Estimate—enclosure, grating and walkways

ni MHa BM IW MW

14.40

12.5 ton

180 12.5 180

6.21.2 Turbine enclosure, grating, and walkways Roof section Side upper; frame end upper Door Frame side/end upper/lower Panels Make up field joints; roof, frames, and panels Floor unit Support steel Make up field joints; floor units Estimate—turbine load compartment Turbine load compartment Left lower quarter section Right lower quarter section Top half section Bottom plate Doors Field joints Install enclosure to base Set enclosure on base

144 110 72 52 159 39 31 7 52 29 202 30 20 20 42 30 20 20 20

1891

0

144 110 72 52 159 39 31 7 52 29 202 0 30 20 20 42 30 20 20 20

0

180 0 180

0

1891

12.40 12.40 10.00 12.40 24.00 0.75

5.5 6.5 4.0 16.9 9.2 723.6

ton ton EA ton ton LF

5.5 6.5 4.0 16.9 9.2 723.6

68 80 40 210 221 543

68 80 40 210 221 543

24.00 64.00 0.75

5.3 0.4 773.0

ton ton LF

5.3 0.4 773.0

127 24 580

127 24 580

60.00 60.00 60.00 60.00 10.00 0.75

0.4 0.4 0.7 0.5 2.0 72.6

ton ton ton ton EA LF

0.4 0.4 0.7 0.5 2.0 72.6

280.00

1.0

EA

1.0

199 26 26 39 32 20 54 280 280

0

0

199 26 26 39 32 20 54 280 280

0

0

0

140

Industrial Construction Estimating Manual

6.21.3 Inlet filter house, transition duct, ductwork Sloped roof hopper Pipe/tubing Hand rails Filter cartridges Filter modules (center) Filter modules (left and right hand) Walkway assembly (center) Walkway assembly (LH and RH) D15 weather hoods Field joints Inlet filter house transition duct Top section Floor section Side section Side section Bell section Make-up duct field joints Support steel Erect support steel Inlet ductwork Transition duct Expansion joint (kit) Elbow duct upper w/trash screen Elbow duct lower Heating duct Silencer duct w/panels Empty duct Make-up duct field joints

8.40 20.00 1.94 0.25 0.75 8.40 8.40 8.40 8.40 8.40 0.75

2.1 1.0 49.7 21.1 1020.0 15.5 9.3 4.7 3.5 9.9 620.6

ton ton LF LF EA ton ton ton ton ton LF

2.1 1.0 49.7 21.1 1020.0 15.5 9.3 4.7 3.5 9.9 620.6

28.00 28.00 28.00 28.00 28.00 0.75

1.3 1.5 1.0 0.6 1.3 235.4

ton ton ton ton ton LF

1.3 1.5 1.0 0.6 1.3 235.4

14.50

86.0

ton

86.0

8.40 40.00 8.40 8.40 8.40 8.40 8.40 0.75

5.9 1.0 8.7 10.9 4.8 22.3 3.1 1072.2

ton kit ton ton ton ton ton LF

5.9 1.0 8.7 10.9 4.8 22.3 3.1 1072.2

6.21.4 Inlet plenum, exhaust system, duct/stack Plenum support structure Plenum extension Plenum cone (inlet case extension) Lower/upper quarter section Lot 1, 2, and 3 Make-up duct field joints

18 20 96 5 765 130 78 39 29 83 465 337 38 43 27 17 37 177 1247 1247 1311 50 40 73 91 40 187 26 804

18 20 96 5 765 130 78 39 29 83 465 337 38 43 27 17 37 177 1247 1247 1311 50 40 73 91 40 187 26 804

841

841

2.2 0.8 1.6 14.9 2.5 227.5

ton ton ton ton ton LF

2.2 0.8 1.6 14.9 2.5 227.5

86 22 44 417 100 171

86 22 44 417 100 171

8.40 8.40 40.00 40.00 0.75

11.4 10.3 1.0 1.0 148.8

ton ton EA kit LF

11.4 10.3 1.0 1.0 148.8

374 96 87 40 40 112

374 96 87 40 40 112

8.40 8.40

12.0 28.0

ton ton

12.0 28.0

1391 110 235

1391 110 235

Estimate—exhaust duct/stack Exhaust duct/stack Upstream duct transition Duct silencer

1730

40.00 28.00 28.00 28.00 40.00 0.75

Exhaust system

Exhaust duct Upstream upper/lower quadrant Downstream upper/lower quadrant Downstream expansion joint (kit) Support steel (kit) Make-up duct field joints

1730

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

141

(Continued) 6.21.4 Inlet plenum, exhaust system, duct/stack Downstream duct transition Lower stack transition Silencer Upper stack transition Stack segments Make-up duct field joints Support steel

8.40 8.40 5.20 8.40 8.40 0.75 24.00

6.0 4.5 24.0 4.5 16.0 687.4 6.1

ton ton ton ton ton LF ton

6.0 4.5 24.0 4.5 16.0 687.4 6.1

841

841

50 38 125 38 134 516 145

50 38 125 38 134 516 145

6.22 CTG vendor piping Qty

SB supply LB supply Interconnect Duct Unit SB Unit LB

PF

ni

Unit

ni MHa

MH/LF

8860 4320 1460 860 360 840 1020

lf lf lf lf lf lf lf

14,634 5876 2968 1335 1022 1153 2279

1.65 1.36 2.03 1.55 2.84 1.37 2.23

6.22.1 CTG—vendor piping sheet 1

MH Line no. SB supply FGA fuel gas supply TGH combustion turbine supply TGH combustion turbine supply TGH combustion turbine supply FWF demin water storage and supply WSD potable water supply CGA hydrogen storage supply CAA station air supply LB supply Combustion turbine Combustion turbine Combustion turbine Combustion turbine Wastewater collection and disposal Combustion turbine Fuel gas

4320 lf

5876

Qty

PF

Material Size

Sch/Thk MHa ni

CS CS 304 SS Galv 316 SS CS CS Galv

2v 2v 2vv 2v 2v 2v 2v 2v

80 80 S40S 40 S40S 80 80 40

1.20 1.20 1.50 1.15 3.97 1.63 2.93 1.34

CS SS Galv CS CS CS CS

2-1/2v 2-1/2v 2-1/2v 3v 3v 4v 6v

40 S40S 40 40 40 40 40

1.61 1.40 1.20 2.93 2.08 0.93 1.56

4320 40 80 320 1660 80 220 60 1860 1460 80 60 220 40 40 340 20

Unit Qty ni lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

40 80 320 1660 80 220 60 1860 80 60 220 40 40 340 20

ni MHa 5876 48 96 480 1908 317.2 358.8 175.5 2492 2968 128.7 84 264 117 83.2 315.9 31.2

(Continued )

142

Industrial Construction Estimating Manual

(Continued)

MH

4320 lf

5876

Qty

PF

Line no.

Material Size

Sch/Thk MHa ni

Fuel gas Combustion turbine Combustion turbine Fuel gas Combustion turbine Combustion turbine Fuel gas Combustion turbine Pipe cleaning/flushing Interconnect Water and carbon dioxide Water and carbon dioxide Drains Water wash Fire protection Pipe cleaning/flushing

CS CS SS CS CS SS CS SS

8v 8v 8v 10v 10v 10v 12v 12v

40 40 S40S 40 40 S40S 40 S40S

2.67 2.77 2.15 3.92 1.86 3.64 8.84 2.50

CS CS CS CS CS

1v 2v 2v 2v 2v

80 80 80 80 80

2.28 3.85 1.20 1.20 1.13

20 180 40 80 100 40 20 180 1 860 40 100 240 120 360 1

Unit Qty

lf lf lf lf lf lf lf lf lf lf lf lf lf lf

ni

ni MHa

20 180 40 80 100 40 20 180 1

53.3 497.9 85.8 313.3 185.9 145.6 176.8 449.8 36 1335 91 384.8 288 144 405.6 22

40 100 240 120 360 1

6.22.2 CTG—vendor piping sheet 2 Duct Inlet air heating duct air Venting square duct Pipe cleaning/flushing Unit SB MSD no. 2 bearing lube oil feed drain MSD no. 1 bearing lube oil feed drain MSD load compartment LO feed drain/sealing air/lift oil MSD end of generator LO feed drain/sealing air/lift oil Control oil Accessory module MSD LO feed drain/fuel gas Compressor water wash Inlet and exhaust drains Seal oil Liquid level detector H2 control Unit LB MSD no. 1 bearing lube oil feed drain MSD no. 2 bearing lube oil feed drain Generator hydrogen gas supply Accessory module MSD LO feed drain/fuel gas MSD no. 2 bearing lube oil feed drain MSD no. 1 bearing lube oil feed drain Air extraction Cooling water to turbine flame scanners Generator cooling water Cooling and sealing air

360 CS 8v Duct 48v

1.70 160 3.75 200

CS CS CS CS CS CS CS CS CS CS CS

2v 2v 2v 2v 2v 2v 2v 2v 2v 2v 2v

80 80 80 80 80 80 80 80 80 80 80

1.17 1.17 1.35 1.50 1.40 1.40 1.40 1.40 1.40 1.40 1.20

CS CS CS CS CS CS CS CS CS CS

2-1/2v 4v 4v 6v 8v 8v 8v 8v 8v 12v

40 40 40 40 40 40 40 40 40 std

1.30 2.08 1.30 1.38 2.18 2.18 8.50 1.32 1.20 1.35

840 20 20 120 80 120 80 80 80 80 80 80 1020 20 20 80 100 40 40 100 60 100 120

lf

1022

lf 160 272 lf 200 750 lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

20 20 120 80 120 80 80 80 80 80 80 20 20 80 100 40 40 100 60 100 120

1153 23.4 23.4 162 120 168 112 112 112 112 112 96 2279 26 41.6 104 137.8 87.1 87.1 850.2 79.2 120.3 161.9

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

143

(Continued) Duct Cooling fan module (exhaust frame blowers) Generator lube oil Cooling fan module Performance monitor tubing H2 supply manifold, dryer, and CO2 manifold

CS CS CS CS CS

12v 12v 24v

360

lf

std 1.34 100 std 1.42 100 std 4.71 40 1.00 60 1.5 40

lf lf lf lf lf

1022 100 100 40 60 40

133.9 141.7 188.5 60 60

6.23 BOP equipment 6.23.1 Balance of plant installation man-hour estimate

Excel estimate—pumps Excel estimate—tanks and vessels Excel estimate—skid-mounted units Excel estimate—heaters Excel estimate—compressors Excel estimate—heat exchangers Excel estimate—eyewash/shower

6644

1475

1552

3618

ni MHa

BM

IW

MW

3274 650 468 280 1568 180 224

141 650

514

2619

468 280 570

998

180 224

6.23.2 Balance of plant equipment sheet 1 Description

Excel estimate—pumps Boiler feedwater pump A/B HRSG blowdown sump pump A/B Condensate pump A/B/C Vacuum pump skid A/B CT area sump pump A CT area sump pump A HP STG area sump pump A/B HP WT area sump pump A HP circulating water pump 1 and 2 HP potable water well pump Auxiliary cooling water pump HP closed cooling water pump A/B/C HP STG wastewater injection pump A/B Wastewater injection pump A/B HP condensate extraction pumps Excel estimate—tanks and vessels HRSG blowdown tank (05 ton) Closed cooling water chemical feed tank (05 ton)

MH

Qty Unit Qty

HP

MHa ni

ni

ni MHa BM IW

MW

320.0 15.0 75.0 30.0 15.0 15.0 15.0 15.0 50.0 25.0 75.0 250.0 75.0 75.0 75.0

1.00 2.10 1.60 2.10 2.10 2.10 2.10 2.10 1.80 2.10 1.60 1.30 1.60 1.60 1.60

2 2 3 2 1 1 2 1 2 1 1 3 2 2 1

ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea.

2 2 3 2 1 1 2 1 2 1 1 3 2 2 1

141 514 128 12.6 72 25.2 6.3 6.3 12.6 6.3 36 10.5 24 195 48 48 24 650 60 60

2619 512 50.4 288 100.8 25.2 25.2 50.4 25.2 144 42 96 780 192 192 96

1 1

3274 640 63 360 126 31.5 31.5 63 31.5 180 52.5 120 975 240 240 120 650 60 60

60 60

1 1

ea. ea.

60

1

ea.

1

60

60

(Continued )

144

Industrial Construction Estimating Manual

(Continued) Description

MH HP

Closed cooling water expansion tank (05 ton) Separator drains tank (05 ton) Water wash drains tank (UG) External steam drains tank (05 ton) Fuel gas scrubber drains tank (610 ton) Demineralized water storage tank (1120 ton) Potable water bladder tank (05 ton) Excel estimate—skid-mounted units Injection water filtration skid (03000 lb) Condensate polishing skid (30016000 lb) Fuel gas scrubber skid (600115,000 lb) Wastewater injection pump skid (03000 lb) Circulating water sulfuric acid dosing pump skid (03000 lb) Circulating water corrosion inhibitor dosing skid (03000 lb) Circulating water dispersant dosing pump skid (03000 lb) Service water pump skid (03000 lb) Closed cooling water pump skid (03000 lb) Circulating water sodium hypochlorite dosing pump skid (03000 lb) Circulating water biocide dosing pump skid (03000 lb) Ammonia dosing pump skid (03000 lb) Oxygen dosing pump skid (03000 lb) Rotary screw air compressor and receiver/ dryer skid (600115,000 lb)

Qty Unit Qty

MHa ni

ni

ni MHa BM IW

60 60 60 90 140

1 1 1 1 1

ea. ea. ea. ea. ea.

1 1 1 1 1

60 60 60 90 140

60 60 60 90 140

60

1

ea.

1

60 468

28 40 60 28

1 1 1 1

ea. ea. ea. ea.

1 1 1 1

60 468 28 40 60 28

28

1

ea.

1

28

28

28

1

ea.

1

28

28

28

1

ea.

1

28

28

28 28

1 1

ea. ea.

1 1

28 28

28 28

28

1

ea.

1

28

28

28

1

ea.

1

28

28

28 28 60

1 1 1

ea. ea. ea.

1 1 1

28 28 60

28 28 60

MW

28 40 60 28

6.23.3 Balance of plant equipment sheet 2 Excel estimate—heaters Condensate preheater (0500 lb) CT fuel gas heater (5011500 lb) Fuel gas performance heater (10012000 lb) CLG. TWR. Chem tank area ESW. Heater (0500 lb) Water treatment bldg. ESW. Heater (0500 lb) CLG. TWR. Chem tote area ESW. Heater (0500 lb) Sample panel area ESW. Heater (0500 lb) Excel estimate—compressors Fuel gas compressor A/B 500 HP; 22.6 ton (2 ea.) Gas compressor cooler 1 and 2 (2 ea.) Air compressor A/B 05000 LBS (2 ea.) Excel estimate—heat exchangers

280 30 50 80 30 30 30 30

1 1 1 1 1 1 1

ea. ea. ea. ea. ea. ea. ea.

1 1 1 1 1 1 1

30 50 80 30 30 30 30 1568 624 2 ea. 2 1248 60 2 ea. 2 120 100 2 ea. 2 200 180

280 30 50 80 30 30 30 30 570 998 250 998 120 200 180

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

145

(Continued) Excel estimate—heaters Closed cooling water heat exchanger A/B/C Excel estimate—eyewash/shower CLG. TWR. Chem tank area 1 eyewash/shower CLG. TWR. Chem tank area 2 eyewash/shower CLG. TWR. Chem tank area 3 eyewash/shower Water treatment bldg. area 1 eyewash/shower Water treatment bldg. area 2 eyewash/shower CLG. TWR. Chem tote area eyewash/shower Sample panel area eyewash/shower

60 32 32 32 32 32 32 32

280

280

3 ea. 3 180 224 1 ea. 1 32 1 ea. 1 32 1 ea. 1 32 1 ea. 1 32 1 ea. 1 32 1 ea. 1 32 1 ea. 1 32

180 224 32 32 32 32 32 32 32

6.24 Structural steel 6.24.1 Structural steel installation man-hour estimate

HRSG utility steel bridge STG utility bridge steel STG utility bridge steel inside enclosure GSU transformer access platforms Stair tower and ladders Iso-phase support steel Dead-end structure 230 kV Switchyard structure including bus supports Transmission line poles Grating, handrail, and toe plate

11,837

11,837

ni MHa

IW

3804 3453 691 311 464 759 759 380 138 1080

3804 3453 691 311 464 759 759 380 138 1080

6.24.2 Structural steel estimate Description

HRSG utility steel bridge Light—019 lb/ft. Medium—2039 lb/ft. Heavy—4079 lb/ft. X heavy—80120 lb/ft. STG utility bridge steel Light—019 lb/ft. Medium—2039 lb/ft. Heavy—4079 lb/ft. X heavy—80120 lb/ft.

MH

Qty

Unit

MHa

ni

24 23 18 16

11 33 105.6 55

ton ton ton ton

24 23 18 16

8.4 27.9 99 51.7

ton ton ton ton

Qty ni

ni MHa

IW

204.6 11 33 105.6 55 187 8.4 27.9 99 51.7 37

3803.8 264 759 1900.8 880 3453 201.6 641.7 1782 827.2 691

3804 264 759 1901 880 3453 201.6 641.7 1782 827.2 691

(Continued )

146

Industrial Construction Estimating Manual

(Continued) Description

STG utility bridge steel inside enclosure Light—019 lb/ft. Medium—2039 lb/ft. Heavy—4079 lb/ft. X heavy—80120 lb/ft. GSU transformer access platforms Light and medium Stair Tower and ladders Light and medium Stair treads Ladders Iso-phase support steel Light and medium Dead-end structure Light and medium 230 kV Switchyard structure including bus supports Light and medium Transmission line poles Light and medium Grating, handrail and toe plate 2v Serrated floor grating 1.5v Serrated floor grating Handrail and toe plate

MH

Qty

MHa

ni

Unit

Qty ni

ni MHa

IW

24 23 18 16

1.7 5.6 19.8 10.3

ton ton ton ton

1.7 5.6 19.8 10.3 14

40.8 128.8 356.4 164.8 311

40.8 128.8 356.4 164.8 311

23

13.5

ton

23 0.55 0.30

10.4 300 200

ton ea. lf

23

33

ton

23

33

ton

13.5 14.2 10.4 300 200 33 33 33 33 16.5

310.5 464 239.2 165 60 759 759 759 759 380

310.5 464 239.2 165 60 759 759 759 759 380

379.5 138 138 1080 560 205 315

379.5 138 138 1080 560 205 315

23

16.5

ton

23

6

ton

16.5 6 6

0.05 0.05 0.15

11,200 4100 2100

lf lf lf

11,200 4100 2100

6.25 Summary underground piping man-hours Qty

Underground piping Estimate EKG-fuel gas Estimate HAN-boiler blowdown Estimate GAC-raw water Estimate GHC-condensate makeup Estimate GKB-potable water Estimate GMA-wastewater collection Estimate EKG-fuel gas Estimate UG cicr water piping

PF/Laborer

ni

Unit

ni MHa

MH/LF

8699 1130 730 850 1000 900 1068 1130 1891

lf lf lf lf lf lf lf lf lf

13,913 1766 580 1236 547 455 606 1665 7058

1.60 1.56 0.79 1.45 0.55 0.51 0.57 1.47 3.73

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

6.25.1 Underground piping Specification

MH

8699 lf

13,913

Qty

PF/ Laborer

Material

Size Sch/Thk

MHa ni

30A3S 30A3S 30A3S

12 6 2

std wt std wt xs

1130 1.72 610 1.40 460 1.25 60 730

15F51S

8

HAN-boiler blowdown

15F51S

3

HAN-boiler blowdown

15F51S

4

HAN-boiler blowdown Estimate GAC-raw water GAC-raw water Estimate GHC-condensate makeup GHC-condensate makeup GHC-condensate makeup GHC-condensate makeup Estimate GKB-potable water GKB-potable water GKB-potable water Estimate GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection Estimate EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas Estimate UG cicr water piping UG cicr water piping cylinder pipe bell end

15A1S

4

150# DICement Lined 150# DICement Lined 150# DICement Lined std wt

12J8S

12

150# HDPE

12J8S 12J8S 12J8S

4 3 2

150# HDPE 150# HDPE 150# HDPE

12J62S 12J62S

3 2

150# HDPE 150# HDPE

12J8S 12J8S 12J8S 12J8S 12J8S

4 4 4 4 4

150# 150# 150# 150# 150#

30A3S 30A3S 30A3S

12 6 2

std wt std wt xs

Line no. Estimate EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas Estimate HAN-boiler blowdown HAN-boiler blowdown

5416

HDPE HDPE HDPE HDPE HDPE

147

Unit Qty

ni

ni MHa

lf lf lf lf lf

610 460 60

1766 1047 644 75 580

1.04 180

lf

180

187

0.66 140

lf

140

93

2.76 40

lf

40

110

0.51 370 850 1.45 850 1000

lf lf lf lf

370

190 1236 1236 547

0.60 510 0.55 200 0.45 290 900 0.55 500 0.45 400 1068

lf lf lf lf lf lf lf

0.51 0.58 0.71 0.60 0.65

lf lf lf lf lf lf lf lf lf lf

468 168 49 276 106 1130 1.72 610 1.20 460 1.10 60 1891

3.73 1891 lf

850

510 200 290 500 400

468 168 49 276 106 610 460 60

306 110 131 455 275 180 606 239 97 35 166 69 1665 1047 552 66 7058

1891 7058

148

Industrial Construction Estimating Manual

6.26 Summary aboveground piping man-hours Qty

Aboveground piping Estimate EKG-fuel gas Estimating EKT-fuel gas heating Estimate GAC-raw water Estimate GHC-condensate makeup Estimate GKB-potable water Estimate GMA-wastewater collection Estimate HAN-boiler blowdown Estimate HSJ-anhydrous ammonia Estimate LAB-boiler feedwater Estimate LBA-high-pressure steam Estimate LBB-hot reheat steam Estimate LBC-cold reheat steam Estimate LBG-auxiliary steam Estimate-LBM-low-pressure steam Estimate-LCA-condensate Estimate LDK-condensate polishing Estimate MA-steam turbine Estimate MAJ-air extraction Estimate MAL-steam turbine drains Estimate MB-combustion turbine Estimate PAB-circulating water Estimate PBN-circulating water chemical feed Estimate PCB-service water Estimate PGB-closed cooling water Estimate QC-cycle chemical feed Estimate QFB-instrument/service air Estimate QH-aux boiler Estimate QJ-nitrogen Estimate QU-sampling and analysis

PF

ni

Unit

ni MHa

MH/LF

38,914 1160 662 25 645 875 1370 4033 354 1344 530 473 505 490 462 1626 370 500 320 2900 508 710 1225 1620 3135 880 5600 650 500 5442

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

77,741 2362 1056 126 761 1016 1479 5484 238 2273 2484 2269 1950 669 1229 3154 732 593 537 2973 719 7759 1242 2271 6548 880 6447 1057 550 18,884

2.0 2.0 1.6 5.0 1.2 1.2 1.1 1.4 0.7 1.7 4.7 4.8 3.9 1.4 2.7 1.9 2.0 1.2 1.7 1.0 1.4 10.9 1.0 1.4 2.1 1.0 1.2 1.6 1.1 3.5

6.27 Aboveground balance of plant piping 6.27.1 Aboveground piping sheet 1

Specification

MH

38,914 lf

77,741

Qty

PF

Line no.

Material

Size Sch/Thk MHa ni

Estimate EKG-fuel gas EKG-fuel gas EKG-fuel gas

30A3S 30A3S

12 8

std wt std wt

1160 2.53 170 2.53 35

Unit Qty

lf lf lf

ni

ni MHa

170 35

2362 429 89

(Continued )

149

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

(Continued)

Specification

MH

38,914 lf

77,741

Qty

PF

Line no.

Material

Size Sch/Thk MHa ni

EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas EKG-fuel gas Estimating EKT-fuel gas heating EKT-fuel gas heating EKT-fuel gas heating EKT-fuel gas heating EKT-fuel gas heating EKT-fuel gas heating EKT-fuel gas heating EKT-fuel gas heating Estimate GAC-raw water GAC-raw water GAC-raw water GAC-raw water Estimate GHC-condensate makeup GHC-condensate makeup GHC-condensate makeup GHC-condensate makeup GHC-condensate makeup GHC-condensate makeup Estimate GKB-potable water GKB-potable water GKB-potable water GKB-Potable water GKB-potable water Estimate GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection GMA-wastewater collection

30A3S 30A3S 30A3S 30A3S 30A3S 30A3S 30A3S 30A3S 30A3S 30A3S

6 2 1.5 1 8 8 2 2 1.5 1

std wt xs xs xs std wt std wt xs xs xs xs

90A1S 90A1S 90A1S 90A1S 90A1S 90A1S 90A1S

24 10 4 4 4 1.5 1

1.531 0.718 0.337 0.337 0.337 0.200 0.179

30.1 6.9 1.1 1.0 1.8 1.0 1.0

15A1S 15A1S 15A1S

10 1.5 1

std wt xs xs

5.8 1.9 2.1

15D1S 15D1S 15D1S 15D1S 15D1S

6 4 3 2 1

10s 10s 10s 40s 40s

5.5 1.9 1.0 1.0 1.4

15M61S 15M61S 15M61S 15M61S

3 2 1.5 1

std wt xs xs xs

2.7 1.0 1.1 1.3

15D11S 15D11S 15A2S 60D3S 15D11S 60D1S 15A1S 15A1S 15A1S 15A1S 15A1S

1 1.5 4 1 1.5 4 8 4 2 1.5 1

40s 40s std wt 40s 40s 10s std wt std wt xs xs xs

2.1 2.1 1.6 2.1 2.1 3.3 4.4 2.0 0.5 2.0 3.5

7.19 1.70 1.46 2.49 2.76 1.84 1.76 1.73 1.13 1.93

Unit Qty ni

ni MHa

15 250 40 20 100 100 300 100 20 10 662 10 10 350 250 20 12 10 25 20 3 2 645

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

15 250 40 20 100 100 300 100 20 10

108 425 59 50 276 184 528 173 23 19 1056 301 69 379 250 35 12 10 126 116 6 4 761

10 75 385 150 25 875 25 250 500 100 1370

lf lf lf lf lf lf lf lf lf lf lf

10 75 385 150 25

10 10 100 10 10 100 40 60 1000 20 10

lf lf lf lf lf lf lf lf lf lf lf

10 10 350 250 20 12 10 20 3 2

25 250 500 100

10 10 100 10 10 100 40 60 1000 20 10

55 141 375 155 36 1016 67 249 569 131 1479 21 21 161 21 21 332 175 119 533 40 35

150

Industrial Construction Estimating Manual

6.27.2 Aboveground piping sheet 2 Specification Line no. Estimate HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown HAN-boiler blowdown Estimate HSJ-anhydrous ammonia HSJ-anhydrous ammonia HSJ-anhydrous ammonia Estimate LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater LAB-boiler feedwater

MH

Qty

Material

Size Sch/Thk

MHa ni

15A1S 15A1S 15A1S 15A1S 15A1S 15A5S 15A5S 15A5S 15A5S 15C3S 15C3S 60C1S 60C5S 250C1S 250C1S

1 1.5 2 3 4 2 6 24 1.5 1.5 12 1.5 12 1.5 12

xs xs xs std wt std wt xs std wt std wt xs xs-P22 std wt-P22 xs-P91 std wt-P91 xs-P91 std wt-P91

6.7 3.6 1.6 3.6 4.6 1.7 2.3 3.2 0.9 4.9 6.7 1.3 3.4 1.6 3.4

30D1S 30D1S

2 1.5

40s 40s

0.6 3.3

15A1S 30A1S 30A1S 30A1S 30A1S 30A1S 90A1S 90A1S 90A1S 90A1S 90A1S 250A1S 250A1S 250A1S 90A1S

2 10 6 4 1.5 1.5 6 4 2 1.5 1 8 2 1.5 1

xs std wt std wt std wt xs xs xs xs xs xs xs .84v CS 160 160 xs

1.0 3.4 2.2 1.3 4.8 4.0 2.2 1.7 0.9 2.7 4.7 2.5 0.9 2.4 4.7

Unit Qty

4033 5 8 20 10 20 10 10 70 1200 40 10 1700 20 900 10 354

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

350 4 1344 130 120 100 70 8 11 165 70 180 14 4 160 196 18 4

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

PF

ni

ni MHa

5 8 20 10 20 10 10 70 1200 40 10 1700 20 900 10

5484 34 29 32 36 92 17 23 221 1066 194 67 2133 67 1441 34 238

350 4 130 120 100 70 8 11 165 70 180 14 4 160 196 18 4

224 13 2273 128 412 215 89 39 44 366 121 160 38 19 396 182 44 19

6.27.3 Aboveground piping sheet 3 Specification Line no.

Material

Estimate LBA-high-pressure steam LBA-high-pressure steam 250C1S LBA-high-pressure steam 250C1S LBA-high-pressure steam 250C1S LBA-high-pressure steam 250C1S

MH

Qty Unit Qty PF

Size Sch/Thk

MHa ni

14 10 6 3

46.8 5.7 12.3 4.0

160 P91 160 P91 160 P91 160 P91

530 2 270 9 10

lf lf lf lf lf

ni

ni MHa

2 270 9 10

2484 94 1531 110 40

(Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

151

(Continued) Specification

MH

Line no.

Material

Size Sch/Thk

LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam LBA-high-pressure steam Estimate LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam LBB-hot reheat steam

250C1S 250C1S 250C1S 250C1S 250C1S 60C5S 60A1S 250C1S 250C1S 250C1S 60C5S

2 2 1.5 1 10 14 14 2 1.5 1 2

60CS1 60CS1 60CS1 60CS1 60CS1 60CS1 60CS1 60CS1 60CS1 60CS1

20 16 10 8 2 1.5 1 20 30 1

Qty Unit Qty PF

MHa ni

xs-P91 1.0 70 xs-P91 1.3 45 xs-P91 2.4 10 xs-P91 2.1 16 160 P91 20.2 12 std wt-P91 2.6 30 40 5.7 15 xs-P91 3.8 15 xs-P91 2.7 6 xs-P91 2.1 16 xs-P22 2.7 4 473 xs-P91 4.2 260 std wt-P91 5.1 30 std wt-P91 5.6 6 std wt-P91 4.5 6 xs-P91 2.5 60 xs-P91 1.6 12 xs-P91 1.5 10 xs-P91 11.5 15 xs-P91 8.5 70 xs-P91 1.5 4

ni lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

ni MHa

70 45 10 16 12 30 15 15 6 16 4

69 59 24 34 242 78 86 57 16 34 11 2269 260 1100 30 153 6 34 6 27 60 153 12 19 10 15 15 172 70 592 4 6

6.27.4 Aboveground piping sheet 4 Specification

MH

Line no.

Material

Size Sch/Thk

Estimate LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam LBC-cold reheat steam

60A1S 60A1S 60C5S 60C5S 60C5S 60C5S 60C5S 60C5S 60C5S 60C5S 90A1S 90A1S 90A1S 60C5S 60A1S 60A1S 60A1S 60A1S 60A1S

24 20 20 4 4 3 10 2 1.5 1 2 1.5 1 2 6 10 2 1.5 1

Qty Unit Qty PF

MHa ni

505 lf 60 32.0 2 lf 40 6.4 110 lf xs-P91 6.0 110 lf std wt-P91 1.3 25 lf std wt-P91 1.0 100 lf std wt-P91 1.8 20 lf std wt-P91 15.7 6 lf xs-P91 2.7 45 lf xs-P91 1.7 4 lf xs-P91 1.4 8 lf xs 1.0 20 lf xs 1.2 4 lf xs 1.2 4 lf xs-P22 3.5 3 lf std wt 1.9 20 lf std wt 4.4 3 lf xs 1.1 15 lf xs 1.3 4 lf xs 1.3 2 lf

ni

ni MHa

2 110 110 25 100 20 6 45 4 8 20 4 4 3 20 3 15 4 2

1950 64 704 665 34 98 37 94 121 7 11 21 5 5 11 37 13 16 5 3

(Continued )

152

Industrial Construction Estimating Manual

(Continued) Specification Line no. Estimate LBG-auxiliary steam LBG-auxiliary steam LBG-auxiliary steam LBG-auxiliary steam LBG-auxiliary steam Estimate-LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam LBM-low-pressure steam

MH

MHa ni

Material

Size Sch/Thk

30A5S 30A5S 30A5S 30A5S

6 4 4 3

std std std std

15A5S 15A5S 15A5S 15A5S 15A5S 15A5S 15A5S 15C3S 15A5S 15C3S 30A1S 30A1S 30A1S 30A5S

14 10 2 8 6 2 12 18 1.5 1 2 1.5 1 2

std wt 2.7 std wt 2.4 xs 1.9 std wt 12.8 std wt 11.7 xs 0.9 std wt 4.5 std wt-P22 5.0 xs 1.3 xs-P22 1.6 xs 2.3 xs 1.2 xs 1.2 xs 1.2

wt wt wt wt

Qty Unit Qty PF

2.1 1.1 1.3 0.9

ni

ni MHa

490 120 200 100 70 462 200 30 50 3 3 60 15 45 2 2 30 6 8 8

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

669 248 228 130 63 1229 200 543 30 73 50 94 3 39 3 35 60 52 15 67 45 225 2 3 2 3 30 68 6 7 8 9 8 10

Qty

Unit Qty PF

120 200 100 70

6.27.5 Aboveground piping sheet 5 Specification Line no. Estimate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate LCA-condensate Estimate LDK-condensate polishing LDK-condensate polishing

MH

Material

Size Sch/Thk MHa ni

15A1S 15A1S 15A1S 15A1S 15A1S 15A1S 15A1S 30A1S 30A1S 30A1S 30A1S 30A1S 30A1S 30A1S 30A1S 30A1S 90A1S 90A1S 90A1S

18 6 3 2 1.5 1 0.8 10 10 6 4 3 2 1.5 1 0.8 6 1.5 1

std std std xs xs xs xs std std std std std xs xs xs xs xs xs xs

15A1S

1.5

xs

wt wt wt

wt wt wt wt wt

1626 50 10 10 70 10 40 2 350 110 100 30 205 130 425 15 1 60 4 4 370 0.8 200

11.8 4.4 2.0 0.8 2.5 2.1 2.0 2.3 2.9 2.2 3.0 1.3 0.8 1.0 1.7 2.1 1.7 1.2 1.2

ni lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

ni MHa

3154 592 44 20 54 25 86 4 794 319 215 89 260 100 414 25 2 101 5 5 732 200 170

50 10 10 70 10 40 2 350 110 100 30 205 130 425 15 1 60 4 4

(Continued )

153

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

(Continued) Specification

MH

Qty

Line no.

Material

Size Sch/Thk MHa ni

LDK-condensate polishing LDK-condensate polishing Estimate MA-steam turbine MA-steam turbine MA-steam turbine MA-steam turbine MA-steam turbine MA-steam turbine MA-steam turbine MA-steam turbine Estimate MAJ-air extraction MAJ-air extraction MAJ-air extraction MAJ-air extraction MAJ-air extraction MAJ-air extraction

15A1S 15A1S

10 12

std wt std wt

15A1S 15A1S 15A1S 15A1S 15A5S 15A5S 15D1S

1 1.5 2 4 4 6 6

xs xs xs std wt std wt std wt 10s

15A1S 15A1S 15A1S 15A1S 15A1S

24 8 6 6 0.8

std std std std xs

wt wt wt wt

3.8 60 3.0 110 500 2.0 30 0.8 150 0.8 200 2.3 30 1.0 30 1.3 40 5.1 20 320 4.1 40 1.5 190 3.0 6 6.1 4 0.7 80

Unit Qty PF ni lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

ni MHa

60 229 110 332 593 30 60 150 121 200 160 30 68 30 30 40 51 20 103 537 40 162 190 279 6 18 4 25 80 54

6.27.6 Aboveground piping sheet 6 Specification Line no. Estimate MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains MAL-steam turbine drains Estimate MB-combustion turbine MB-combustion turbine MB-combustion turbine MB-combustion turbine MB-combustion turbine MB-combustion turbine MB-combustion turbine MB-combustion turbine MB-combustion turbine MB-combustion turbine MB-combustion turbine

Material

MH Size Sch/Thk

Qty

Unit Qty PF

MHa ni

ni

2900 lf

ni MHa 2973

15A5S 15A5S 15C3S 250C1S 250C1S 250C1S 30A5S 60C1S 60C1S 60C5S 60C5S 316SS

1.5 2 1.5 1.5 2 3 2 1.5 2 2 4 6

xs xs xs-P22 xs-P91 xs-P91 160 P91 xs xs-P91 xs-P91 xs-P22 std wt-P91 40s

0.9 1.0 1.1 1.0 1.1 1.3 0.9 1.1 1.1 1.0 1.0 1.8

490 275 70 400 250 65 380 300 250 220 100 100 508

lf lf lf lf lf lf lf lf lf lf lf lf lf

490 275 70 400 250 65 380 300 250 220 100 100

437 283 74 389 281 85 330 317 277 222 98 178 719

15A1S 15A1S 15A1S 15A1S 15A1S 15D1S 15D1S 15D1S 15D1S 30A3S

1 1.5 2 6 6 1 1.5 2 6 1.5

xs xs xs std wt std wt 40s 40s 40s 10s xs

1.8 0.9 1.1 3.2 6.3 2.8 1.1 1.1 2.1 1.1

8 80 40 12 8 10 100 60 80 40

lf lf lf lf lf lf lf lf lf lf

8 80 40 12 8 10 100 60 80 40

14 73 44 38 50 28 108 69 170 43

(Continued )

154

Industrial Construction Estimating Manual

(Continued) Specification

MH

Qty

Unit Qty PF

Line no.

Material

Size Sch/Thk

MHa ni

ni

ni MHa

MB-combustion turbine MB-combustion turbine Estimate PAB-circulating water PAB-circulating water PAB-circulating water PAB-circulating water PAB-circulating water PAB-circulating water PAB-circulating water PAB-circulating water PAB-circulating water PAB-circulating water PAB-circulating water

30D1S 60A4S

2 1.5

40s xs

15A2S 15A2S 15A2S 15A2S 15A2S 15A2S 15A2S 15A2S 15A2S 15D11S

54 42 36 30 24 18 16 6 4 1

lf lf lf lf lf lf lf lf lf lf lf lf lf

39 43 7759 70 1465 165 1593 140 953 35 818 60 556 50 915 50 645 20 197 40 221 40 249

PAB-circulating water

15D11S

1.5

.500v Wall .375v Wall .375v Wall .375v Wall std wt std wt std wt std wt std wt 40s-Duplex ss 40s-Duplex ss

1.3 30 1.1 40 710 20.9 70 9.7 165 6.8 140 23.4 35 9.3 60 18.3 50 12.9 50 9.9 20 5.5 40 6.2 40 3.7 40

lf

40

30 40

147

6.27.7 Aboveground piping sheet 7 Specification Line no.

Material

MH Size Sch/Thk

Estimate PBN-circulating water chemical feed PBN-circulating water chemical feed PBN-circulating water chemical feed PBN-circulating water chemical feed

12J4S 12J4S 15D2S

2 1 2

PBN-circulating water chemical feed

15D2S

0.5

PBN-circulating water chemical feed

15D11S

1.5

PBN-circulating water chemical feed PBN-circulating water chemical feed PBN-circulating water chemical feed PBN-circulating water chemical feed PBN-circulating water chemical feed PBN-circulating water chemical feed Estimate PCB-service water PCB-service water PCB-service water PCB-service water PCB-service water PCB-service water PCB-service water PCB-service water Estimate PGB-closed cooling water PGB-closed cooling water PGB-closed cooling water PGB-closed cooling water

15D1S 150Q1S 15D1S 150Q1S 15D1S 150Q1S

Qty

Unit Qty PF

MHa ni

ni

1225 lf

ni MHa 1242

1.0 1.0 1.1

40 550 45

lf lf lf

40 40 550 550 45 50

1.0

40

lf

40

40

1.0

70

lf

70

70

1 0.5 1 0.5 1 0.5

80-CPVC 80-CPVC 80s-Alloy 20 80s-Alloy 20 40s-Duplex ss 40s ss tube 40s ss tube 40s ss tube

1.1 1.0 1.1 1.0 1.1 1.0

14 10 6 4 3 2 1.5

std wt std wt std wt std wt std wt xs xs

6.9 3.9 3.3 1.0 1.0 1.0 1.1

15A1S 15A1S 15A1S

24 16 14

std wt std wt std wt

6.9 4.9 2.3

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

40 120 40 120 40 120

15A1S 15A1S 15A1S 15A1S 15A1S 15A1S 15A1S

40 120 40 120 40 120 1620 50 40 70 300 205 275 680 3135 130 90 530

44 120 44 120 44 120 2271 345 154 232 305 211 275 748 6548 892 443 1208

50 40 70 300 205 275 680 130 90 530

(Continued )

155

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

(Continued) Specification

MH

Qty

Line no.

Material

Size Sch/Thk

MHa ni

PGB-closed cooling water PGB-closed cooling water PGB-closed cooling water PGB-closed cooling water PGB-closed cooling water PGB-closed cooling water PGB-closed cooling water PGB-closed cooling water

15A1S 15A1S 15A1S 15A1S 15A1S 15A1S 15A1S 15A1S

10 8 6 4 3 2 1.5 1

2.3 1.6 2.2 1.3 1.5 1.1 1.1 2.9

std wt std wt std wt std wt std wt xs xs xs

Unit Qty PF

420 520 410 250 160 95 480 50

lf lf lf lf lf lf lf lf

ni

ni MHa

420 520 410 250 160 95 480 50

947 815 888 334 238 105 533 146

6.27.8 Aboveground piping sheet 8 Specification Line no.

Material

MH Size

Sch/Thk

Qty

Unit Qty

MHa ni 880

ni lf

PF ni MHa

Estimate QC-cycle chemical feed QC-cycle chemical feed QC-cycle chemical feed QC-cycle chemical feed Estimate QFB-instrument/ service air QFB-instrument/service air

880

316 SS 316 SS 316 SS

0.5 0.5 0.5

80s-316 ss 80s-316 ss 80s-316 ss

1.0 350 1.0 350 1.0 180 5600

lf lf lf lf

350 350 180

350 350 180 6447

15D7S

3

1.0 600

lf

600

613

QFB-instrument/service air

15D7S

2

QFB-instrument/service air

15D7S

1.5

QFB-instrument/service air

15D7S

1

QFB-instrument/service air Estimate QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler QH-aux boiler Estimate QJ-nitrogen Estimate QU-sampling and analysis QU-sampling and analysis

150Q1S

0.5

5S-304SS Pressfit 5S-304SS Pressfit 5S-304SS Pressfit 5S-304SS Pressfit 80s-316 ss

15A1S 15A1S 15A1S 15A1S 15A5S 15A5S 15D1S 15D1S 15D1S 30A5S 30A5S 30A5S 30A5S 30A5S 15A1S

1 1.5 2 4 6 4 1 1.5 2 6 4 3 2 1 1

xs xs xs std wt std wt std wt 40s 40s 40s std wt std wt std wt xs xs xs

150Q1S

0.25

ss tube

1.2 1200 lf

1200 1446

1.3 1000 lf

1000 1349

1.2 1000 lf

1000 1239

1.0 1800 650 2.0 10 1.0 100 1.1 100 2.0 40 2.5 50 2.1 30 2.8 10 1.2 50 1.2 50 5.8 30 1.4 45 2.7 15 1.0 115 2.6 5 1.1 500 5442

1800 1800 1057 10 20 100 100 100 108 40 82 50 124 30 63 10 28 50 62 50 62 30 175 45 65 15 40 115 115 5 13 500 550 18,884

lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf lf

2.0 3500 lf

3500 7000

(Continued )

156

Industrial Construction Estimating Manual

(Continued) Specification Line no. QU-sampling QU-sampling QU-sampling QU-sampling QU-sampling QU-sampling QU-sampling QU-sampling QU-sampling QU-sampling

and analysis and analysis and analysis and analysis and analysis and analysis and analysis and analysis and analysis and analysis

MH

Qty

Material

Size

Sch/Thk

MHa ni

150Q1S 150Q1S 150Q1S 250Q2S 250Q2S 250Q2S 250Q4S 250Q4S 250Q4S 250Q4S

0.375 0.5 0.75 0.25 0.5 0.75 0.75 0.25 0.5 0.75

ss ss ss ss ss ss ss ss ss ss

2.0 2.0 2.0 2.0 2.0 2.0 2.0 22.0 2.0 2.0

tube tube tube tube tube tube tube tube tube tube

Unit Qty

1100 17 17 200 1 1 200 400 3 3

lf lf lf lf lf lf lf lf lf lf

PF

ni

ni MHa

1100 17 17 200 1 1 200 400 3 3

2200 34 34 400 2 2 400 8800 6 6

6.28 Heat recovery steam generator configuration There are many different configurations for combined cycle power plants: G G G G

Each gas turbine has one associated HRSG. 2 3 1 Configuration, two GT/HRSG trains supply one STG. Multiple HRSG trains supply steam to one STG. There can be 1 3 1, 3 3 1, and 4 3 1 arrangements.

6.29 Combined cycle power plant equipment man-hour breakdown The direct craft man-hours, provided in this manual, have been cost coded, collected in the field, summarized, and verified by statistical analysis. Manhours are for direct labor and do not include indirect and staff labor. The craft man-hours can be modified as the user’s experience and situation require. Combined cycle power plant Owner-furnished equipment

6.29.1 Combined cycle power plant: configuration: 2 3 1 Direct craft man-hours

Actual

Scope of work

MH

E and F class CTGequipment installation manhours Reheat double-flow STGinstallation man-hours

13,260

Qty

BM

IW

MW

Estimate

MH

MH

MH

MH

2

14,462

7674

4385

26,521

10,420

1

1636

1335

7449

10,420

24,258

2

48,516

48,516 (Continued )

157

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

(Continued) Direct craft man-hours

Actual

Scope of work

MH

HRSG triple pressure; three wide-installation man-hours Air cooled condenser (36 cell)-installation man-hours Balance of plant installation man-hours

Qty

BM

IW

MW

Estimate

MH

MH

MH

MH

89,604

1

40,176

33,948

15,480

89,604

6644

1

1475

1552

3618

6644

6.29.2 Combined cycle power plant owner-furnished equipment Direct craft man-hours

Actual

BM

IW

MW

Scope of work

MH

MH

MH

MH

MH

E and F class CTG-equipment installation man-hours Reheat double-flow STGinstallation man-hours HRSG triple pressure; three wide-installation man-hours HRSG triple pressure; double wide-installation man-hours HRSG double pressure; single wide-installation man-hours HRSG single pressure; double wide-installation man-hours Air cooled condenser (36 cell)-installation man-hours Surface condenser-equipment installation man-hours Balance of plant installation man-hours ZLD-equipment installation man-hours

13,260

7231

3837

2192

13,260

10,420

1636

1335

7449

10,420

24,258

24,258

24,258

16,500

16,500

16,500

7456

7456

7456

30,958

30,958

30,958

89,605

40,176

3460

3460

6644

1475

6969

33,948

15,480

89,604 3460

1552

3618

6644

6156

840

6996

Cells

36

158

Industrial Construction Estimating Manual

6.30 Direct craft man-hour summary 6.30.1 Combined cycle power plant: configuration: 1 3 1 Direct craft man-hours

Estimate

Scope of work

MH

Carpenter

Labor

IW

7347 5528

1138 1025

4550 3330

1659 1173

15,865

2939

9471

3455

7161

2046

3962

1152

17,628

5932

8138

3557

BM

13,260

Foundations Boiler foundations CTG and CTGrelated foundations STG and STGrelated foundations Plant mechanical systemrelated foundations Utility distribution plant electrical controls foundations Mechanical equipment (CTG, STG, HRSG), w/piping E and F class CTGequipment installation man-hours Reheat double-flow STG-installation man-hours HRSG triple pressure; Three wide-installation man-hours Balance of plant installation man-hours HRSG—large bore code piping HRSG—small bore code piping HRSG—risers and down comers HRSG—field trim piping SP-01 AIG piping STG—vendor piping STG piping

MW

PF

IW

MW

PF

7231

3837

2192

10,420

1636

1335

7449

24,258

24,258

6644

1475

1552

3618

15,529

15,529

5191

5191

3827

3827

3341

3341

2262 7014 5928

2262 7014 5928 (Continued )

Combined cycle power plant (1 3 1) labor estimate Chapter | 6

159

(Continued) Direct craft man-hours

Estimate

Scope of work

MH

CTG—vendor piping BOP equipment Balance of plant installation estimate Structural steel Structural steel installation estimate Underground piping Underground piping Aboveground piping Aboveground piping Direct craft man-hours

14,634 6644

Carpenter

Labor

IW

BM 1475

IW 1552

MW 3618

MW

14,634

IW 11,837

11,837

13,913 77,741 273,712

PF

14,556

65,603

33,176

13,259

PF 13,913 PF 77,741 147,118

Chapter 7

Gasifier labor estimate 7.1

Introduction

This chapter provides the readers a basic understanding of the fundamentals and the operating relationship between the plant equipment in the gasification process and covers the craft labor for the assembly and field erection required to put the equipment into operation in a gasification plant. Gasification is a process that converts organic- or fossil fuel based carbonaceous materials into carbon monoxide, hydrogen, and carbon dioxide. This is achieved by reacting the material at high temperatures without combustion, with a controlled amount of oxygen and/or steam. The resulting gas mixture is called syngas or producer gas and is itself a fuel. The power derived from gasification and combustion of the resultant gas is considered to be a source of renewable energy if the gasified compounds were obtained from biomass. Gasification is a technology that converts carbon-containing materials, including coal, waste, and biomass, into synthetic gas that in turn can be used to produce electricity and other valuable products, such as chemicals, fuels, and fertilizers.

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00007-7 © 2020 Elsevier Inc. All rights reserved.

161

162

Industrial Construction Estimating Manual

7.2

Gasifier bid breakdown

7.2.1

Total direct craft man-hours sheet 1

Gasifier labor estimate Chapter | 7

163

7.3 Detailed estimate using the unit quantity model to erect gasifier 7.3.1

Equipment estimate sheet 1

7.3.2

Equipment estimate sheet 2

164

7.3.3

Industrial Construction Estimating Manual

Equipment estimate sheet 3

Gasifier labor estimate Chapter | 7

7.3.4

Equipment estimate sheet 4

165

166

Industrial Construction Estimating Manual

7.3.5

Equipment estimate sheet 5

7.3.6

Equipment estimate sheet 6

Gasifier labor estimate Chapter | 7

7.3.7

Equipment estimate sheet 7

7.3.8

Equipment estimate sheet 8

167

168

7.3.9

Industrial Construction Estimating Manual

Equipment estimate sheet 9

7.3.10 Equipment estimate sheet 10

Gasifier labor estimate Chapter | 7

7.3.11 Equipment estimate sheet 11

7.3.12 Equipment estimate sheet 12

169

170

Industrial Construction Estimating Manual

7.3.13 Equipment estimate sheet 13

Chapter 8

Refinery equipment and storage tank labor estimates 8.1

Introduction

This chapter provides labor estimates for: l l

petroleum refinery equipment API 650 steel welded storage tank

The labor estimate provides the basis for the project schedule. The estimator uses the labor estimate to determine crew craft and makeup requirements, project duration, and to develop Level I and Level II schedules for the project.

8.2 8.2.1

Refinery equipment estimate Refinery equipment installation man-hours activity

Total man-hours Vessels/columns Tanks Reactors Shell and tube heat exchanger Pumps Recycle compressor no. 1, reciprocating 1500 HP Recycle compressor no. 2, reciprocating 1500 HP Rich solvent hydraulic turbine, 1292 HP Miscellaneous equipment and special specialty items

BM-MH

PF-MH

Total MH

18,840 5584 280 2800 1380 2068 1980 1980 2460 308

2100

20,940 5584 280 2800 1380 2068 2780 2780 2960 308

800 800 500

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00008-9 © 2020 Elsevier Inc. All rights reserved.

171

172

Industrial Construction Estimating Manual

8.3

Refinery equipment bid breakdown

Vessels/columns Solvent absorber 80 -6v D 3 690 -0v Rich solvent flash drum 70 -0v D 3 240 -0v Solvent regenerator 80 -0v D 3 720 -6v Solvent regenerator reflux drum 50 -0v D 3 150 -0v Solvent regenerator reboiler steam condensate drum 20 -6v D 3 80 -0v Water makeup drum 10 -0v D 3 20 -8v Solvent sump drum 40 -0v D 3 120 -0v Recycle compressor suction drum 60 -6v D 3 120 -0v Reactor steam drum 110 -0v D 3 330 -0v Mixed alcohol absorber 50 -6v D 3 240 -0v Absorber water feed drum 20 -6v D 3 70 -6v Tanks Solvent-storage tank 120 -0v D 3 24v-0v Reactors Ethanol synthesis reactor (120 -6v D 3 250 -9v) Ethanol synthesis reactor (120 -6v D 3 250 -9v) Ethanol synthesis reactor (120 -6v D 3 250 -9v) Ethanol synthesis reactor (120 -6v D 3 250 -9v) Shell and tube heat exchanger Lean solvent cooler Solvent regenerator reboiler Ethanol synthesis feed/effluent exchanger Reactor feed heater Recycle compressor spillback cooler Absorber feed trim cooler Lean/rich solvent exchangers Solvent regenerator OVHD condenser Absorber feed cooler Pumps Lean solvent booster pumps 150 HP Lean solvent pumps 1750 HP Solvent regenerator reflux pumps 3 HP Absorber water wash pumps 3 HP Solvent makeup pump 3 HP Water makeup pump 7.5 HP Solvent sump drum pump 3 HP Steam drum circulation pump 75HP Sulfating agent injection pump 3HP Absorber water feed pump 25HP Recycle compressor no. 1, reciprocating 1500 HP Recycle compressor no. 2, reciprocating 1500 HP Rich solvent hydraulic turbine, 1292 HP Miscellaneous equipment and special specialty items Solvent makeup filet, cartridge Solvent filter package, skid 160 L 3 100 W Antifoam injection package, chemical skid

BM-MH 5584 1620 376 1032 220 60 32 176 472 664 884 48 280 280 2800 700 700 700 700 1380 80 40 320 60 100 240 240 60 240 2068 480 680 40 40 20 48 20 540 40 160 1980 1980 2460 308 48 140 120

PF-MH

800 800 500

Refinery equipment and storage tank labor estimates Chapter | 8

8.3.1

173

Vessels/columns sheet 1 Qty

Qty

Qty

Field Jt

Boltup

Scope

Wt. (ton)

Hdl/ Set

MH/ Qty

BMMH

Solvent absorber 80 -6v D 3 690 -0v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300 removable-davit) Install double downflow valve trays (16 trays) Install demisting pads (single gridsupport, pad, grid-top) Vortex breaker Packing (pall rings) Rich solvent flash drum 70 -0v D 3 240 -0v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300 Hinged) Inlet box Vortex breaker Install demisting pads (single gridsupport, pad, grid-top) Solvent regenerator 80 -0v D 3 720 6v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300 removable-davit) Install double downflow valve trays (12 trays) Install demisting pads (single gridsupport, pad, grid-bottom) Vortex breaker Packing (pall rings) Solvent regenerator reflux drum 50 0v D 3 150 -0v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300 Hinged)

319.7 319.7

1

1.88

1620 600

200 40

200 40

16

40

640

1

60

60

1 1

32 48

32 48 376

10.7

160

1 1

48 24

48 24

1 1 1

60 24 60

60 24 60

1 1

1

14.9 14.9

39 39

1032 1

8.2

320

160 40

160 40

12

32

384

1

48

48

1 1

32 48

32 48 220

1

30.8

80

1 1

60 24

60 24

1 1

1

2.6 2.6

(Continued )

174

Industrial Construction Estimating Manual

(Continued)

Scope

Wt. (ton)

Install demisting pads (single gridsupport, pad, grid-top) Vortex breaker Solvent regenerator reboiler steam condensate drum 20 -6v D 3 80 -0v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Water makeup drum 10 -0v D 3 20 -8v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Solvent sump drum 40 -0v D 3 120 -0v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300 Hinged) Vortex breaker

8.3.2

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

BMMH

1

32

32

1

24

24 60

1.5

1

60

60

0.2 0.2

1

32

32 32

2.2 2.2

1

36.4

176 80

1 1

40 24

40 24

1

16

16

MH/ Qty

BMMH

1.5

Vessels/columns/tank sheet 2

Scope

Wt. (ton)

Recycle compressor suction drum 60 -6v D 3 120 -0v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300 Hinged) Install demisting pads (single gridsupport, pad, grid-top) Reactor steam drum 110 -0v D 3 330 0v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300 Hinged) Mixed alcohol absorber 50 -6v D 3 240 -0v

45.4 45.4

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

472 1

7.93

360

1 1

48 24

48 24

1

40

40

293.3

1

293.3

1

1.8

520

1 1

120 24

120 24

53.3

1

664

884 (Continued )

Refinery equipment and storage tank labor estimates Chapter | 8

175

(Continued) Qty

Qty

Qty

Field Jt

Boltup

Scope

Wt. (ton)

Hdl/ Set

Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Remove and replace manway cover (24v 300 removable-davit) Install double downflow valve trays (12 trays) Install demisting pads (single gridsupport, pad, grid-top) Packing (pall rings) Absorber water feed drum 20 -6v D 3 70 -6v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Vortex breaker Tanks Solvent-storage tank 120 -0v D 3 24v0v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB

53.3

8.3.3

MH/ Qty

BMMH

1

7.13

380

1 1

120 40

120 40

12

24

288

1

32

32

1

24

24 48

1

36.4

40

1

8

8

1,1 1.1

13.1 13.1

280 1

21.4

280

MH/ Qty

BMMH

Reactors sheet 3

Scope

Wt. (ton)

Ethanol synthesis reactor (120 -6v D 3 250 -9v Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Ethanol synthesis reactor (120 -6v D 3 250 -9v) Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders Ethanol synthesis reactor (120 -6v D 3 250 -9v) Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders

309 309

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

700 1

1.94

600

1

100

100 700

1

1.94

600

1

100

100 700

1

1.94

600

1

100

100

309 309

309 309

(Continued )

176

Industrial Construction Estimating Manual

(Continued)

Scope

Wt. (ton)

Ethanol synthesis reactor (120 -6v D 3 250 -9v) Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Install platforms and ladders

309

8.3.4

309

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

BMMH 700

1

1.94

600

1

100

100

MH/ Qty

BMMH

Shell and tube heat exchanger sheet 4 Qty

Qty

Qty

Field Jt

Boltup

Scope

Wt. (ton)

Hdl/ Set

Lean solvent cooler Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Solvent regenerator reboiler Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Ethanol synthesis feed/effluent exchanger Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Reactor feed heater Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Recycle compressor spillback cooler Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Absorber feed trim cooler Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Lean/rich solvent exchangers Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Solvent regenerator OVHD condenser Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Absorber feed cooler Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB

18 18

1

4.44

80 80

5 5

1

8

40 40

100

320

100

1

3.2

320

6.5 6.5

1

9.23

60 60

38 38

1

2.63

100 100

90 90

1

2.67

240 240

90 90

1

2.67

240 240 60

1

60

60

1

240

240 240

Refinery equipment and storage tank labor estimates Chapter | 8

8.3.5

177

Pumps sheet 5

Scope Lean solvent booster pumps 150 HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout Lean solvent pumps 1750 HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout Solvent regenerator reflux pumps 3 HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout Absorber Water wash pumps 3 HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout Solvent makeup pump 3 HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout Water makeup pump 7.5 HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout Solvent sump drum pump 3 HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout Steam drum circulation pump 75HP Unload, handle, haul up to 20000 , rig, set, and align, couple, and grout Sulfating agent injection pump 3 HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout Absorber water feed pump 25HP Unload, handle, haul up to 20000 , rig, set, and align, couple and grout

Wt. (ton)

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

BMMH

2

240

480 480

2

340

680 680 40

2

20

40

2

20

40 40

1

20

20 20

2

24

48 48

1

20

20 20

3

180

540 540

2

20

40 40

2

80

160 160

178

8.3.6

Industrial Construction Estimating Manual

Recycle compressor no. 1 sheet 6

Scope

Wt. (ton)

Recycle compressor no. 1, reciprocating 1500 HP Frame and gear 340 -5v Cylinder 220 -0v Cylinder First-stage suction damper First-stage discharge damper Extended bearing and postal Lube oil consul 2 ea. Moister separator 3 ea. Full maintenance deck IC pipe—interstate piping spools between pulsation bottles and coolers Rotor and extension shaft Motor stator

8.3.7

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

BMMH 1980

1 1 1 1 1 1 1 1 1 1

340 180 120 60 60 60 120 180 240 800

340 180 120 60 60 60 120 180 240

1 1

240 180

240 180

Recycle compressor no. 2 sheet 7

Scope Recycle compressor No. 2, reciprocating 1500 HP Frame and gear 340 -5v Cylinder 220 -0v Cylinder First-stage suction damper First-stage discharge damper Extended bearing and pestal Lube oil consul 2 ea. Moister separator 3 ea. Full maintenance deck IC pipe—interstage piping spools between pulsation bottles and coolers Rotor and extension shaft Motor stator Motor enclosure (soleplates, inc)

Wt. (ton)

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

BMMH

PFMH

1980

800

1 1 1 1 1 1 1 1 1 1

340 180 120 60 60 60 120 180 240 800

340 180 120 60 60 60 120 180 240

1 1 1

240 180 200

240 180 200

800

Refinery equipment and storage tank labor estimates Chapter | 8

8.3.8

Rich solvent hydraulic turbine, 1292 HP Sheet 8

Scope

Wt. (ton)

Rich solvent hydraulic turbine, 1292 HP Turbine/gearbox skid Rotor High/low-speed cplg spacers and disk packs Steam inlet trip and throttle valve Lube oil skid Generator w/sole plates Generator panels 2 ea. Gear terminal boxes IC pipe

8.3.9

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

1 1 1

460 320 60

1

80

1 1 1 1 1

140 800 80 600 420

BMMH

PFMH

2460

500

460 320 60 80 140 800 80 600 420

Miscellaneous equipment and special specialty items sheet 9

Scope

Wt. (ton)

Miscellaneous equipment and special specialty items Solvent makeup filter, cartridge Unload, handle, haul up to 20000 , rig, set, and align Solvent filter package, skid 160 L 3 100 W Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB Antifoam injection package, chemical skid Unload, handle, haul up to 20000 , rig, set, and align, make up Fdn AB

8.4

179

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

BMMH

PFMH

308 48 1

48

48 140

1

140

140

120 1

120

120

API 650 oil storage tanks

Estimate for API Std welded steel storage tanks used for petroleum products and other liquid products stored in the petroleum industry.

180

8.4.1

Industrial Construction Estimating Manual

Tank data

Tank dimensions: 800 D 3 240 H Standard Sheet: 100 L 3 80 W Tank shell plate: Number of sheets per ring 26 Ring 1 26 sheets 3 0.75v Thk. Ring 2 26 sheets 3 0.5625v Thk. Ring 3 26 sheets 3 0.4375v Thk. Roof and floor sheets Number of roof sheets 63 3 0.5v Thk. Number of floor sheets 63 3 0.5v Thk. Gallons: 902,430 gallons Barrels (42 Gallons/BBL) 21,486 BBL

8.5 8.5.1

Tank construction estimate Introduction

This section provides a general method to erect a welded steel storage tank. Tank erectors each has a particular method, which has been developed by experience that is suitable for their field crews to work economically and provide quality work. To erect tanks that are of sound quality, appearance, and without distortion, the erector must adherer to corrected welding sequences and maintain adequate supervision.

8.5.2

Tank erection bid breakdown BM-MH Activity Erect knuckle ring steel welded storage tank Receive and offload bottom shell and roof plates, and all material Set bottom plates and weld Shell plate erection Roof erection Tank testing

8.5.3

4005 224 676 1356 1605 144

Bottom plate placement

When tank foundation is complete, the bottom plate will be placed on the foundation and welded in sequence. Plates are placed and welded in the correct sequence to avoid weld distortion.

Refinery equipment and storage tank labor estimates Chapter | 8

8.5.4

Bottom plate placement and welding sequence

Scope Set bottom plates and weld Place plates and tack weld Set and weld center sump Weld rectangular plates, end seams first, lap jt fillet weld Weld outer radial seams of annular plates First ring set and welded; weld first ring to annular plate fillet weld Weld remaining seams of annular plates Weld rectangular and sketch plates together and to annular

8.5.5

181

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

BMMH

1 792

2 4 0

676 95 4 198

12

120 502.7

1 0

60 176

12

120 112

1 1

60 84

63 1 22

Shell plate erection

Shell plates are rigged and set in place using the crane; fit up, tacked, and the vertical seams are welded in place. The shell rings are done ring-by-ring to the top curb angle. Each ring must be completely weld before another ring can be added.

8.5.6

Shell plate erection

Scope 8.5.6 Shell plate erection First ring; rig and set sheets in place Fit and weld vertical seams (0.75v BW) Weld scaffold brackets and erect scaffold Second ring: rig and set sheets, fit, and tack Set weld buggy and fit and weld vertical seams (0.5625v BW) Fit and hand weld horizontal seam (0.5625v BW); second ring to first ring Weld scaffold brackets and move scaffold to next ring Third ring: rig and set sheets, fit, and tack Move weld buggy to next ring and fit and weld vertical seams (0.4375v BW) Fit and hand weld horizontal seam (0.4375v BW); third ring to second ring

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

26 25 1 26 25

MH/ Qty

BMMH

200

2 1 32 3 1

1356 52 285 32 65 195

251

1

207

40

40

200

3 1

78 195

251

1

207

200

1 26 25

182

8.5.7

Industrial Construction Estimating Manual

Roof erection

Scope Roof erection Set and weld center post/column Rig, set, and fit tack knuckle ring to third ring Weld scaffold brackets and move scaffold to next ring Rig, place fit, and weld wind girder Weld vertical seams knuckle ring (0.4375v BW) Weld knuckle ring horizontal weld to third ring (0.4375v BW) Rig and place rafters Attached rafters to center post and knuckle ring Rig, place, and fit roof sheets Set and weld roof vents Weld roof sheets Stairway, handrails, and platforms Drain pipe Manhole

8.5.8

Qty

Qty

Qty

Hdl/ Set

Field Jt

Boltup

MH/ Qty

BMMH

1 26

16 3.1

1605 16 81

2

40

80

251 150

0.75 0.975

188 146

251

0.825

207

4 1.5

100 75

2 24 6 120 40 24

126 24 378 120 40 24

26 25

25 50 63 1 63 1 1 1

Tank testing

Bottom plate welds are tested to ensure bottom has no leaks. Test using a vacuum box Hydrotest tank; test tank for leakage and foundation for capability of taking tank load

1

64

144 64

1

80

80

Chapter 9

Circulating fluidized bed combustion (FBC) labor estimates 9.1

Introduction

This chapter provides the reader a basic understanding of the fundamentals and operating relationship between the plant equipment in the combustion process and covers the craft labor for the assembly and field erection required to put the equipment into operation in a circulating fluidized bed boiler. Fluidized bed combustion (FBC) is a combustion technology used to burn solid fuels. Fuel particles are suspended in a hot, bubbling fluidity bed of ash, and other materials, such as sand and limestone, through which jets of air are blown to provide oxygen required for combustion or gasification. The resultant fast and intimate mixing of gas and solids promotes raped heat transfer and chemical reactions within the bed. The plants are attractive because of the following reasons: l

l

l

FBC plants burn low-grade solid fuels, including woody biomass, without expensive fuel preparation. FBCs are smaller than equivalent conventuals and have significant advantages over the latter in terms of cost and flexibility. FBCs have SO2 and NO2 emissions below Federal Standards.

9.2

Combustor bid breakdown

Combustor Combustor support structure Platforms (two levels) Cones (90 3 100 ) Manifold assembly Plenum box [fabr in (1) section] (120 3 40 ) Panels

BM

Laborer

Total MH

8902 40 440 100 1000 474 1840

560 560

9462 600 440 100 1000 474 1840 (Continued )

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00009-0 © 2020 Elsevier Inc. All rights reserved.

183

184

Industrial Construction Estimating Manual

(Continued) BM Wall tubes Roof panels Stoker Metering bins Burners

9.3

Laborer

2700 280 360 696 972

Total MH 2700 280 360 696 972

Combustor

9.3.1

Combustor equipment labor hours sheet 1

Scope

Qty

Unit

MH/ Qty

10 10 16

ea. ea. ea.

16

Combustor support structure Erect columns Column field splice Erect horizontal beams, bolt connections Structural X-brace, bolt connections Shim, bolt column base plate to fdn Grout column base plates Platforms (two levels) Platform structural steel Grating Handrail Stairs Ladders Cones (90 3 100 ) Field fabr cone sections (2 sections) Set cones and attach to support structure Manifold assembly Install sand plows (L 1 1/2v) Plug weld nozzle holes (9/32v) Prefabricated air headers Seal weld/butt weld manifolds together Install nozzles (1-1/2v) Plenum box [fabr in (1) section] (120 3 40 ) Set plenum and weld to manifold Seal weld Structural weld

BM

Laborer

Total MH

520 100 80 140

40

10 8 8.75

560 100 80 140

ea.

10

160

160

10

ea.

4

40

40

10

ea.

4

40

40 440 150 140 60 80 10 100 60

660 660 212 85 32

sf sf lf lf lf

2

ea.

30

440 150 140 60 80 10 100 60

2

ea.

20

40

40

80 70 6 160

ea. ea. ea. lf

1.0 1.1 20.0 1.4

1000 80 80 120 216

1000 80 80 120 216

840

ea.

0.6

504 474

504 474

2

pcs

60

60

120 25

lf lf

144 30

144 30

0.23 0.21 0.28 0.94 0.31

30 1.2 1.2

(Continued )

185

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

(Continued) Scope

Qty

Unit

MH/ Qty

BM

Combustor lower A plenum splices Combustor middle A plenum splices Combustor upper A plenum splices

10

ea.

8

80

80

10

ea.

8

80

80

10

ea.

8

80

80

9.3.2

Laborer

Total MH

Combustor equipment labor hours sheet 2

Scope Panels Lower section (100 3 130 ) Set panels (4 ea.), fit up vertical seam, and butt weld Weld lower section to manifolds Transition Erect transition panels (2 panels/ side) Fit up and weld (4 ea.) Fit up and weld (4 ea.) Weld transition panels to lower section Upper section 6 panels/ring 3 5 rings Set panels (6 ea.) 3 5 Fit up and weld vertical (6 3 5 3 7.2) Fit up and weld horizontal (92 3 4) Weld upper section to transition Wall tubes 3.5v 3 s 80 cs 3 500 3 70 ea. wall tubes rig and place in unit Headers embedded in wall—not included in estimate Headers embedded in wall—not included in estimate Headers embedded in wall—not included in estimate 3.5v 3 s 80 CS field butt weld NDE X-ray 3.5v CS fillet weld exp Jt to lid Spring hanger Hydrotest

Qty

Unit

MH/ Qty

BM

Laborer

Total MH

1840

1840

40

ea.

2.5

100

100

46

lf

1.30

60

60

8

ea.

10.00

80

80

100 124 46

lf lf lf

1.20 1.13 1.30

120 140 60

120 140 60

30 216

ea. lf

16.00 1.20

480 260

480 260

368 92

lf lf

1.14 1.30

3500

lf

0.35

420 120 2700 1240

420 120 2700 1240

210

ea.

4.67

980

980

70 10 1

ea. ea. lot

2.57 6.00 240

180 60 240

180 60 240 (Continued )

186

Industrial Construction Estimating Manual

(Continued) Scope

Qty

Roof panels Panels Set panels (4 ea.) Fit up and weld panels

Unit

4 166

ea. lf

MH/ Qty

20 1.20

BM

Laborer

Total MH

280

280

80 200

80 200

9.3.3

Combustor equipment labor hours sheet 3

Scope

Qty

Unit

MH/ Qty

2 2 2

ea. ea. ea.

10 10 10

360 20 20 20

360 20 20 20

48 4 4 4 6

lf ea. ea. ea. ea.

1.67 5 10 10 10

80 20 40 40 60

80 20 40 40 60

6

ea.

10

2 2 2 2 2 18 2 2 2

ea. ea. ea. ea. ea. Ton ea. ea. ea.

40 40 30 30 50 14.2 10 10 10

2 60 1 30 2 2 6 2 2 7 2 15

ea. lf ea. lf ea. ea. pcs pcs ea. ea. Ls lf

40 2 40 2 40 40 13.3 20 10 5.7 20 1.3

60 696 80 80 60 60 100 256 20 20 20 972 80 120 40 60 80 80 80 40 20 40 40 20

60 696 80 80 60 60 100 256 20 20 20 972 80 120 40 60 80 80 80 40 20 40 40 20

Stoker LH fixed frame assembly Center fixed frame assembly RH fixed frame assembly Pipe 4v straight pipe/pipe Supports Fuel distributors 36v 3 10v Rotating air dampers Balance dampers High pressure air headers and nozzles Manual control damper Metering bins Metering bins Discharge chute Metering bin screw Feed chutes Expansion joint Metering bin fuel feed structure Bin inlet slide gate Inlet metering bin slide gate Fuel spreaders Burners Overbed burner and wind box Burner IV .75v IC piping Underbed burner and wind box Burner IV .75v IC piping Fuel gas skid Underbed burner gas train Ductwork (24v dia) Ductwork (18v dia) Dampers (18v dia) Duct supports Misc. duct, flex, orifice, valve Seal weld

BM

Laborer

Total MH

(Continued )

187

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

(Continued) Scope

Qty

Unit

MH/ Qty

BM

Buck stays Attachment clips Sight glass assembly Doors

16 280 4 2

ea. ea. ea. ea.

10 0.5 8 10

160 140 32 20

9.4

9.5.1

Total MH 160 140 32 20

Boiler bid breakdown

Boiler Support structure 45 ton Boiler access steel Modules Boiler outlet/inlet transition Expansion joint at inlet/outlet (at combustor and economizer) Hoppers Drum IC piping, BD, vents, drains, and trim at drum Soot blowers Silencers Hydrotest Stack (3—sections) w/1 platform

9.5

Laborer

BM

PF

Total MH

5368 1200 1120 920 388 160

5192

10,560 1200 1120 920 388 160

120 60 5192 400 360 240 400

120 60 5192 400 360 240 400

Boiler Boiler labor hours sheet 1

Scope Support structure 45 ton Erect columns Column field splice Erect horizontal beams, bolt connections Structural X-brace, bolt connections Shim, bolt column base plate to fen Grout column base plates Boiler access steel Grating Handrail

Qty

Unit

MH/ Qty

16 32 64

ea. ea. ea.

10 8 5

32 16 16

ea. ea. ea.

10 4.5 4.5

4000 1200

sf lf

0.19 0.25

BM

PF

Total MH

1200 160 256 320

1200 160 256 320

320 72 72 1120 760 300

320 72 72 1120 760 300 (Continued )

188

Industrial Construction Estimating Manual

(Continued) Scope

Qty

Unit

MH/ Qty

BM

Stairs Modules SH # 1 box rig and set SH # 2 box rig and set Evap #1 box rig and set Eva #2 box rig and set Field joint (box to box, box to transition) 5 EA Boiler outlet/inlet transition Roof, wall, and side panels Panel clips (3/4v 3 10v 3 12v lg) Seal weld Structural weld Bolt and tack weld Remove lifting brackets (interior) Expansion joint at inlet/outlet (at combustor and economizer) Install expansion joint 80 3 200 Hoppers Set hoppers and bolt to structure Drum Set drum and drum supports

61

lf

0.98

1 1 1 1 296

ea. ea. ea. ea. lf

80 80 80 80 2.03

60 920 80 80 80 80 600

60 920 80 80 80 80 600

8 20 90 40 20 16

ea. ea. lf lf pcs ea.

20 1.20 1.3 1.20 1 1

388 160 24 120 48 20 16 160

388 160 24 120 48 20 16 160

2

ea.

80

4

ea.

30

1

ea.

60

160 120 120 60 60

160 120 120 60 60

9.5.2

PF

Total MH

Boiler labor hours sheet 2

Scope IC piping, BD, vents, drains, and trim at drum Avg 28v s 80 CS pipe NDE BD, vents and drains (2v sch 80 cs) Boiler trim at drum (pipe and instruments) Boiler piping (from steam drum to soot blowers) NDE Superheater welds (10v dia) NDE, PWHT Boiler piping (downcomers) Soot blowers Install soot blowers Silencers Erect silencer support Install silencers Silencer Piping (10v s 40 cs)

Qty

Unit

MH/ Qty

BM

PF

Total MH

5192

5192

400 320 1

lf lf lot

2.2 2.5 340

880 800 340

880 800 340

360

lf

3.2

1152

1152

2

ea.

20

40

40

900

lf

2.2

1980

1980 400 400 360 120 40 200

20

ea.

20

2 2 60

ea. ea. lf

60 20 3.33

400 400 360 120 40 200

(Continued )

189

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

(Continued) Scope

Qty

Unit

MH/ Qty

Hydrotest Hydrotest boiler Stack (3—sections) w/1 platform

1 1

lot ea.

240 400

9.6

BM

PF

Total MH

240 240 400

240 240 400

Boiler circulation water bid breakdown BM Boiler circulating water North/south wall downcomers 10v s80 900# CS pipe North/south wall r12v s80 900# CS pipe East wall downcomers 10v s80 900# CS pipe East wall risers 12v s80 900# CS pipe West wall downcomers 10v s80 900# CS pipe West wall risers Structural support for spring hangers Spring hangers Shoes

9.7

PF

Total MH

6048 1083 465 1797 375 420 548 240 896 224

6048 1083 465 1797 375 420 548 240 896 224

Boiler circulation water

Circulating water

9.7.1

Boiler circulating water piping labor hours sheet 1

Scope North/south wall downcomers 10v s80 900# CS pipe Tie in to header-buttwelds, s80 (0.594 WT) Pipecarbon steel, s80, 3 spools 3 100 L32 Buttwelds, s80 (0.594 WT) Pipecarbon steel, s80, 1 spools 3 200 L32 Buttwelds, s80 (0.594 WT) Pipecarbon steel, s80, 3 spools 3 140 L32 Buttwelds, s80 (0.594 WT) Pipecarbon steel, s80, 3 spools 3 140 L32

Qty

Unit

MH/ Qty

BM

PF

Total MH

1083

1083

8

ea.

9.5

76

76

60

lf

1.2

72

72

12 40

ea. lf

9.5 1.2

114 48

114 48

8 84

ea. lf

9.5 1.2

76 101

76 101

12 84

ea. lf

9.5 1.2

114 101

114 101 (Continued )

190

Industrial Construction Estimating Manual

(Continued) Scope

Qty

Unit

Buttwelds, s80 (0.594 WT) Pipecarbon steel, s80, 4 spools 3 120 L32 Buttwelds, s80 (0.594 WT) NDE X-ray, s80 North/south wall risers 12v s80 900# CS pipe Set headers (loose) Pipecarbon steel, s80, 6 spools 3 120 L32 Buttwelds, s80 (.688 WT) NDE X-ray, s80 East wall downcomers 10v s80 900# CS pipe Tie in to header-buttwelds, s80 (.594 WT) Pipecarbon steel, s80, 9 spools 3 120 L38 Buttwelds, s80 (0.594 WT) NDE X-ray, s80

12 96

ea. lf

16 68

ea. ea.

MH/ Qty

BM

PF

Total MH

9.5 1.2

114 115

114 115

9.5

152

152

465

465

2 144

ea. lf

20 1.80

40 259

40 259

12 12

ea. ea.

13.80

166

166

1797

1797

8

ea.

9.5

76

76

864

lf

1.2

1037

1037

72 72

ea. ea.

9.5

684

684

9.7.2

Boiler circulating water piping labor hours sheet 2

Scope

Qty

Unit

MH/ Qty

4 72

ea. lf

12 12

ea. ea.

East wall risers 12v s80 900# CS pipe Set headers (loose) Pipecarbon steel, s80, 6 spools 3 120 L Buttwelds, s80 (0.688 WT) NDE X-ray, s80 West wall downcomers 10v s80 900# CS pipe Tie in to header-buttwelds, s80 (0.594 WT) Pipecarbon steel, s80, 8 spools 3 120 L 3 2 Buttwelds, s80 (0.594 WT) NDE X-ray, s80 West wall risers Set headers (loose) Pipecarbon steel, s80, 6 spools 3 140 L 3 2 Buttwelds, s80 (0.688 WT)

BM

PF

Total MH

20 1.80

375 80 130

375 80 130

13.80

166

166

420

420

4

ea.

9.50

38

38

192

lf

1.20

230

230

16 16

ea. ea.

9.50

152

152

4 168

ea. lf

20 1.80

548 80 302

548 80 302

12

ea.

13.80

166

166

(Continued )

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

191

(Continued) Scope

Qty

Unit

NDE X-ray, s80 Structural support for spring hangers Spring hangers Shoes

12 2 56 56

ea. Ton ea. ea.

9.8

MH/ Qty 120 16 4

PF

Total MH

240 896 224

240 896 224

Fans bid breakdown BM Fans Combustor OFA FD fan—150 HP Combustor UFA FD fan—200 HP ID fan (500 HP)

9.9

BM

PF

1160 197 153 811

Total MH 1160 197 153 811

Fans

9.9.1

Fans labor hours sheet 1

Scope Combustor OFA FD fan—150 HP Inlet damper (30 3 90 ) Motor Inlet silencer (30 3 90 3 90 ) Inlet expansion joint (30 3 90 ) Inlet expansion joint (60 3 40 ) Silencer Combustor UFA FD fan—200 HP Inlet damper (30 3 90 ) Motor Inlet silencer (30 3 90 3 90 ) Inlet expansion joint (30 3 90 ) Inlet expansion joint (60 3 40 ) Silencer ID fan (500 HP) ID fan 8.5 ton Damper Motor Silencer Millwright

Qty

Unit

MH/Qty

1 1 1 1 1 1

ea. ea. ea. ea. ea. ea.

74.6 20.0 42.0 20.0 20.0 20.0

1 1 1 1 1 1

ea. ea. ea. ea. ea. ea.

42.9 20.0 30.0 20.0 20.0 20.0

1 1 1 1 1

ea. ea. ea. ea. ea.

246.5 40.0 100.0 40.0 384.0

BM 197 75 20 42 20 20 20 153 43 20 30 20 20 20 811 247 40 100 40 384

PF

Total MH 197 75 20 42 20 20 20 153 43 20 30 20 20 20 811 247 40 100 40 384

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Industrial Construction Estimating Manual

9.10 Fans—FD, ID, OFA bid breakdown BM Fans—FD, ID, OFA ductwork FD duct overfire FD duct underfired ID duct

PF

1940 872 700 368

Total MH 1940 872 700 368

9.11 Fans—FD, ID, OFA ductwork 9.11.1 Fans—FD, ID, OFA labor hours sheet 1 Scope FD duct overfire Ductwork (36v dia)/(18v dia) Inlet damper (18v dia) Seal weld FD duct underfire Ductwork Underbed expansion Jt (40 3 40 ) Seal weld ID duct ID fan discharge ductwork Expansion jet Seal weld ductwork

Qty

Unit

MH/Qty

6 3 120

pcs ea lf

40 80 3.27

1 220 1

ea. lf ea.

320.0 0.5 260.0

1 1 80

ea. ea. lf

120.0 120.0 1.6

BM

PF

Total MH

872 240 240 392 700 320 120 260 368 120 120 128

872 240 240 392 700 320 120 260 368 120 120 128

9.12 Economizer/inlet duct/hoppers bid breakdown BM Economizer/inlet duct/hoppers Support structure Economizer access steel Economizer

PF

1520 300 260 960

Total MH 1520 300 260 960

9.13 SCR/economizer support structure 9.13.1 SCR/economizer support structure labor hours sheet 1 Scope Support structure Erect columns Column field splice

4 4

Unit

MH/ Qty

ea. ea.

10 10

BM 300 40 40

PF

Total MH 300 40 40 (Continued )

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

193

(Continued) Scope Erect horizontal beams, bolt connections Structural X-brace, bolt connections Shim, bolt column base plate to fdn Grout column base plates Economizer access steel Access steel Grating Handrail Ladders Economizer Economizer—2 ea. modules Plenum outlet 4 pcs inlet duct, 208 lf seal weld 6 ea. soot blowers 4 ea. hoppers

Unit

MH/ Qty

BM

PF

Total MH

4

ea.

14

56

56

4 4 4

ea. ea. ea.

20 15 6

3 700 280 30

ton sf lf lf

14 0.20 0.25 0.30

2 1 208 6 4

ea. ea. lf ea. ea.

120 80 0.77 60 30

80 60 24 260 42 139 70 9 960 240 80 160 360 120

80 60 24 260 42 139 70 9 960 240 80 160 360 120

9.14 Multiclonebid breakdown BM

PF

1440 572 748 120

Multiclone Support structure Hoppers Upper housing

Total MH 1440 572 748 120

9.15 Multiclone 9.15.1 Multicone labor hours sheet 1 Scope Support structure Erect columns Column field splice Erect horizontal beams, bolt connections Structural X-brace, bolt connections Shim, bolt column base plate to fen Grout column base plates Multiclone access steel Grating

Qty

Unit

MH/ Qty

BM

PF

Total MH

6 6 4

ea. ea. ea.

10 9.3 14

572 60 56 56

572 60 56 56

4 4 4 4 120

ea. ea. ea. ton sf

52 12 6 14 0.30

208 48 24 56 36

208 48 24 56 36 (Continued )

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(Continued) Scope

Qty

Unit

MH/ Qty

BM

PF

Total MH

Handrail Ladders Hoppers Set hoppers and weld to housing Set cones in structure (tubesheets) and weld Upper housing Erect sides Fit up and weld vertical (8.4 3 4)

100 10

lf lf

0.25 0.30

2 8

ea. ea.

54 80

25 3 748 108 640

25 3 748 108 640

4 33.6

ea. ea.

20 1.19

120 80 40

120 80 40

9.16 Spray dryer bid breakdown BM Spray dryer Support structure 4 panels/ring 3 11 rings Stair tower Penthouse (4 panels)/piping in penthouse (1 lot)

PF

3560 720 1440 1100 300

Total MH 3560 720 1440 1100 300

9.17 Spray dryer 9.17.1 Spray dryer labor hours sheet 1 Scope Support structure Erect columns Column field splice Erect horizontal beams, bolt connections Structural X-brace, bolt connections Shim, bolt column base plate to fdn Grout column base plates 4 panels/ring 3 11 rings Set panels (4 ea.) 3 1 Fit up and weld vertical (70 3 11) 3 4 Fit up and weld horizontal (10 3 20) Floor/roof Stair tower Erect columns w/beams Column field splice

Qty

Unit

MH/ Qty

12 12 8

ea. ea. ea.

10 8.3 12.5

8 12 12

ea. ea. ea.

20 13.3 6.7

44 380 240 4

ea. elf lf ea.

10 1.21 1.25 60

4 4

ea. ea.

30 10

BM

PF

Total MH

720 120 100 100

720 120 100 100

160 160 80 1440 440 460 300 240 1100 120 40

160 160 80 1440 440 460 300 240 1100 120 40 (Continued )

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

195

(Continued) Scope

Qty

Unit

MH/ Qty

BM

Platforms w/grating/handrail/ladders Stairs/handrail Shim, bolt column base plate to fdn Grout column base plates Penthouse (4 panels)/piping in penthouse (1 lot)

7 180 4 4 1

ea.

31.4 1.9 12 8 300

220 340 48 32 300

ea. ea. lot

PF

Total MH 220 340 48 32 300

9.18 Ductwork—multiclone to spray dryer 9.18.1 Ductwork—multicone to spray dryer labor hours sheet 1 Scope Ductwork—Multiclone to spray dryer Vertical duct Expansion joint Weld duct at FJ Horizontal duct Expansion joint Weld Duct at FJ

Qty

7 1 6 8 2 7

Unit

ea. ea. ea. ea. ea. ea.

MH/ Qty

20 40 36.7 40 60 37.1

BM

PF

Total MH

1100

1100

140 40 220 320 120 260

140 40 220 320 120 260

9.19 Baghouse bid breakdown BM Baghouse Support structure Hopper Baghouse modules manifold, plenum, damper, bags, and conveyor Conveyors Penthouse

PF

Total MH

6160 760 320 1980

6160 760 320 1980

880 2220

880 2220

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9.20 Baghouse 9.20.1 Baghouse labor hours sheet 1 Scope Support structure Erect columns Column field splice Erect horizontal beams, bolt connections Structural X-brace, bolt connections Shim, bolt column base plate to fdn Grout column base plates Hopper Set hoppers and bolt to structural Hopper headers Top lid/air header Baghouse modules manifold, plenum, damper, bags, and conveyor Set baghouse modules/attach to structural Install manifold Fabr and erect inlet/outlet plenum (3 sections 3 2), weld to modules Dampers to each module (8) and (1) bypass damper Install bags in hoppers (300 bags/ hopper) Conveyors Ash hopper screw conveyor, AustinMAC Ash conditioner, ash tech model M-12 Tail and trough Penthouse Penthouse floor sections Stacking legs/brace assemblies/hold downs Frames Purlins Girts Sag rods Louvers Man door Sliding door Wall fans Cladding Penthouse bridge crane

Qty

Unit

MH/ Qty

12 12 8

ea. ea. ea.

10 10 15

8 12 12

ea. ea. ea.

20 13.3 6.7

4 4 4

ea. ea. ea.

60 10 10 1980

BM

PF

Total MH

760 120 120 120

760 120 120 120

160 160 80 320 240 40 40

160 160 80 320 240 40 40 1980

4

ea.

60

240

240

3 2

ea. ea.

60 150

180 300

180 300

36

ea.

18.3

660

660

1200

ea.

0.5

600

600

2

ea.

60

880 120

880 120

2 2

ea. ea.

90 290

10 1

ea. lot

10 120

180 580 2220 100 120

180 580 2220 100 120

2 375 400 8 4 1 1 2 1 1

ea. lf lf ea. ea. ea. ea. ea. lot ea.

10 0.53 0.5 10 10 10 10 10 1180 240

20 200 200 80 40 10 10 20 1180 240

20 200 200 80 40 10 10 20 1180 240

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

197

9.21 Ductwork to baghouse labor hours sheet 1 Scope

Qty

Unit

MH/Qty

BM

Ductwork Vertical duct Expansion joint Weld duct at FJ

6 2 6

ea. ea. ea.

20 60 40

480 120 120 240

PF

Total MH 480 120 120 240

9.22 Ash tank 150 dia 3 400 labor hours

Ash tank Place floor sheets on foundation Weld floor sheets 12 sheets (7.90 W 3 80 H) ring/5 rings First ring—welded Set first ring sheets Vertical—fit and weld Corner weld (inside/outside) Set ring 25 Bolt sheets together—vertical and horizontal Center pole/roof structural steel Place roof sheets on structural Weld floor sheets Stairway to tank (grade)—structural (120 3 140 3 200 ) Erect columns Column field splice Platforms w/grating/handrail Stairs/handrail Shim, bolt column base plate to fen Grout column base plates Install mixer Unload auger Caged ladder

Qty

Unit

MH/ Qty

BM

PF

Total MH

1 106

ea. lf

60 1.13

2060 60 120

2060 60 3

12 96 189 48 1707

ea. lf lf ea. ea.

5 1.25 1.16 5 0.26

60 120 220 240 440

60 120 220 240 439.7

1 1 106

ea. ea. lf

80 60 1.13

80 60 120

80 60 120

4 4 3 6 4 4 1 1 40

ea. ea. ea. ea. ea. ea. ea. ea. ea.

10 10 33.33 33.33 15 10 20 20 0.5

40 40 100 200 60 40 20 20 20

40 40 100 200 60 40 20 20 20

9.23 Ash piping bid breakdown BM Ash piping 4v std CS piping 3v std CS piping

PF

Total MH

1524 50 69

1524 50 69 (Continued )

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Industrial Construction Estimating Manual

(Continued) BM 30 /5v std CS piping Boiler ash assembly Reducer assembly Economizer, downcomer, and baghouse piping

PF

Total MH

101 48 58 1198

101 48 58 1198

9.24 Ash piping 9.24.1 Ash piping labor hours sheet 1 Scope 4v std CS piping 4v std 150# CS pipe spool assembly handle pipe 4v std 150# CS pipe spool assembly handle pipe 4v std 150# CS pipe spool assembly handle pipe 4v std 150# CS pipe spool assembly handle pipe 4v std 150# CS pipe spool assembly handle pipe 4v std 150# CS pipe spool assembly handle pipe 4v std LR BW 90 deg elbow CS 4v Butt Weld, std CS 3v std CS piping 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std LR BW 90 deg elbow CS 3v butt weld, std CS 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 30 /5v std CS piping 5v std 150# CS pipe spool assembly 5v std 150# CS pipe spool assembly

Qty

Unit

MH/ Qty

16

DIF

31

BM

PF

Total MH

0.28

50 4.5

50 4.5

DIF

0.07

2.2

2.2

39

DIF

0.07

2.8

2.8

68

DIF

0.07

4.7

4.7

34

DIF

0.07

2.4

2.4

200

DIF

0.07

14.0

14.0

42 32

DIF DI

0.07 0.5

17 61 16 15 20 62 25 32 274 27 181 24 31 36 15

DIF DIF DIF DIF DIF DIF DIF DIF DIF DIF DIF DI DIF DIF DIF

0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.5 0.07 0.07 0.07

24 27

DIF DIF

0.07 0.07

2.9 16 69 1.2 4.3 1.1 1.0 1.4 4.3 1.8 2.2 19.2 1.9 12.7 12 2.2 2.5 1.0 101 1.7 1.9

2.9 16 69 1.2 4.3 1.1 1.0 1.4 4.3 1.8 2.2 19.2 1.9 12.7 12 2.2 2.5 1.0 101 1.7 1.9

(Continued )

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

199

(Continued) Scope

Qty

Unit

MH/ Qty

5v std 150# CS pipe spool assembly 5v std 150# CS pipe spool assembly 5v std 150# CS pipe spool assembly 5v std LR BW 90 deg elbow CS 5v butt weld, std CS

29 44 801 234 40

DIF DIF DIF DIF DI

0.07 0.07 0.07 0.07 0.5

BM

PF

Total MH

2.0 3.1 56.1 16.4 20.0

2.0 3.1 56.1 16.4 20.0

9.24.2 Ash piping labor hours sheet 2 Scope Boiler ash assembly 50 std 150# CS boiler ash assembly 30 std 150# CS boiler ash assembly 30 std 150# CS boiler ash assembly 30 std 150# CS boiler ash assembly 50 std 150# CS boiler ash assembly 5v std 150# CS elbow 5v Std CS butt weld, std Reducer assembly 40 std 150# CS reducer assembly 40 std CS butt weld, std 40 std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 3v std 150# CS pipe spool assembly 30 std CS air heater ash pot air inlet spool 3v std baghouse ash pot air inlet spool 30 std boiler ash pot air inlet spool 3v std boiler ash pot air inlet spool 30 std blower air outlet spool 3v std LR BW 90 deg elbow CS 3v butt weld, std CS

Qty

Unit

MH/ Qty

65 61 14 16 61 187 40

DIF DIF DIF DIF DIF DIF DI

0.07 0.07 0.07 0.07 0.07 0.07 0.5

181 32 101 49 49 48 8

DIF DIF DIF DIF DIF DIF DIF

16 6 18 58 89 24

BM

PF

Total MH

0.07 0.07 0.07 0.07 0.07 0.07 0.07

48.3 5 4.3 1.0 1.1 4.2 13.1 20.0 58 12.7 2.2 7.1 3.4 3.4 3.3 0.6

48.3 5 4.3 1.0 1.1 4.2 13.1 20.0 58 12.7 2.2 7.1 3.4 3.4 3.3 0.6

DIF

0.07

1.1

1.1

DIF DIF DIF DIF DI

0.07 0.07 0.07 0.07 0.5

0.4 1.3 4.1 6.3 12.0

0.4 1.3 4.1 6.3 12.0

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Industrial Construction Estimating Manual

9.24.3 Ash piping labor hours sheet 3 Scope Economizer, downcomer, and baghouse piping 5v std 150# CS pipe spool assembly 4v std 150# CS pipe spool assembly pipe 3v std 150# CS pipe spool assembly 5v Reducer assembly 5v elbow 5v tee 5v butt weld, std 4v elbow 3v elbow 3v tee 3v elbow 3v butt weld, std 3v economizer ash pot aid inlet spool 3v ash pot inlet adapter 3v ash pot inlet adapter 3v downcomer assembly 3v ash drop Assembly 3v downcomer assembly, boiler ash drop 3v Ash hopper outlet assembly 3v ash drop wye branch assembly 3v ash pot inlet adaptor 3v baghouse ash pot, noninsulated 3v air heater ash pot, noninsulated 3v ash pot, noninsulated (stainless steel) 12v knife gate 12v pathway U-bolt Pipe support T-bolt clamp Flex boot 5v 150# boltup 4v 150# boltup 150# boltup Ash blower Hydrotest Ash hopper screw conveyor Ash conditioner

Qty

Unit

MH/ Qty

BM

PF

Total MH

1198

1198

735 168

DIF DIF

0.07 0.07

51.5 11.8

51.5 11.8

123 21 15 14 155 16 4 8 7 93 16

DIF DIF DIF DIF DI DIF DIF DIF DIF DI DIF

0.07 0.07 0.07 0.07 0.5 0.07 0.07 0.07 0.07 0.5 0.07

8.6 1.4 1.0 1.0 77.5 1.1 0.3 0.6 0.5 46.5 1.2

8.6 1.4 1.0 1.0 77.5 1.1 0.3 0.6 0.5 46.5 1.2

27 22 173 188 99

DIF DIF DIF DIF DIF

0.07 0.07 0.07 0.07 0.07

1.9 1.5 12.1 13.2 6.9

1.9 1.5 12.1 13.2 6.9

223 80 48 201 90 302

DIF DIF DIF DIF DIF DIF

0.07 0.07 0.07 0.07 0.07 0.07

15.6 5.6 3.4 14.1 6.3 21.1

15.6 5.6 3.4 14.1 6.3 21.1

3 5 12 35 26 7 19 13 1 1 1 1.75 1.71

ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. ea. Ton Ton

5.4 5.4 2.00 4.00 4.00 4.00 3.25 2.60 20.00 20.00 142 80 80

16.2 27.0 24.0 140.0 104.0 28.0 61.8 33.8 20.0 20.0 142.0 140.0 137.1

16.2 27.0 24.0 140.0 104.0 28.0 61.8 33.8 20.0 20.0 142.0 140.0 137.1

Circulating fluidized bed combustion (FBC) labor estimates Chapter | 9

201

9.25 Sand system bid breakdown BM Sand system Floor sheets 12 sheets (7.90 W 3 8.60 H) ring/6 rings Conveyors

PF

3680 360 1600 1720

Total MH 3680 360 1600 1720

9.26 Sand system 9.26.1 Sand system labor hours sheet 1 Scope

Qty

Sand system Sand tank 15.4 Dia 3 520 H Receive, unload, and haul to 1 erection Place floor sheets on foundation 1 Weld floor sheets 108 12 sheets (7.90 W 3 8.60 H) ring/6 rings 1st Ring—welded Set first ring sheets 12 Vertical—fit and weld 103 Corner weld (inside/outside) #### Set ring 26 60 Bolt sheets together—vertical and #### horizontal Center pole/roof structural steel 1 Place roof sheets on structural 1 Weld floor sheets 108 Caged ladder 52 Decking, 6v dia pipe w/PS 1 Sand tank 60 Dia 3 100 (shop fabr) set 1 in field Conveyors Bucket elevator 20v 3 48v 8100 pieces Drive head and neck section 1 Transition and trough section 1 Tail and trough 1 Buckets 120 Vibrating conveyor set/weld down 36.4 Cone connections 3 Diverter valve 1

Unit

MH/ Qty

ea.

180

ea. lf

BM

PF

Total MH

360 180

360 180

60 1.1

60 120 1600

60 120 1600

ea. lf lf ea. ea.

5

0.26

60 120 240 300 460

60 120 240 300 460

ea. ea. lf lf lot ea.

80 60 1.11 0.38 120 20

80 60 120 20 120 20

80 60 120 20 120 20

1720

1720

180 300 300 480 380 60 20

180 300 300 480 380 60 20

ea. ea. ea. ea. ea. ea. ea.

1.16 1.24 5

180 300 300 4 10.44 20 20

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Industrial Construction Estimating Manual

9.27 BOP interconnecting pipe 9.27.1 BOP interconnecting pipe labor hours sheet 1 Scope BOP interconnecting pipe 2v misc. drains and vents 0.75v vent and drain on economizer 6v feedwater to economizer 6v economizer feedwater to boiler 2v steam to sample station 2v Spray dryer drains 2v Instrument air 2v air to sand reinjection 2v view port cooling air 2v atomizing air 6v natural gas supply 2v potable water 6v cooling water 2v bearing cooling water (supply and return) 2v condensate return

Qty

Unit

MH/ Qty

400 60

lf lf

200 200 100 100 1600 120 200 200 400 500 160 240 300

BM

PF

Total MH

1.80 1.80

9180 720 108

9180 720 108

lf lf lf lf lf lf lf lf lf lf lf lf

2.40 2.40 1.80 1.80 1.80 1.80 1.80 1.80 2.40 1.80 2.40 1.80

480 480 180 180 2880 216 360 360 960 900 384 432

480 480 180 180 2880 216 360 360 960 900 384 432

lf

1.80

540

540

9.28 Bid breakdown circulating fluidized bed boiler (FBC)

Circulating fluidized bed boiler (FBC) Combustor Boiler Boiler circulating water Fans Fans—FD, ID, OFA ductwork Economizer/inlet duct/hoppers Multicione Spray dryer Baghouse Ductwork Ash tank Ash piping Sand system BOP interconnecting pipe

BM

Laborer

PF

Total MH

36,270 8902 5368

40 40

21,944

58,254 8942 10,560 6048 1160 1940 1520 1440 3560 6160 480 2060 1524 3680 9180

5192 6048

1160 1940 1520 1440 3560 6160 480 2060 1524 3680 9180

Chapter 10

Bid assurance 10.1 Introduction Accurate, reliable, and quality cost estimates prevent contractors from losing money and the customer from overpaying. The accuracy of a cost estimate relies on: l l l l

quality of the project plan level the estimator defines project scope accuracy of the cost information quality of tools and procedures the estimator uses

The “optimum bid” or the “best bid” will result in a successful bid. When the bid leads to winning a job, then there is an opportunity to verify the estimate’s accuracy, reliability, and quality. This chapter describes unbalanced bidding strategy, analysis of estimates, estimate errors, and estimate assurance.

10.2 Unbalanced bidding strategy For many reasons the management will reduce the bid price and estimators will decrease the unit labor units. The reduction of the total price and decreasing the unit cost on labor is biased estimating and the adjustment is called unbalanced estimating. Main reasons for unbalanced bidding are: l

l l

l

front loading—bidding a higher percent than is allowed for mobilization cost, using preliminary estimating methods with less information, using detail of data warehouses, which has not been verified or matches work scope, and total price reduction.

A mathematically unbalanced bid is one containing lump sum or unit bid items that do not reflect reasonable actual cost plus a reasonable proportionate share of the bidder’s anticipated profit, overhead cost, which contractor anticipates for the performance of the items in question. Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00010-7 © 2020 Elsevier Inc. All rights reserved.

203

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A balanced bid is one where each bid item includes direct cost, overhead, other cost, and markup. Each item has a proportionate share of the cost that is required for the performance of the task. The unit-quantity model is a balanced unit estimate. The contractor assumes the risks and disadvantages of an unbalanced bid, and the bid can result in losses.

10.3 Analysis of estimates Historical data cost coded and collected in the field must be verified by statistical analysis and the actual cost compared with the original estimate. Fig. 10.1 illustrates the distribution of estimates plotted against actual cost. The data in Fig. 10.1 has been normalized using regression analysis. Deviations in the cost estimates are expressed by the ratio Cᵦₑ/Cₔ. This ratio equals 1 when actual cost equals the estimated cost and the ratio is the break-even point. Points to the left of the x axes are negative because the contractor is operating at a loss. Depending on bid strategy and objectives, contractor will profit to the right of the break-even point. The contractor’s survival depends on balanced unit estimates.

10.3.1 Regression analysis—deviation of estimate ratio from actual value Cᵦₑ/Cₔ, x

No. of estimates, y

0 1 2 3 4

2100 0 100 200 300

COVAR (R1, R2) VARP (R2) Slope (R1, R2) Intercept (R1, R2)

200.00 20,000.00 100.0000 2100.0000

10.3.2 Estimate error Accurate construction estimating is essential for contractors to prosper. The deviation between the estimate and actual cost for losing estimates may be due to errors in the estimate. Errors are not obvious immediately particularly when small. Errors can cost time, money, and reputation.

Bid assurance Chapter | 10

No. of estimates, y

400

205

y = 100x –200 R² = 1

300 200 100 0 –100

0

–200

1

2

Ratio

3

4

x

FIGURE 10.1 Distribution of estimates plotted against actual cost.

Three kinds of errors in estimating are: l l l

mistakes policy risk

10.3.3 Mistakes l l l l l l l l l

Underestimating labor—underestimating time a task will take Last-minute changes—forgotten line items Under estimating margin Selective bidding (union vs nonunion) and bidding too many projects Error in takeoff off scope Spreadsheets with too much detail Arithmetic, and error in formulas Risk—lack of or improper factoring Poorly defined scope of work—not understanding complete scope of work

10.3.4 Policy l l l l

Excessive or low overhead ratios Using data that has not been verified Estimating with data sets or books using unconfirmed data Data collection

10.3.5 Risk l l

Bid is intentionally low to keep workforce busy. Risk error is the difference between contractors’ bid and the winning bid.

206 l l

Industrial Construction Estimating Manual

Material and subcontractor pricing. Incomplete clarifications and exceptions.

An important objective of the contractor is to prepare exact estimates. However, estimates will deviate from the actual cost and reasons for the deviation between the estimate and actual cost include pitfalls that negatively impact the estimate and undermine the accuracy and validity of the estimate. Estimate pitfalls: l l

l l l l

Errors and unbalanced bidding. Evaluation of actual value between the estimate and historical data is not timely. Historical data is not collected to allow a comparison. There is no analysis of low and unsuccessful bids. Historical data is not verified. Too much time and effort spent preparing the estimate. Estimator pitfalls

l

l

l l l l l l l

Padding estimator adds a factor to work task, a cushion, that increases cost. Estimator uses third party data that is misleading relaying on data without understanding how data was derived. Estimator does not read the project documents carefully. Estimator does not factor for labor productivity and risk. Estimator does not divide task between multiple resources. Estimator does not update cost estimate and scope changes. Estimator lacks experience with similar projects. Estimator does not incorporate cost or enter cost correctly. Estimator uses material takeoff spreadsheets with too much detail that causes mistakes in data entry and errors.

Mistakes, errors, and estimator errors can cause estimates to lose money and cause the contractor to lose business. Errors are prevented by planning, well-thought-out policies, data collection, and estimate analysis.

10.4 Estimate assurance Comparison of actual-to-estimate values is important in the cost of construction work. Detailed estimating using the unit-quantity model is significant in bid assurance. The unit-quantity model is a balanced bid strategy. Standard unit of construction work is completed before construction is started. In estimating construction work the contractor must determine the materials that are required to complete the work, time and labor productivity for each task, and schedule indirect and staff for complete total construction. The aim is to specify the most effective method to complete the construction at the lowest

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practical cost. This planning occurs when the unit-quantity model is used to estimate the construction work. Unit cost estimated simply associates unit cost with each assembly involved in a construction process. The estimate is accurate and reliable, using comparable historical data (assemblies used previously) with evidence to justify the unit cost for each assembly. Detail estimating influences database development, computer advantages, is consistent and has many advantages compared to other estimating methods.

Chapter 11

Detailed estimating applications to construction 11.1 Introduction Contractors regardless of their size have difficulty estimating and focusing on the best and most profitable work. The contractor must avoid bidding too low, losing money, and cannot bid too high, and not win new work. The estimate needs to be high enough to make a profit but low enough to win a job. With all the pitfalls that undermine the accuracy and validity of an estimate, the contractor must have estimates that are accurate and consistent to make a profit and grow their reputation. The focus of this chapter is how to overcome and sustain profitability and streamline the estimating process. This chapter includes practical examples of applications to enable the reader to use the industrial construction estimating process to prepare process piping, equipment and civil estimates to set up databases. The following illustrative example for the industrial construction estimating process enables the reader to streamline the estimating process using the detailed estimating method to: l

l

evaluate the accuracy and verify the historical data collected in the field for process piping, equipment and civil work installed in a combined cycle power plant provides the unit-quantity model for detailed estimating that has many advantages compared to other estimating methods. Industrial construction estimating process

l

l l l l l l

Scope of work is defined by the plant process, piping and instrument diagrams (P&IDs) and process flow diagrams (PFDs), and field-specific scope. Make detailed material takeoff (MTO) for piping. Set up cost codes—job cost by cost code and type. Collect direct craft data in the field; field report. Summarize, verify, and validate data using the regression model. Set up databases for industrial process plants. Apply man-hour units to the quantified MTO.

Industrial Construction Estimating Manual. DOI: https://doi.org/10.1016/B978-0-12-823362-7.00011-9 © 2020 Elsevier Inc. All rights reserved.

209

210 l

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Enter the man-hour rates from the tables and takeoff quantities into the estimate sheets and calculate the direct craft labor using the unit-quantity model (man-hour rate 3 quantity) and then estimated man-hours are compared to actual.

11.2 Illustrative example for construction estimating process—lube oil supply 11.2.1 Scope of work is defined by the plant process, piping and instrument diagrams, and process flow diagrams Lube oil supply 20 ft. 6v s10s 20 ft. 4v s10s 40 ft. 2v s40s 20 ft. 1v s40s 80 ft. 4v s10s 20 ft. 2v s40s 20 ft. 2v s40s 40 ft. 4v s10s 40 ft. 2v s40s

304L 304L 304L 304L 304L 304L 304L 304L 304L

SS SS SS SS SS SS SS SS SS

pipe pipe pipe pipe pipe pipe pipe pipe pipe

11.2.2 Make detailed material takeoff for lube oil supply piping 2.7.1 Steam Turbine Generator (STG) vendor piping sheet 1 Line Lube oil supply Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

Material Size Sch/ Pipe BW, Valve Boltup Instrument PS Thk SW 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS

6 4 2 1 4 2 2 4 2

S10S S10S S40S S40S S10S S40S S40S S10S S40S

20 20 40 20 80 20 20 40 40

4 7 13 17 21 9 9 13 13

1

1 1 1 2 1 1 1 1 1

1 1 2 4

2 4

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211

11.2.3 Set up cost codes—job cost by cost code and type Job cost by cost code and type—lube oil supply piping Cost code

Type

xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx

6v 4v 2v 1v 4v 2v 2v 4v 2v

Qty

s10s 304L SS s10s 304L SS s40s 304L SS s40s 304L SS s10s 304L SS s40s 304L SS s40s 304L SS s10s 304L SS s40s 304L SS

pipe pipe pipe pipe pipe pipe pipe pipe pipe

20 20 40 20 80 20 20 40 40

11.2.4 Collect direct craft data in the field—field report Foreman’s report Project: Combined cycle power plant STG vendor LO piping Foreman

Date

Craft: pipefitter Cost code

Type

xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx

6v s10s 304L SS 4v s10s 304L SS 2v s40s 304L SS 1v s40s 304L SS 4v s10s 304L SS 2v s40s 304L SS 2v s40s 304L SS 4v s10s 304L SS 2v s40s 304L SS

pipe pipe pipe pipe pipe pipe pipe pipe pipe

Qty

MH

20 20 40 20 80 20 20 40 40

37 36 51 24 119 32 32 69 58

11.2.5 Summarize, verify, and validate data using the regression model The historical data from the field report is verified using the regression model. Least squares regression model Facility—Combined cycle power plant Data for input: Man-hours for field installation lube oil supply piping Quantity (x): R1 5 20, 20, 40, 20, 80, 20, 20, 40, 40 Man-hour (y): R2 5 37, 36, 51, 24, 119, 32, 32, 69, 58 Table linear regression: Fitting a straight line (Fig. 11.1).

Man-hour (y)

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150 y = 1.4322x + 2.9741 R² = 0.9595

100 50 0

Series 1 Linear (Series 1)

0

10

20

30

40

50

60

70

80

90

Linear (Series 1)

Quantity (x)

FIGURE 11.1 Installation lube oil supply piping.

X

y

Qty

MH

x

y

20 20 40 20 80 20 20 40 40 COVAR (R1, R2) VARP (R2) SLOPE (R1, R2) INTERCEPT (R1, R2)

37 36 51 24 119 32 32 69 58 509.23 760.12 1.4322 2.9741

CORREL (R1, R2) 5 correlation coefficient

0.9795

CORREL (R1, R2) 5 coefficient determination

0.9595

2

The coefficient of determination is R2 5 0.9595 and the correlation coefficient, R 5 0.9795, is a strong indication of correlation. A percentage of 98.5 of the total variation on Y can be explained by the linear relationship between X and Y (described by the regression equation; Y 5 1.4322x 1 2.9741). The relationship between X and Y variables is such that as X increases, Y also increases.

11.3 Man-hour database for combined cycle power plant and industrial plant 11.3.1 Schedule A—Combined cycle power plant piping Standard labor-estimating units

Detailed estimating applications to construction Chapter | 11

Facility—Combined cycle power plant

213

Large bore piping

Small bore piping

Unit of measure

Unit of measure

Description

Man-hours per unit

Man-hours per unit

Handle and install pipe, carbon steel, welded joint

Diameter inch feet

MH/LF

WT # 0.375v 0.406v # WT # 0.500v 0.562v # WT # 0.688v 0.718v # WT # 0.938v 1.031v # WT # 1.219v 1.250v # WT # 1.312v Welding butt welds, carbon steel, arc-uphill WT # 0.375v 0.406v $ WT # 0.500v 0.562v $ WT # 0.688v 0.718v $ WT # 0.938v (PWHT) 1.031v $ WT # 1.219v (PWHT) 1.250v # WT # 1.312v (PWHT) Olet- (SOL, TOL, WOL) Stub in Socketweld PWHT craft support labor Boltup of flanged joints by weight class 150/300 boltup 600/900 boltup 1500/2500 boltup Handle valves by weight class 150 and 300 manual valves 600 and 900 manual valves Heavier manual valve $ 1500

0.07 0.09 0.11 0.14 0.2 0.25 Diameter inch 0.5 0.55 1.05 1.2 1.45 2.2 2 3 BW 1.5 3 BW

0.18 0.23 0.28 0.35 0.5 0.75 MH/EA 1.1 1.2 2.2 2.45 2.7 4.4 2 3 BW 1.5 3 BW Per SW table 1 MH/EA 1 1.2 1.6 MH/EA 1 1.8 2

0.45 Diameter inch 0.4 0.5 0.65 Diameter inch 0.45 0.9 1.8

Facility—Industrial plant

11.3.2 Hydrostatic testing Man-hours per?lineal?foot Wall?thickness in inches Pipe?size 0.375v?or?less 0.406v 0.500v 0.562v 0.688v 0.718v 0.938v 1.031v 1.219v 0.5 0.022 0.028 0.034 0.042 0.060 0.75 0.022 0.028 0.034 0.042 0.060 (Continued )

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(Continued) Man-hours per?lineal?foot Wall?thickness in inches 1 1.5 2 2.5 3 4 6 8 10 12 14 16 18 20 24

0.022 0.022 0.022 0.021 0.025 0.034 0.050 0.067 0.084 0.101 0.118 0.134 0.151 0.168 0.202

0.028 0.028 0.028 0.027 0.032 0.043 0.065 0.086 0.108 0.130 0.151 0.173 0.194 0.216 0.259

0.034 0.034 0.034 0.033 0.040 0.053 0.079 0.106 0.132 0.158 0.185 0.211 0.238 0.264 0.317

0.042 0.042 0.042 0.042 0.050 0.067 0.101 0.134 0.168 0.202 0.235 0.269 0.302 0.336 0.403

0.060 0.060 0.060 0.060 0.072 0.096 0.144 0.192 0.240 0.288 0.336 0.384 0.432 0.480 0.576

Man-hours to place/remove blinds, open/close valves, removal/replacement of valves and specialty item 1 s and pipe sections as required, and drain lines after testing

11.3.3 Schedule G—Alloy and nonferrous weld factors Welding percentages for alloy and nonferrous metals

Material classificationgroup numbers

Pipe size 2 3 4 5 6 8 10 12 14 16 18 20 24

1 0.25 0.275 0.30 0.315 0.345 0.39 0.425 0.45 0.49 0.525 0.59 0.65 0.73

2 0.54 0.58 0.61 0.63 0.65 0.74 0.85 2.00 2.15 2.23 2.30 2.45

3 0.20 0.23 0.25

4 0.58 0.61 0.68

5 2.11 2.15 2.22

6 2.25 2.32 2.35

7 0.225 0.25 0.28

0.30 0.50 0.75 0.80

0.75 0.88 0.95 2.04

2.28 2.38 2.45 2.50

2.40 2.50 2.75 3.00

0.30 0.34 0.375 0.40

8 0.45 0.495 0.54 0.57 0.62 0.70 0.765 0.81 0.88 0.945 2.06 2.17 2.24

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215

GROUP 1 CHROME MOLYBLENUM STEEL CHROME —1/2% 13% MOLY—to 1% GROUP 2—18 8 STAINLESS STEEL TY, 304, 316, 347 GROUP 3—COPPER, BRASS, EVERDUR GROUP 4—ALUMINUM, MONEL and COPPER CHROME NICKEL GROUP 5—NICKEL GROUP 6—HASTELLOY GROUP 7—GALVANIZED GROUP 8—A335 P91

11.4 Lube oil supply piping estimate l l

Apply man-hour units to the quantified MTO. Enter the man-hour rates from the tables and takeoff quantities into the estimate sheets and calculate the direct craft labor using the unitquantity model (man-hour rate 3 quantity) then estimated man-hours are compared to actual. Facility—Combined cycle power plant STG vendor lube oil supply piping

11.4.1 Estimate sheet 1-Handle and install pipe-welded joint Pipe handle

PF

Hydro

PF

Total MH

Description

Size

LF

DIF

MH/ DIF

MH DIF

MH/ DIF

MH

Lube oil supply Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Column totals

6 4 2 1 4 2 2 4 2

20 20 40 20 80 20 20 40 40 300

120 80 80 20 320 40 40 160 80 940

0.07 0.07 0.18 0.18 0.07 0.18 0.18 0.07 0.18

8.4 5.6 14.4 3.6 22.4 7.2 7.2 11.2 14.4 94.4

0.050 0.034 0.022 0.022 0.034 0.034 0.034 0.034 0.034

6 14.4 2.72 8.3 1.76 16.2 0.44 4.0 10.88 33.3 1.36 8.6 1.36 8.6 5.44 16.6 2.72 17.1 32.7 127.1

Facility—Combined cycle power plant STG vendor lube oil supply piping

120 80 80 20 320 40 40 160 80 940

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11.4.2 Estimate sheet 2-Welding: BW, SW, PWHT arc-uphill BW

SW

BW

SW

PWHT

PF

Description

Size

JT

JT

DI

MH/ DI

MH/ JT

Factor

MH/ JT

MH

Lube oil supply Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Column totals

6 4 2 1 4 2 2 4 2

4 7 13 17 21 9 9 13 13 106

0 0 0 0 0 0 0 0 0 0

24 28 26 17 84 18 18 52 26 293

0.50 0.50 0.80 0.65 0.50 0.80 0.80 0.50 0.80

0 0 0 0 0 0 0 0 0

1.65 1.61 1.54 1.54 1.61 1.54 1.54 1.61 1.54

0 0 0 0 0 0 0 0 0

19.8 22.5 32.0 17.0 67.6 22.2 22.2 41.9 32.0 277.3

Facility—Combined cycle power plant STG vendor lube oil supply piping

11.4.3 Estimate sheet 3-Boltup of flanged joint by weight class 150/ 300

600/ 900

1500/ 2500

PF

Description

Size

Boltup

Boltup

Boltup

DI

MH/ DI

MH/ DI

MH/ DI

MH

Lube oil supply Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

6 4 2 1 4 2 2 4 2

1 1 1 2 1 1 1 1 1

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

6 4 2 2 4 2 2 4 2

0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65

2.4 1.6 0.8 0.8 1.6 0.8 0.8 1.6 0.8

Column totals

10

Facility—Combined cycle power plant STG vendor lube oil supply piping

28

11.2

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217

11.4.4 Estimate sheet 4-Handle valves by weight class Description Lube oil supply

Size

Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

6 4 2 1 4 2 2 4 2 3

Column totals

150/ 300

600/ 900

1500/ 2500

Valve

Valve

Valve

DI

MH/ DI

MH/ DI

MH/ DI

MH

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 2 0 2

0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45

0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9

1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8

0 0 0 0 0 0 0 0.9 0 0.9

1

PF

1

Facility—Combined cycle power plant STG vendor lube oil supply piping

11.4.5 Estimate sheet 5-Pipe supports Pipe Description

Material

Size

Sch/ Thk

Lube oil supply Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Column totals

304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS

6 4 2 1 4 2 2 4 2

S10S S10S S40S S40S S10S S40S S40S S10S S40S

Facility—Combined cycle power plant STG vendor lube oil supply piping

Support

1 1 2 4

2 4 14

PF DI

MH/ DI

MH

0 4 2 2 16 0 0 8 8 40

1 1 1 1 1 1 1 1 1

0 4 2 2 16 0 0 8 8 40

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11.4.6 Estimate sheet 6-Instrument PF Description

Material

Size

Sch/The

Instrument

MH/EA

MH

Lube oil supply Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS

6 4 2 1 4 2 2 4 2

S10S S10S S40S S40S S10S S40S S40S S10S S40S

0 0 0 0 0 0 0 0 0 0 0

1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

0 0 0 0 0 0 0 0 0

Column totals

0

Facility—Combined cycle power plant STG vendor lube oil supply piping

11.4.7 Estimate sheet 7-Summary HP piping and supports PF Description

MH

Estimate sheet 1-handle and install pipe-welded joint Estimate sheet 2-welding: BW, SW, PWHT arc-uphill Estimate sheet 3-boltup of flanged joint by weight class Estimate sheet 4-handle valves by weight class Estimate sheet 5-pipe supports Estimate sheet 6-instrument Column totals

127.1 277.3 11.2 0.9 40 0 456

MH/LF

1.52

11.5 Piping summary converted to MH/LF Lube oil supply

Pipe Pipe Hdl

Welding Boltup Valve PS Instrument MH

MH/ LF

Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

20 20 40 20 80 20

19.8 22.5 32.0 17.0 67.6 22.2

1.83 1.82 1.27 1.19 1.48 1.58

14.4 8.3 16.2 4.0 33.3 8.6

2.4 1.6 0.8 0.8 1.6 0.8

0 0 0 0 0 0

0 4 2 2 16 0

0 0 0 0 0 0

36.6 36.5 51.0 23.9 118.5 31.5

(Continued )

Detailed estimating applications to construction Chapter | 11

219

(Continued) Lube oil supply

Pipe Pipe Hdl

Welding Boltup Valve PS Instrument MH

MH/ LF

Pipe-304L SS Pipe-304L SS Pipe-304L SS Column totals

20 40 40 300

22.2 41.9 32.0 277

1.58 1.73 1.45 1.52

8.6 16.6 17.1 127

0.8 1.6 0.8 11

0 0.9 0 1

0 8 8 40

0 0 0 0

31.5 69.0 58.0 456

11.6 Excel estimate sheet Lube oil supply

Material

SIZE

Sch

MH/LF

Qty

lf

MH

Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS 304L SS

6 4 2 1 4 2 2 4 2

S10S S10S S40S S40S S10S S40S S40S S10S S40S

1.83 1.82 1.27 1.19 1.48 1.58 1.58 1.73 1.45

20 20 40 20 80 20 20 40 40

lf lf lf lf lf lf lf lf lf

37 36 51 24 119 32 32 69 58

11.7 STG-lube oil supply piping installation man-hours Facility—Combined cycle power plant

Actual

Estimated

Description

MH

PF

Lube oil supply

456

456

Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS Pipe-304L SS

37 36 51 24 119 32 32 69 58

37 36 51 24 119 32 32 69 58

11.8 Illustrative example to develop a database for tank farm boltup flanged joints The historical data is collected on site every day and summarized in a spreadsheet. The data for bolt up is cost-coded and collected in the field.

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11.8.1 Field data report The field report is collected in the field for similar work, and a spreadsheet is devised for the data. The report is used for time control and to find the number of man-hours for a task. The spreadsheet prepares the data for statistical analysis. The estimator determines the productivity rate, and the rate is used for future cost analysis and estimating similar scopes of work. Foreman

Date

Craft: PF Cost code

Type

MH/JT

xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx

2 150/300 boltup 2.5 150/300 boltup 3 150/300 boltup 4 150/300 boltup 6 150/300 boltup 8 150/300 boltup 10 150/300 boltup 12 150/300 boltup 14 150/300 boltup 16 150/300 boltup 18 150/300 boltup 20 150/300 boltup 24 150/300 boltup 2 600 boltup 2.5 600 boltup 3 600 boltup 4 600 boltup 6 600 boltup 8 600 boltup 10 600 boltup 12 600 boltup 14 600 boltup 16 600 boltup 18 600 boltup 20 600 boltup 24 600 boltup

1.0 1.0 1.2 1.6 2.4 3.2 4.0 4.8 5.6 6.4 7.2 8.0 9.6 1.3 1.5 1.8 2.4 3.6 4.8 6.0 7.2 8.4 9.6 10.8 12.0 14.4

The historical data from the field report is verified using the regression model.

11.8.2 Least squares regression model—150 lb/300 lb Facility—Petroleum—tank farm piping Data for input: Man-hours for field 150 lb/300 lb boltup Pipe size (x): R1 5 2, 2.5. 3, 4, 6, 8, 10, 12, 14, 16 18, 20, 24 MH/JT (y): R2 5 1.0, 1.0, 1.2, 1.6, 2.4, 3, 2, 4.0, 4.8, 5.6, 6.4, 7.2, 8.0, 9.6 Table linear regression: Fitting a straight line (Fig. 11.2).

MH/JT

Detailed estimating applications to construction Chapter | 11

12.0 10.0 8.0 6.0 4.0 2.0 0.0

y = 0.3972x + 0.0449 R² = 0.9997

221

Series 1 Linear (Series 1) Linear (Series 1)

0

5

10

15

20

25

30

Pipe size FIGURE 11.2 Tank farm field 150 lb/300 lb boltup.

X

Y

Pipe size

MH/JT

X

Y

2 2.5 3 4 6 8 10 12 14 16 18 20 24 COVAR (R1, R2) VARP (R2) SLOPE (R1, R2) INTERCEPT (R1, R2)

1.0 1.0 1.2 1.6 2.4 3.2 4.0 4.8 5.6 6.4 7.2 8.0 9.6 19.38 7.70 0.3972 0.0449

CORREL (R1, R2) 5 correlation coefficient CORREL (R1, R2) 5 coefficient determination 2

2 1.00 1.00

The coefficient of determination, R2, is exactly 11 and indicates a positive fit. All data points lie exactly on the straight line. The relationship between X and Y variables is such that as X increases, Y also decreases. Field data is verified for field 150 lb/300 lb boltup

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11.8.3 Least squares regression model—600 lb field boltup

MH/JT

Facility—Petroleum—tank farm piping Data for input: Man-hours for field 600 lb bolt Pipe size (x): R1 5 2, 2.5. 3, 4, 6, 8, 10, 12, 14, 16 18, 20, 24 MH/JT (y): R2 5 1.3, 1.5, 1.8, 2.4, 3.6, 4.8, 6.0, 7, 2, 8.4, 9.6, 10.8, 12.0, 14.4 Table linear regression: fitting a straight line (Fig. 11.3).

16.0 14.0 12.0 10.0 8.0 6.0 4.0 2.0 0.0

x

y

Pipe size

MH/JT

2 2.5 3 4 6 8 10 12 14 16 18 20 24 COVAR (R1, R2) VARP (R2) SLOPE (R1, R2) INTERCEPT (R1, R2)

1.3 1.5 1.8 2.4 3.6 4.8 6.0 7.2 8.4 9.6 10.8 12.0 14.4 29.21 17.49 0.5986 0.0225

y = 0.5986x + 0.0225 R² = 1 Series 1 Linear (Series 1)

0

10

20

Pipe size FIGURE 11.3 Tank farm 600 lb boltup.

30

Detailed estimating applications to construction Chapter | 11

CORREL (R1, R2) 5 correlation coefficient

223

2 1.00

CORREL (R1, R2)2 5 coefficient determination

1.00

The coefficient of determination, R2, is exactly 11 and indicates a positive fit. All data points lie exactly on the straight line. The relationship between X and Y variables is such that as X increases, Y also decreases. Field data is verified for field 600 lb boltup.

11.8.4 Verification of tank farm bolted flange connections l l

man-hours for field 150 lb/300 lb boltup man-hours for field 600 lb bolt

R2 5 1 indicates that the model fits the data. The historical data collected, summarized, and analyzed using the regression model is verified, and the estimator sets up the unit man-hour table, for tank farm boltup, to include in the piping database. Table tank farm field boltup MH/JT Facility—Petroleum—tank farm piping man-hours per joint Pipe

Pressure rating

Size

150 lb/300 lb

600 lb

2 2.5 3 4 6 8 10 12 14 16 18 20 24

1.0 1.0 1.2 1.6 2.4 3.2 4.0 4.8 5.6 6.4 7.2 8.0 9.6

1.3 1.5 1.8 2.4 3.6 4.8 6.0 7.2 8.4 9.6 10.8 12.0 14.4

Man-hours per joint to bolt up valves, expansion joints, flanged fittings and spools.

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11.9 Illustrative example for verification of LP piping and supports—ASME Section 1 installation 11.9.1 LP piping and supports MTO LB Line

LB

LB

Material Size Sch/ Pipe BW PWHT Valve Boltup Instrument PS The

LP piping and supports—ASME Section 1 LP-10 steam SA-106-B 14 std 26 drum to LP SHTR 1 LP-10 steam SA-106-B 10 40 34 drum to LP SHTR 1 LP-10 steam SA-106-B 8 40 12 drum to LP SHTR 1 LP-14 SHTR 1 SA-106-B 10 40 32 to LP SHTR 2 LP-15 SHTR 1 SA-106-B 10 40 30 to LP SHTR 2

4

4

3

2

2

2

2

11.9.2 LP piping and supports—ASME Section 1 field estimate

Line

Material

Size

Sch/ Thk

MH

Qty

MHa

ni

LP piping and supports— ASME Section 1 LP-10 steam drum to LP SHTR 1 LP-10 steam drum to LP SHTR 1 LP-10 steam drum to LP SHTR 1 LP-14 SHTR 1 to LP SHTR 2 LP-15 SHTR 1 to LP SHTR 2

Unit

134.0

lf

Qty

PF

ni

ni MHa 300.2

SA-106-B

14

std

2.22

26

lf

26

57.7

SA-106-B

10

40

2.32

34

lf

34

78.8

SA-106-B

8

40

3.11

12

lf

12

37.3

SA-106-B

10

40

2.01

32

lf

32

64.4

SA-106-B

10

40

2.07

30

lf

30

62.0

Detailed estimating applications to construction Chapter | 11

225

11.9.3 Least squares regression model LP piping Facility—Combined cycle power plant Data for input: Man-hours for LP piping and supports Quantity (x): R1 5 26, 34, 12, 32, 30 MM/LF (y): R2 5 57.7, 78.8, 37.3, 64.4, 62.0 Table linear regression: Fitting a straight line (Fig. 11.4). x

Y

Qty (lf)

MH/LF

26 34 12 32 30 COVAR (R1, R2) VARP (R2) SLOPE (R1, R2) INTERCEPT (R1, R2)

57.7 78.8 37.3 64.4 62.0 100.43 179.31 1.6262 16.4588

CORREL (R1, R2) 5 correlation coefficient

0.9544

CORREL (R1, R2)2 5 coefficient determination

0.9108

The coefficient of determination is R2 5 0.9108 and the correlation coefficient, R 5 0.9544, is a strong indication of correlation. A percentage of 95.4 of the total variation on Y can be explained by the linear relationship between X and Y (described by the regression equation; Y 5 1.6262x 1 16.459). The relationship between X and Y variables is such that as X increases, Y also increases. 100.0 y = 1.6262x + 16.459 R² = 0.9108

MH/LF

80.0 60.0

Series 1

40.0

Linear (Series 1)

20.0

Linear (Series 1)

0.0 0

10

20

30

Quantity (lf) FIGURE 11.4 MH for LP piping and supports.

40

226

Industrial Construction Estimating Manual

11.10 Illustrative example for verification of STG utility bridge steel 11.10.1 Power plant structural steel quantity MTO Project: combined cycle power plant

Revision

Equipment description

X

Date

x/xx/xxxx

Steel weight

Total steel weight

Component description

Quantity

Tons

Tons

Light—0 19 lb/ft. Medium—20 39 lb/ft. Heavy—40 79 lb./ft. X heavy—80 120 lb/ft.

lot lot lot lot

7.6 25.4 90 47

187 8.4 27.9 99 51.7

STG utility bridge steel

11.11 STG utility bridge steel field estimate Description

MH

Qty

MHa

ni

STG utility bridge steel Light—0 19 lb/ft. Medium—20 39 lb/ft. Heavy—40 79 lb/ft. X heavy—80 120 lb/ft.

24 23 18 16

8.4 27.9 99 51.7

ton ton ton ton

Unit

Qty ni

ni MHa

IW

187

3453

3453

3453

8.4 27.9 99 51.7

201.6 641.7 1782 827.2

201.6 641.7 1782 827.2

202 642 1782 827

11.11.1 Least squares regression model STG utility bridge steel Facility—Combined cycle power plant Data for input: Man-hours for STG utility bridge steel Quantity (x): R1 5 8.4, 27.9, 99, 51.7 MH/ton (y): R2 5 201.6, 641.7, 1782, 827.2 Table linear regression: Fitting a straight line (Fig. 11.5).

MH/ton

4000

y = 18.109x + 26.483 R² = 0.9949

3000 2000

Series 1

1000

Linear (Series 1)

0

Linear (Series 1) 0

50

100

Quantity (ton)

FIGURE 11.5 MH STG utility bridge steel.

150

200

Detailed estimating applications to construction Chapter | 11

X

y

Qty (ton)

MH/ton

187

3453

8.4 27.9 99 51.7 COVAR (R1, R2) VARP (R2) SLOPE (R1, R2) INTERCEPT (R1, R2)

227

201.6 641.7 1782 827.2 73,580.92 1,339,231.31 18.1085 26.4828

CORREL (R1, R2) 5 correlation coefficient

0.9975

CORREL (R1, R2) 5 coefficient determination

0.9949

2

The coefficient of determination is R2 5 0.9949 and the correlation coefficient, R 5 0.9975, is a strong indication of correlation. A percentage of 99.7 of the total variation on Y can be explained by the linear relationship between X and Y (described by the regression equation; Y 5 18.109x 1 26.483). The relationship between X and Y variables is such that as X increases, Y also increases.

11.12 Illustrative example for verification of hydrogen plant foundations 11.12.1 MTO hydrogen plant foundation work Description

QTY

Unit

Foundation slabs—4000PSI Footing concrete—4000PSI Pier concrete—4000PSI Elevated floor slab concrete Concrete walls THK 8v 10v

9655 2416 275 109 185

CY CY CY CY CY

228

Industrial Construction Estimating Manual

11.12.2 Job cost by cost code and type—hydrogen plant foundations Cost code

Type

Qty

Unit

xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx

Foundation slabs—4000PSI Footing concrete—4000PSI Pier concrete—4000PSI Elevated floor slab concrete Concrete walls THK 8v 10v

9655 2416 275 109 185

CY CY CY CY CY

11.12.3 Civil databases for hydrogen plant Concrete works

MH

Unit

Foundation slabs—4000PSI Footing concrete—4000PSI Pier concrete—4000PSI Elevated floor slab concrete Concrete walls THK 8v 10v

1.831 2.31 2.751 3.85 3.852

CY CY CY CY CY

11.12.4 Excel estimate spreadsheet for hydrogen plant foundations Historical Description

Foundation slabs— 4000PSI Footing concrete— 4000PSI Pier concrete— 4000PSI Elevated floor slab concrete concrete walls THK 8v 10v

Estimate

MH

Qty Unit

Qty

Carpenter Labor IW

MHa

ni

ni

1.831

9655 CY

9655 17,678

17,678

2.31

2416 CY

2416 5582

5582

2.751

275

CY

275

758

758

3.85

109

CY

109

418

418

3.852

185

CY

185

712

712

ni MHa

11.12.5 Least squares regression model hydrogen plant foundations Facility—Hydrogen plant Data for input: Man-hours for hydrogen plant foundations Quantity (x): R1 5 9655, 2416, 275, 109, 185 Man-hour (y): R2 5 17678, 5582, 758, 418, 712 Table linear regression: Fitting a straight line (Fig. 11.6).

Man-hour, y

Detailed estimating applications to construction Chapter | 11

20000

229

y = 1.7997x + 479.93 R² = 0.9967

15000

Series 1

10000

Linear (Series 1)

5000

Linear (Series 1)

0 0

2000

4000

6000

8000

10,000 12,000

Quantity, cy FIGURE 11.6 Hydrogen plant foundations.

X

y

Qty (cy)

MH

9655 2416 275 109 185 COVAR (R1, R2) VARP (R2) SLOPE (R1, R2) INTERCEPT (R1, R2)

17,678 5582 758 418 712 24,195,791.70 13,444,551.49 1.7997 479.9269

CORREL (R1, R2) 5 correlation coefficient

0.9983

CORREL (R1, R2) 5 coefficient determination

0.9967

2

The coefficient of determination is R2 5 0.9967 and the correlation coefficient, R 5 0.9983, is a strong indication of correlation. A percentage of 99.8 of the total variation on Y can be explained by the linear relationship between X and Y (described by the regression equation; Y 5 1.799x 1 479.93). The relationship between X and Y variables is such that as X increases, Y also increases.

Appendix A

Statistical and mathematical formulas Statistical formulas for the mean, variance, and standard deviation Mean: ybar 5 y1 1 y2 1 ? 1 yn; Σ y/n Variance: S2 5 (y1 2 Ybar)2 1 (Y2 1 Ybar2) 1 ? 1 (Yn 2 Ybar)2/n 2 1 s2 5 Σðyi2ybarÞ2 =ðn 2 1Þ Standard deviation: Ybar)2/n 2 1]1/2

S 5 [(y1 2 Ybar)2 1 (Y2 1 Ybar2) 1 ? 1 (Yn 2

s 5 ½Σðyi2ybarÞ2 =ðn21Þ1=2 Straight line graph: Handle and install large bore standard pipe y 5 a 1 bx; Y 5 a 1 ðy 2 y1Þ=ðx 2 x1Þ ðxÞ where y is the dependent variable, a is the intercept value along the y axis at x 5 0, b is the slope, or the length of the rise divided by the length of the run; b 5 (y 2 y1)/(x 2 x1), x is the independent or control variable. Mathematical expectation: E(X) 5 p1X1 1 p2X2 1 ? 1 pkXk 5 ΣpX Normal distribution: Y 5 1=ðσð2piÞX1=2ÞeX 2 1=2ðX2μÞ2 =σ2 where μ is the mean, σ is the standard deviation, pi 5 3.1416. . .. . ., e 5 2.71828. . .. Standard form: Y 5 1=ð2piX1=2ÞeX 2 1=2ðz2 Þ z is normally distributed with mean 0 and variance 1. Central limit theorem: Wi 5 (xbar)i 2 μ/(σ/k^1/2) N (0,1) in the limit as k approaches infinity. Method of least squares Least square line

231

232

Statistical and mathematical formulas

The least square line approximating the set of points (x1, y1), (x2, y2), . . ., (xn, yn) has the equation y 5 bx 1 a where b is the slope of the line, and a is the y-intercept. The best fit line for the points (x1, y1), (x2, y2), . . ., (xn, yn) is given by y 2 ybar 5 bðx 2 xbarÞ where the slope is b 5 Σðxi 2 xbarÞðyi 2 ybarÞ=Σðxi2xbarÞ2 and the y-intercept is a 5 ybar  bxbar Formula correlation coefficient r: r 5 n (Σ XY) 2 (ΣX) (ΣY)/[n (ΣX2) 2 (ΣX)2] [n (Σy2) 2 (ΣY)2]1/2 Define the U model: Hn 5 H1ðn ^bÞ where Hn is the hours required for the nth unit of production and H1 is the hours required for the first unit. Natural slope b is defined by the formula: S 5 10^b log (2) 1 2 logarithm to base 10. Prediction for the total hours for a “block” of production Define man hours for a block of erection as the total man hours required to erect all units from unit M to another unit N, N . M TM, N is defined as: TM; N 5 H1½M ^ b 1 ðM 1 1Þ ^ b 1 ðM 1 2Þ ^ b 1 ?? 1 N ^ b Approximation formula: TM; N 5 ½H1=ð1 1 bÞ½ðN 1 0:5Þ ^ ð1 1 bÞ 2 ðM 2 0:5Þ ^ ð1 1 bÞ Linear regression—fitting U model to unit historical data y 5 ax ^ b where y is the hours required for the nth unit of production, a is the hours required for the first unit, and b is the natural slope. The power function y 5 ax^b is transformed from a curved line on arithmetic scales to a straight line on loglog scales, let: y 5 log y a 5 log a x 5 log x taking logarithms of both sides, log y 5 log a 1 x log b, appears like, y 5 a 1 bx

Statistical and mathematical formulas Appendix | A

233

Calculating sample size Sample size: absolute precision n 5 z2 3 p 3 ð1 2 pÞ=e2 where z is the z value (1.96 for 95% confidence level), p is the percentage expressed as a decimal (0.2), and e is the acceptable error percentage as a decimal (0.05 5 6 5%). Calculating error limits for a sample size Given sample size is calculated by: n 5 ðz2 3 p 3 ð1 2 pÞÞ=e2 Determine the limit of error, e ^ e 5 z 3 ðp 3 ð1 2 pÞ=nÞ1=2 Work sampling method Model: Hs 5 ðNi ÞðHtÞðRFÞð1 1 PF&DÞ=N where Hs is the standard man hours per task; Ni is the observation of event I; Ht is the total man-hours worked during sample study; RF is rating factor; PF&D is the personal, fatigue, and delay allowance; N is the number of random observations during sample study. Expected-value method If X denotes a discrete random variable that can assume the values X1, X2, . . ., Xi with respective probabilities p1, p2, . . ., pi where p1 1 p2 1 ? 1 pi 5 1, the mathematical expectation of X or simply the expectation of X, denoted by E(X) is defined as E(X) 5 p1 X1 1 p2 X2 1 ? 1 pi Xi 5 Σpj Xj 5 Σ p X where E(X) is the expected value of the estimate for event I, pj is the probability that X takes on value Xj, 0 , 5 Pj (Xj) , 5 1, and Xj is the event. Range method The mean and variance for each of the three single cost elements are calculated as EðCi Þ 5 ðL 1 4M 1 HÞ=6 varðCi Þ 5 ððH 2 LÞ=6Þ2^ where E(Ci) is the expected cost of distribution i, i 5 1, 2, n; L is the lowest cost, or best case estimate of cost distribution; M is the modal value, or most likely estimate of cost distribution; H is the highest cost, or worst case estimate of cost distribution; and var (Ci) is the variance of cost distribution i, I 5 1,2, . . .. . .. . .., n, dollars2.

234

Statistical and mathematical formulas

The mean of the sum is the sum of the individual means, and the variance is the sum of the variances. EðCrÞ 5 EðC1Þ 1 EðC2Þ 1 ? 1 EðCnÞ varðCrÞ 5 varðC1Þ 1 varðC2Þ 1 ? 1 varðCnÞ Where E(Cr) is the expected total cost of independent subdistributions i, and var (Cr) is the variance of total cost of independent subdistributions i. The probability is calculated using Z 5 UL 2 EðCrÞ=½varðCrÞ1=2 where Z is the value of the standard normal distribution; UL is the upper limit of cost, arbitrarily selected. Expected profit is defined as: profit 5 Bp  Ce expected profit 5 P 3 (Bp 2 Ce)where Bp is the bid price, Ce is the estimated cost, P is the probability of event (Bp 2 Ce), 0 # Prob # 1. Capture rate The capture rate is defined as: capture rate 5 ðCsÞ=ðCi Þ 3 100; percent where Cs is the cost estimates that are successful. Moving averages. Smoothing of time series Given a set of numbers Y1; Y2; . . . define a moving average of order N to be given by the sequence of arithmetic means, Y11Y21?1Ny= n; Y21Y31?1yn=n; Y31Y41?1yn= n;... The sums in the numerators are moving totals of order n. Estimation of moving averages The average of n most recent observations, computed at time t, is given by: Ma 5

ðyt 1 yt 2 1 1 ? 1 yt 2 n 1 1Þ n

where Ma is the moving average of response variable; y is the data, labor, cost, price, etc.; t is the unit of time, years, months, etc.; and n is the denominator of group of time units.

Statistical and mathematical formulas Appendix | A

235

Exponential smoothing Formula: ðD 3 SÞ 1 ðF 3 ð1 2 sÞÞ where D is the most recent period’s demand, S is the smoothing factor in decimal form, and F is the most recent period’s forecast. Cost index The current cost is found by using the formula: C 5 HðIc=IhÞ where C is the current or future cost, H is the historical or past cost, Ic is the index corresponds to current or future time period, and Ih is the index corresponds to historical or past time period.

Appendix B

Excel functions and mathematical functions Excel functions Graphic analysis of data Use Excel’s chart capabilities to plot the graphical straight line given by the equation y 5 a 1 bx to use the Excel chart capabilities, highlight the range x:y, and select Insert, and select from Charts, Scatter, go to quick access bar and select from Chart Tools, Design and from Chart Layouts, Select Layout 9. Excel functions Excel Statistical Functions for forecasting the value of y for any x. Thus a and b can be calculated in Excel. Where R1 5 the array of y values and R2 5 the array of x values. b 5 SLOPE (R1, R2) 5 COVAR (R1, R2)/VARP (R2) a 5 INTERCEPT (R1, R2) 5 AVERAGE (R1) 2 b  Average (R2) SLOPE (R1, R2) 5 slope of regression line INTERCEPT (R1, R2) 5 y 2 intercept of the regression line FORECAST (x, R1, and R2) calculates the predicted value of y for given value of x. Thus FORECAST (x, R1, and R2) 5 a 1 b  x where a 5 INTERCEPT (R1, R2) and b 5 SLOPE (R1, R2) TREND (R1, R2) 5 array function that produces an array of predicted y values corresponding to x values stored in array R2, based on the regression line calculated from x values stored in array R2, and y values stored in array R1. COVAR (R1, R2) 5 returns covariance, the average of the products of deviations for each data point pair in two data cells VARP (R2) 5 calculates variance based on the entire population (ignores logical values and text in the population) Correlation CORREL (R1, R2) 5 correlation coefficient of data in arrays R1 and R2

237

238

Excel functions and mathematical functions

CORREL (R1, R2)^2 5 coefficient determination The mean, variance, and standard deviation measures of central tendency AVERAGE (number 1, number 2): Returns the average (arithmetic mean) of its arguments, which can be numbers or names, arrays, or references that contain numbers. VAR (number 1, number 2): Estimates variance based on a sample (ignores logical values and text in the text in the sample STDEV (number 1, number 2): Estimates standard deviation based on a sample (ignores logical values and text in the sample) Math & Trig functions Math formulas To use the math formulas, go to quick access toolbar; select Math & Trig; and then select SUMPRODUCT. SUMPRODUCT 5 Returns the sum of the products of corresponding ranges or arrays. Arrays 1, 2, and 3 are 2 255 arrays for which you want to multiply and then add components. All arrays must have the same dimensions. LOG 5 Returns the logarithm of a number to the base you want the logarithm. Number is the positive real number for which you want the logarithm. SQRT 5 Returns the square root of a number. Number is the number for which you want the square root.

Appendix C

Area and volume formulas Formulas—areas and volumes Square: area 5 (edge)2; A 5 a2 Rectangle: base 3 altitude; A 5 ba Right triangle: Area 5 1/2 base 3 altitude; A 5 1/2 ba Pythagorean theorem: (Hypotenuse)2 1 sum of squares of two legs of right triangle C2 5 a2 1 b2; a 5 [c2 2 b21/2] Oblique triangle; Area 5 1/2 base 3 altitude; A 5 1/2 bh A 5 [s(s 2 a)(s 2 b)(s 2 c)]^1/2, where s 5 (a 1 b 1 c)/2 Parallelogram; opposite sides are parallel; A 5 bh Trapezoid; one pair of opposite sides parallel A 5 1/2 sum of bases 3 altitude; A 5 1/2 (a 1 b) h Circle: circumference 5 2 (pi)(radius) 5 (pi) (diameter; C 5 2(pi)R 5 (pi)D Area 5 (pi) (radius)2 5 (pi)/4) (diameter)2: A 5 (pi)R2 5 (pi/4)D2 Sector of circle; area 5 1/2 radius 3 arc; A 5 1/2 Rc 5 1/2 R2 angle Segment of circle; area (segment) 5 area (sector) 2 area(triangle) A 5 Rc 2 1/2 ba Ellipse; area 5 (pi)ab Parabolic segment; area 5 2/3 ld Right circular cone; V 5 (pi)r2h; A 5 side area 1 base area; A 5 (pi)r[r 1 (r2 1 h2)^1/2] Right circular cylinder; V 5 (pi)r2h 5 (pi)d2h/4 A 5 side area 1 end areas 5 2 (pi)r (h 1 r)

239

Appendix D

Standard to metric Lengths Metric conversion 1 centimeter 5 10 millimeters; 1 cm 5 10 mm 1 meter 5 100 centimeters; 1 m 5 100 cm Standard conversions 1 foot 5 12 inches; 1 ft. 5 12 in. 1 yard 5 3 feet; 1 yd 5 3 ft. 1 yard 5 36 inches; 1 yd 5 36 in. Metric standard conversions 1 millimeter 5 0.03937 inches; 1 mm 5 0.03937 in. 1 centimeter 5 0.39370 inches; 1 cm 5 0.39370 in. 1 meter 5 39.39008 inches; 1 m 5 39.37008 in. 1 meter 5 3.28084 feet; 1 m 5 3.28084 ft. 1 meter 5 1.093.6133 yards; 1 m 5 1.0993.6133 yd Standard metric conversions 1 inch 5 2.54 centimeters; 1 in. 5 2.54 cm 1 foot 5 30.48 centimeters; 1 ft. 5 30.48 cm 1 yard 5 91.44 centimeters; 1 yd 5 91.44 cm 1 yard 5 0.9144 meters; 1 yd 5 0.3144 m

Volumes Metric conversion 1 cubic centimeter 5 1000 cubic millimeters; 1 cu cm 5 1000 cu mm 1 cubic meter 5 1 million cubic centimeters; 1 cu m 5 1,000,000 cu cm Standard conversions 1 cubic foot 5 1728 cubic inches; 1 cu ft. 5 1728 cu in. 1 cubic yard 5 46,656 cubic inches; 1 cu yd 5 46,656 cu in. 1 cubic yard 5 27 cubic feet; 1 cu yd 5 27 cu ft. Metric standard conversions 241

242

Standard to metric

1 cubic centimeter 5 0.06102 cubic inches; 1 cu cm 5 0.06102 cu in. 1 cubic meter 5 35.31467 cubic feet; 1 cu m 5 35.31467 cu ft. 1 cubic meter 5 1.30795 cubic yards; 1 cu m 5 1.30795 cu yd Standard metric conversions 1 cubic inch 5 16.38706 cubic centimeters; 1 cu in. 5 16.38706 cu cm 1 cubic foot 5 0.02832 cubic meters; 1 cu ft. 1 0.02832 cu m 1 cubic yard 5 0.76455 cubic meters; 1 cu yd 5 0.76455 cu m

Areas Metric conversion 1 sq centimeter 5 100 sq millimeters; 1 sq cm 5 100 sq mm 1 sq meter 5 10,000 sq centimeters; 1 sq m 5 10,000 sq cm Standard conversions 1 sq foot 5 144 sq inches; 1 sq ft. 5 144 sq in. 1 sq yard 5 9 sq feet; 1 sq yd 5 9 sq ft. Metric standard conversions 1 sq centimeter 5 0.15500 sq inches; 1 sq cm 5 0.15500 sq in. 1 sg meter 5 10.76391 sq feet; 1 sq m 5 10.76391 sq ft. 1 sq meter 5 1.19599 sq yards; 1 sq m 5 1.9599 sq yd Standard metric conversions 1 sq inch 5 6.4516 sq centimeters; 1 sq in. 5 6.4516 sq cm 1 sq foot 5 929.0304 sq centimeters; 1 sq ft. 5 929.0304 cm 1 sq foot 5 0.09290 sq meters; 1 sq ft. 5 0.09290 sq m

Appendix E

Boiler man hour tables Wachs Trav-L-Cutter—use 0.0330.050 MH/in. of circumference for every 0.5v of wall thickness to be removed (Table E.1). Mill with power tool—use 0.050.10 MH/in. of circumference for every 0.5v of wall thickness to be removed. Saw or grind—use mill with power tool rate Formula: Circumference in inches 3 rate/inch) 3 no of passes (0.5v cut per pass) Example: 22v diameter 3 2v wall [(220 diameter 3 3.1416) 3 0.033/in.] (2v wall 1/2) 5 9.1 hours Circumference

Rate

No: of passes

Rates for carbon steel only, double for all other material Excludes overhead labor, set-up, maintenance, and removal of equipment (Tables E.2 and E.3).

TABLE E.1 Cutting and milling rates for 05000 PSI. Torch

Saw or

Mill with

Size (OD)

Cut

Grind

Power tool

0v , diameter # 3v

0.150.20

0.350.50

0.350.50

3v , diameter # 4.5v

0.180.30

0.3751.00

0.3751.00

4.5v , diameter # 6.5v

0.250.60

0.503.00

0.503.00

6.5v , diameter # 35v with WT from 0.5v thru 5.5v

Torch cut

243

244

Boiler man hour tables

TABLE E.2 Expanding rates, MH per tube end. PSI

2v

2.5v

3v

4v

160

0.19

0.22

0.44

0.94

200

0.20

0.24

0.45

0.95

300

0.22

0.27

0.47

0.96

400

0.25

0.31

0.49

0.97

500

0.28

0.36

0.50

0.99

600

0.30

0.40

0.53

1.02

700

0.36

0.43

0.59

1.07

800

0.36

0.43

0.66

1.33

900

0.36

0.43

0.72

1.60

1000

0.36

0.43

1100

0.50

1200

0.50

1300

0.50

1400

0.50

1500

0.50

1600

0.50

1700

0.50

1800

1.20

1900

1.20

2000

1.20

2100

1.20

1.87

For seal welding 2v generating tubes inside drums, reexpanding, and NDE, use 1.2 MH/JT (Table E.4). Field welding of tubes in the heat input zones of all boilers of 2000 psi design and over is by the TIG process. Field welding of tubes by the SMAW process; root pass by the TIG process PWHT: 1. Carbon steel . 0.75v thick 2. Chrome molly steel with carbon content .0.25% and wall thickness .0.50v 3. Croloy materials with more than 3% chromium, or diameter .4v and WT . 0.50v (Table E.5).

TABLE E.3 Socket and seal welding, MH per weld. Seal welding

Socket welding

MH per weld

Outside

Inside

W/O stress

W/stress

Size

Header

Header

Relieving

Relieving

1v O.D. tube

0.7

0.9

1.1

1.4

Over 1v1.5v O.D. tube

0.9

1.1

1.2

1.5

Over 1.5v2v O.D. tube

1.2

1.3

1.4

1.7

Over 2v2.5v O.D. tube

1.4

1.5

1.7

2.2

Over 2.5v3.25v O.D. tube

1.7

1.8

2.1

2.6

Over 3.25v4v O.D. tube

1.9

2.1

Over 4v4.5v O.D. tube

2.1

2.4

Over 4.5v5.5v O.D. tube

2.3

2.7

Place and weld 2.5v H.H. fitting

2.2

3.25v H.H. fitting

2

4v H.H. fitting or blind nipple

2.5

4.5v H.H. fitting or blind nipple

2.7

Radiograph and header end plugs

2.8

TABLE E.4 Field tube welding, MH/weld. Tube welding—MH Per weld Design pressure (PSI) Up

501

1001

1501

2001

2501

To

To

To

To

To

To

500

1000

1500

2000

2500

3000

1v , BW # 1.5v TIG

2.4

2.6

2.8

3.0

3.2

3.4

1.5v , BW # 2v TIG

2.7

2.9

3.4

3.7

4.0

4.3

Tube size (OD)

2v , BW # 2.5v TIG

3.2

3.3

3.8

4.2

4.2

4.4

2.5v , BW # 3v TIG

3.7

4.0

4.1

4.8

4.6

4.8

3v , BW # 3.5v TIG

4.3

4.6

4.8

5.3

5.3

5.6

3.5v , BW # 4v TIG

4.9

5.2

5.4

5.9

5.9

6.2

4v , BW # 4.5v TIG

5.5

5.8

6.1

6.5

6.5

6.7

4.5v , BW # 5.5v TIG

6.8

7.1

7.4

7.7

8.0

8.3

4.5v , ring weld # 5.5v SMAW PWHT

8.4

9.4

10.3

11.5

12.4

13.6

5.5v , ring weld # 6.5v SMAW

5.0

5.8

6.4

6.8

7.0

7.2

5.5v , BW # 6.5v TIG

7.7

8.0

8.5

9.0

9.5

10.0

10.2

11.0

12.0

13.8

14.2

15.0

5.5v , ring weld # 6.5v SMAW PWHT

TABLE E.5 Field pipe welding, MH per weld. Wall thickness in inches Diameter inches

0.250

0.500

0.750

1.000

1.250

1.500

1.750

2.000

2.250

2.500

2.750

3.000

6

3.0

3.3

7.2

8.7

13.2

15.0

16.2

17.4

8

4.0

4.4

9.6

11.6

17.6

20.0

21.6

23.2

24.8

28.0

10

5.0

5.5

12.0

14.5

22.0

25.0

27.0

29.0

31.0

35.0

38.0

43.0

12

6.0

6.6

14.4

17.4

26.4

30.0

32.4

34.8

37.2

42.0

45.6

51.6

14

7.0

7.7

16.8

20.3

30.8

35.0

37.8

40.6

43.4

49.0

53.2

60.2

16

8.0

8.8

19.2

18

9.0

9.9

21.6

23.2

35.2

40.0

26.1

39.6

45.0

43.2

46.4

49.6

56.0

60.8

68.8

48.6

52.2

55.8

63.0

68.4

77.4

20

10.0

11.0

24.0

29.0

44.0

50.0

54.0

58.0

62.0

70.0

76.0

86.0

22

11.0

12.1

26.4

31.9

48.4

55.0

59.4

63.8

68.2

77.0

83.6

94.6

24

12.0

13.2

28.8

34.8

52.8

60.0

64.8

69.6

74.4

84.0

91.2

103.2

26

13.0

14.3

31.2

37.7

57.2

65.0

70.2

75.4

80.6

91.0

98.8

111.8

28

14.0

15.4

33.6

40.6

61.6

70.0

75.6

81.2

86.8

98.0

106.4

120.4

30 32

15.0

16.5

36.0

43.5

66.0

75.0

81.0

87.0

93.0

105.0

114.0

129.0

16.0

17.6

38.4

46.4

70.4

80.0

86.4

92.8

99.2

112.0

121.6

137.6

34

17.0

18.7

40.8

49.3

74.8

85.0

91.8

98.6

105.4

119.0

129.2

146.2

35

17.5

19.3

42.0

50.8

77.0

87.5

94.5

101.5

108.5

122.5

133.0

150.5

248

Boiler man hour tables

PWHT: 1. Carbon steel . 0.75v thick 2. Chrom moly steel with carbon content .0.25% and wall thickness .0.50v 3. Croloy materials with more than 3% chromium, or diameter .4v and WT . 0.50v (Table E.6).

TABLE E.6 Diamond soot blowers, MH per SB W/PVF. Manual Type of unit

Operation

MH

Unit

G-2, G-21, G-9B, A2E

SB

22

EA

SB W/PVF

44

EA

Total

66

EA

SB

20

EA

SB W/PVF

44

EA

Total

64

EA

SB

35

EA

SB W/PVF

51

EA

Total

86

EA

SB

18

EA

SB W/PVF

51

EA

IR and 1S

1K, T9, and T11

G9B, A2E (swinging arm)

Total

69

EA

SB

100

EA

SB W/PVF

51

EA

Total

151

EA

Pressure reducing station

70

EA

Trays and channels for supporting tubing

18

EA

Tubing for automatic sequential air operation

40

EA

1K, DE2, SE2 (strait line)

Air compressor and/or receiver

18

ton

Auto sequential panel or air master controller

86

Panel

IK structural supports

6

Blower

249

Boiler man hour tables Appendix | E

TABLE E.7 Structural steel. Structural steel and miscellaneous iron Erect structural steel Main steel

MH

Unit

Light—019 lb/ft.

28.0

ton

Medium—2039 lb/ft.

24.0

ton

Heavy—4079 lb/ft.

20.0

ton

X heavy—80120 lb/ft.

16.0

ton

21.0

ton

Erect structural steel; # 20 ton

Erect structural steel; 20 ton . tons # 100 ton Light—019 lb/ft. Medium—2039 lb/ft.

18.0

ton

Heavy—4079 lb/ft.

15.0

ton

X heavy—80120 lb/ft.

12.0

ton

Light—019 lb/ft.

16.8

ton

Medium—2039 lb/ft.

14.4

ton

Heavy—4079 lb/ft.

13.2

ton

X heavy—80120 lb/ft.

11.8

ton

Erect structural steel; .100 ton

PLATFORM FRAMING

0.15

SF

HANDRAIL & TOE PLATE

0.25

LF

FLOOR GRATING

0.20

SF

STAIR TREADS

0.85

LF

STRAIGHT LADDER

0.30

LF

CAGED LADDERS

0.35

LF

Ladders and safety cage—KD

1.00

LF

Girths (side wall support steel for metal siding)

28.00

ton

Purlins (roof support steel for metal siding)

28.00

ton

Elevator steel

38.00

ton

For combustion steam and air blowing soot blowers, double PVF man hours. For Vulcan soot blowers, add 24 MH/soot blower for scavenger drain PVF

250

Boiler man hour tables

TABLE E.8 Burners. Description Circular burners

MH

Unit

32.00

ton

Air jet low NOx coal burner

180.00

EA

DRB-4Z low NOx coal burner

240.00

EA

XLC low NOx oil and gas burner

240.00

EA

Dual zone NOx port (over fire air system)

200.00

EA

Inter tube burners, includes blocks, tips, and riffle casings

18.00

ton

Shop assembled burners in wind box, includes welding

24.00

ton

Automatic lighters—includes welding

6.00

EA

Oil atomizers

4.00

EA

Removal of soot blower use 50% of table man hours (Tables E.7 and E.8).

Index Note: Page numbers followed by “f” and “t” refer to figures and tables, respectively.

A Aboveground piping man-hours, 148 aboveground BOP piping, 148156 API 650 oil storage tanks, 179180 tank construction estimate, 180182 bottom plate placement, 180181 erection bid breakdown, 180 roof erection, 182 shell plate erection, 181 tank testing, 182 welding sequence, 181 tank data, 180 Area and volume formulas, 239240 Ash piping bid breakdown, 197198 labor hours, 198200 Ash tank 150 dia 3 400 labor hours, 197 ASME B31.1 piping and supports, 123125 ASME Section 1 installation, LP piping and supports verification, 224225 material takeoff, 224 field estimate, 224 least squares regression model, 225, 225f

B Baghouse bid breakdown, 195 labor hours, 196 Balance of Plant (BOP) aboveground BOP piping, 148156 equipment, 143145 estimating database, 5455 set, align, couple, and grout pumps, 5455 interconnecting pipe labor, 202 Bid assurance, 203 analysis of estimates, 204206, 205f estimate errors, 204205

mistakes, 205 policy, 205 regression analysis, 204 risk, 205206 estimate assurance, 206207 unbalanced bidding strategy, 203204 Bid breakdown, 92 ash piping, 197198 baghouse, 195 boiler, 187 circulation water, 189 circulating FBC, 202 economizer/inlet duct/hoppers, 192 fans, 191 FD, ID, OFA ducts, 192 FBC combustor, 183184 gasifier, 162 total direct craft man-hours, 162 refinery equipment, 171179 miscellaneous equipment and special specialty items, 179 pumps, 177 reactors, 175176 recycle compressors, 178 rich solvent hydraulic turbine, 1292 HP, 179 shell and tube heat exchanger, 176 tank construction estimate, 174175 vessels/columns, 173175 tank erection, 180 Boiler bid breakdown, 187 Boiler circulation water, 189191 bid breakdown, 189 piping labor hours, 189191 Boiler foundations Excel estimate spreadsheet for, 100101 HRSG Stack and HRSG (combined cycle power plant), 58 Boiler labor hours, 187189 Boiler man hour tables, 243250, 243t, 244t, 246t, 247t, 248t, 249t, 250t

251

252

Index

Boltup of flanged joint by weight class, 6768, 216 BOP. See Balance of Plant (BOP) Bottom plate placement, 180181 Break-even point, 204

C Circulating fluidized bed boiler bid breakdown, 202 Civil database, for hydrogen plant, 5051 Civil database, hydrogen plant foundations, 228 Code piping heat recovery steam generator small bore vendor piping, 126 Coding, 56 HRSG RP piping and supports, job cost by cost code and type, 6 job cost by cost code and type, 56 Combined cycle power plant boiler foundations—HRSG Stack and HRSG, 58 equipment man-hour breakdown, 156157 owner-furnished equipment, 157 2 3 1 configuration, 156157 material takeoff, 2537 heat recovery steam generator—field trim piping, 3537 LB code piping, 2530 risers and down comers, 3334 small bore code piping, 3133 SP-01 AIG piping, 37 STG vendor piping, 3841 structural and miscellaneous steel quantity, 59 Compressor station piping material takeoff, 2123 Computer-aided estimation, 75 benefits of, 75 cost estimation, 1314 Excel spreadsheets, 7576 estimate summary, 83 general conditions’ cost, 8081 labor cost craft supervision, calculation of, 7879 labor cost project staff, calculation of, 7980 labor cost, calculation of, 7778 material cost, 8182 quantity takeoff, 77 subcontractor cost, 8283 SCR Foundation estimate, using Excel forms, 8493

bid breakdown, 92 estimate analysis, 9293 estimate summary, 9192 general conditions’ cost, 8889 labor cost craft supervision, calculation of, 86 labor cost direct and indirect craft, calculation of, 8485 labor cost project staff, calculation of, 87 material cost, 8990 quantity takeoff detailed work-up sheet, 84 subcontractor cost, 9091 Computerized estimating, 75 Construction-based estimating data, 4344 Construction database, 4 Construction estimates levels of, 2 types of, 12 Construction material, 15 combined cycle power plant material takeoff, 2537 heat recovery steam generator—field trim piping, 3537 LB code piping, 2530 risers and down comers, 3334 small bore code piping, 3133 SP-01 AIG piping, 37 combined cycle power plant STG vendor piping, 3841 STG vendor piping, 3841 estimate worksheet, 1516 material estimate, 15 material takeoff, 1516 compressor station piping material takeoff, 2123 power plant foundations quantity material takeoff, 1921 power plant piping material takeoff, 1617 power plant structural steel quantity material takeoff, 1719 vessels/columns material takeoff, 2425 Construction work, elements of, 1314 computer-aided cost estimation, 1314 Cost analysis, 3 CTG and CTG-related foundations, 101103 CTG vender piping, 1921, 141143

D Database system, 43 balance of plant equipment estimating database, 5455

Index set, align, couple, and grout pumps, 5455 civil database, for hydrogen plant, 5051 development of, 4345 unit man-hour database, benefits of, 4445 facility—industrial plant (simple foundation), 51 pipeline database, 5253 piping man-hour database, 4550 handle and install fitting, cast iron—lead and mechanical joint, 48 handle and install pipe, cast iron—lead and mechanical joint, 4950 mechanical joint MH/JT, cast iron—lead and mechanical joint, 46 pipe set and align, cast iron—lead and mechanical joint, 45 verification of cast iron underground piping, by regression analysis, 49 verify historical data for cast iron pipe— handle and install fitting, 4849, 48f verify historical data for cast iron pipe— mechanical joint MH/JT, 47, 47f verify historical data for cast iron pipe— pipe set and align, 4546, 45f schedule A—combined cycle power plant piping, 5354 structural database, for combined cycle power plant, 52 Data collection, 4 Detailed estimates (or definitive estimates), 2, 209 field data report, 8 labor estimates, 58 lube oil supply piping estimate. See Lube oil supply piping estimate unit-quantity model, 95 using unit quantity model to erect gasifier, 163170 equipment estimate, 163167 Direct craft man-hour summary, 158159 2 3 1 configuration combined cycle power plant, 158159 Ductwork—multicone to spray dryer labor hours, 195 Ductwork to baghouse labor hours, 197

E Economizer/inlet duct/hoppers bid breakdown, 192 Elements of work estimates, 57 Engineer’s estimates, 2

253

Equipment cost, 57 Erection sequence, 5 Estimate assurance, 206207 Estimate worksheet, 1516 Excel estimate spreadsheet, 7576 boiler foundations, 100101 double-flow STG installation estimate, 131135 installation, 131 man-hours, 131 estimate summary, 83 Excel functions and mathematical functions, 237238 F class CTG installation estimate, 138141 man-hours, 138 general conditions’ cost, 8081 heat recovery steam generator small bore vendor piping, 125 hydrogen plant foundations, 228 labor cost, calculation of, 7778 labor cost craft supervision, calculation of, 7879 labor cost project staff, calculation of, 7980 lube oil supply piping, 219 material cost, 8182 quantity takeoff, 77 SCR foundation estimate, using Excel forms, 8493 bid breakdown, 92 estimate analysis, 9293 estimate summary, 9192 general conditions’ cost, 8889 labor cost craft supervision, calculation of, 86 labor cost direct and indirect craft, calculation of, 8485 labor cost project staff, calculation of, 87 material cost, 8990 quantity takeoff detailed work-up sheet, 84 subcontractor cost, 9091 subcontractor cost, 8283

F Facility—industrial plant (simple foundation), 51 FBC. See Fluidized bed combustion boiler (FBC) combustor FD duct bid breakdown, 192 labor hours, 192

254

Index

Field data report, 713 detailed estimate, 8 lube oil supply piping, 211 spreadsheet for, 8 unit method, 810 Field erect-HRSG HP piping and supports, 6172 boltup of flanged joint by weight class, 6768 handle and install pipe-welded joint, 6264 handle valves by weight class, 6870 instrument, 7172 pipe supports, 7071 welding, 6466 Field trim piping, heat recovery steam generator, 128129 HP, IP, LP remote drums, 128129 Fluidized bed combustion boiler (FBC) combustor, 183 ash tank 150 dia 3 400 labor hours, 197 ash piping bid breakdown, 197198 ash piping labor hours, 198200 baghouse bid breakdown, 195 baghouse labor hours, 196 bid breakdown, 183184 boiler circulation water, 189191 bid breakdown, 189 piping labor hours, 189191 boiler bid breakdown, 187 boiler labor hours, 187189 BOP interconnecting pipe labor, 202 circulating FBC bid breakdown, 202 ductwork—multicone to spray dryer labor hours, 195 ductwork to baghouse labor hours, 197 economizer/inlet duct/hoppers bid breakdown, 192 equipment labor hours, 184187 fans bid breakdown, 191 FD, ID, OFA ducts, 192 fans labor hours, 191 FD, ID, OFA ducts, 192 multiclone bid breakdown, 193 multiclone labor hours, 193194 sand system bid breakdown, 201 sand system labor hours, 201 SCR/economizer support structure, 192193 labor hours, 192193 spray dryer bid breakdown, 194 spray dryer labor hours, 194195 Foundation summary man-hours, 115 of 1 3 1 combined cycle power plant, 9699

G Gasification process, 161 Gasifier—feedstock bunker A and B, 61 Gasifier labor estimate, 161 bid breakdown, 162 total direct craft man-hours, 162 detailed estimate using unit quantity model to erect gasifier, 163170 equipment estimate, 163170 General conditions’ cost, 8081, 8889

H Handle and install fitting, cast iron lead and mechanical joint, 48 verify historical data for, 4849, 48f Handle and install pipe, cast iron—lead and mechanical joint, 4950 Handle and install pipe-welded joint, 6264, 215 Handle valves by weight class, 6870, 217 Heat recovery steam generator configuration, 156 field trim piping, 128129 small bore vendor piping, 125126 code piping, 126 Excel spreadsheet summary, 125 risers and down comers, 127128 Heat recovery steam generator field trim piping, 3537 large bore vendor piping, 121125 piping and supports—ASME B31.1, 123125 triple pressure, 116121 Historical data handle and install fitting, 4849 mechanical joint MH/JT, 47 pipe set and align, 4546 HP piping and supports, field erect-HRSG, 6172 boltup of flanged joint by weight class, 6768 handle and install pipe-welded joint, 6264 handle valves by weight class, 6870 instrument, 7172 pipe supports, 7071 welding, 6466 HRSG SB code piping, scope of field work required for, 5 HRSG vendor piping material takeoff, 25 Hydrogen plant, civil database for, 5051 Hydrogen plant foundations, verification of, 227229

Index civil databases, 228 Excel estimate spreadsheet, 228 job cost by cost code and type, 228 least squares regression model, 228229, 229f material takeoff, 227

I ID duct bid breakdown, 192 labor hours, 192 Indirect craft, calculation of, 8485 Industrial construction estimating process, 209

J Job cost by cost code and type, 56 HRSG RP piping and supports, 6 Hydrogen plant foundations, 228 lube oil supply piping, 211

L Labor, 3 cost, 57 calculation of, 7778, 8485 craft supervision, calculation of, 7879, 86 project staff, calculation of, 7980, 87 hour, 57 productivity analysis, 3 Labor estimate, 57 1 3 1 combined cycle power plant. See Labor estimate, for 1 3 1 combined cycle power plant piping estimate, 6172 field erect-HRSG HP piping and supports, 6172 piping summary converted to MH/lf, 73 unit-quantity method, 5861 boiler foundations—HRSG Stack and HRSG (combined cycle power plant), 58 gasifier—feedstock bunker A and B, 61 refinery—vessels/columns, 6061 structural and miscellaneous steel quantity (combined cycle power plant), 59 Labor estimate, for 1 3 1 combined cycle power plant, 95 aboveground piping man-hours, 148 aboveground BOP piping, 148156 BOP equipment, 143145 combined cycle power plant equipment man-hour breakdown, 156157

255

2 3 1 configuration, 156157 owner-furnished equipment, 157 CTG vendor piping, 141143 detailed estimating unit-quantity model, 95 direct craft man-hour summary, 158159 2 3 1 configuration combined cycle power plant, 158159 Excel double-flow STG installation estimate, 131135 man-hours, 131 equipment installation, 131 Excel F class CTG installation estimate, 138141 man-hours, 138 foundation summary, 9699 man-hours, 115 heat recovery steam generator configuration, 156 field trim piping, 128129 risers and down comers, 127128 small bore vendor piping, 125126 triple pressure, 116121 heat recovery steam generator large bore vendor piping, 121125 piping and supports—ASME B31.1, 123125 mechanical equipment, 115116 SP-01 AIG piping, 130 STG piping, 137 STG vendor piping, 135137 structural steel, 145146 estimate, 145146 installation man-hour estimate, 145 underground piping man-hours, 146147 unit-quantity model, work estimates using, 100115 CTG and CTG-related foundations, 101103 Excel estimate spreadsheet for boiler foundations, 100101 plant mechanical system-related foundations, 106110 STG and STG-related foundations, 103106 utility distribution plant electrical controls foundations, 111115 LB code piping, 2530 LP piping and supports verification—ASME Section 1 installation, 224225 field estimate, 224 least squares regression model, 225, 225f material takeoff, 224

256

Index

Lube oil supply piping estimate, 210212 boltup of flanged joint by weight class, 216 cost codes, 211 Excel estimate sheet, 219 field data report, 211 handle and install pipe-welded joint, 215 handle valves by weight class, 217 instrument, 218 material takeoff, 210 pipe supports, 217 regression analysis, 211212, 212f scope of work, 210 STG-lube oil supply piping installation man-hours, 219 summary HP piping and supports, 218 welding, 216

M Man-hour, 3 boiler man hour tables, 243250, 243t, 244t, 246t, 247t, 248t, 249t, 250t Excel double-flow STG installation estimate man-hours, 131 Excel F class CTG installation estimate man-hours, 138 piping database, 4550 handle and install fitting, cast iron—lead and mechanical joint, 48 handle and install pipe, cast iron—lead and mechanical joint, 4950 mechanical joint MH/JT, cast iron—lead and mechanical joint, 46 pipe set and align, cast iron—lead and mechanical joint, 45 verification of cast iron underground piping, by regression analysis, 49 verify historical data for cast iron pipe— handle and install fitting, 4849, 48f verify historical data for cast iron pipe— mechanical joint MH/JT, 47, 47f verify historical data for cast iron pipe— pipe set and align, 4546, 45f refinery equipment installation activity, 171 STG-lube oil supply piping installation, 219 unit database, benefits of, 4445 Man-hour database, for combined cycle power plant and industrial plant, 212215 alloy and nonferrous weld factors, 214215 hydrostatic testing, 213214 lube oil supply piping estimate, 215218

boltup of flanged joint by weight class, 216 handle and install pipe-welded joint, 215 handle valves by weight class, 217 instrument, 218 pipe supports, 217 summary HP piping and supports, 218 welding, 216 piping, 212213 Material cost, 57, 8182, 8990 Material estimate, 15 Material takeoff (MTO), 45, 1516, 57, 77 combined cycle power plant material takeoff, 2537 heat recovery steam generator—field trim piping, 3537 LB code piping, 2530 risers and down comers, 3334 small bore code piping, 3133 SP-01 AIG piping, 37 combined cycle power plant STG vendor piping, 3841 STG vendor piping, 3841 compressor station piping, 2123 LP piping and supports, 224 lube oil supply piping, 210 power plant foundations quantity, 1921 power plant piping, 1617 power plant structural steel quantity, 1719 RP piping and supports, 45 STG utility bridge steel, 226 vessels/columns, 2425 Mechanical equipment, 115116 Mechanical joint MH/JT, cast iron lead and mechanical joint, 46 verify historical data for cast iron pipe— mechanical joint MH/JT, 47, 47f Models of estimation, 2 MTO. See Material takeoff (MTO) Multiclone bid breakdown, 193 Multiclone labor hours, 193194

N Natural gas power plant, 95 Nonrepetitive one-cycle time study, 7

O OFA duct bid breakdown, 192 labor hours, 192

Index

P Personal, fatigue, and delay (PF&D) process of timing the cycle, 7 Pipeline database, 5253 Pipe set and align, cast iron lead and mechanical joint, 45 verify historical data for, 4546, 45f Pipe supports, 217 Piping estimate, 6172 field erect-HRSG HP piping and supports, 6172 Piping man-hour database, 4550 handle and install fitting, cast iron—lead and mechanical joint, 48 handle and install pipe, cast iron—lead and mechanical joint, 4950 mechanical joint MH/JT, cast iron—lead and mechanical joint, 46 pipe set and align, cast iron—lead and mechanical joint, 45 verification of cast iron underground piping, by regression analysis, 49 verify historical data for cast iron pipe— handle and install fitting, 4849, 48f verify historical data for cast iron pipe— mechanical joint MH/JT, 47, 47f verify historical data for cast iron pipe— pipe set and align, 4546, 45f Piping summary converted to MH/LF, 218219 Plant mechanical system-related foundations, 106110 Power plant foundations quantity material takeoff, 1921 Power plant piping material takeoff, 1617 Power plant structural steel quantity material takeoff, 1719 Preliminary estimates (or conceptual estimates), 2 Productivity measurement, 67 Pumps construction estimate, 177

Q Quantity takeoff. See Material takeoff (MTO)

R Reactors construction estimate, 175176 Recycle compressors, 178 Refinery equipment estimate, 171 bid breakdown, 171179

257

miscellaneous equipment and special specialty items, 179 pumps, 177 reactors, 175176 recycle compressors, 178 rich solvent hydraulic turbine, 1292 HP, 179 shell and tube heat exchanger, 176 tank data, 174175 vessels/columns, 173175 installation man-hours activity, 171 Refinery—vessels/columns, 6061 Regression analysis, 4 bid assurance, 204 hydrogen plant foundations, 228229 LP piping and supports, 225, 225f lube oil supply piping, 211212 STG utility bridge steel, 226227, 226f tank farm boltup flanged joints, 220223, 221f unit method, 9 unit-quantity model verification, 1112, 12f verification of cast iron underground piping by, 49 Rich solvent hydraulic turbine, 1292 HP, 179 Risers and down comers, 3334 Roof erection, 182 RP piping and supports average man-hour, calculation of, 89, 10f job cost by cost code and type, 6 material takeoff, 45 scope of work-field erection, 5 unit-quantity model of, 11

S Sand system bid breakdown, 201 labor hours, 201 Schedule A—combined cycle power plant piping, 5354 Scope of work, 5 required for HRSG SB code piping, 5 SCR/economizer support structure, 192193 labor hours, 192193 SCR Foundation estimate, using Excel forms, 8493 bid breakdown, 92 estimate analysis, 9293 estimate summary, 9192 general conditions’ cost, 8889

258

Index

SCR Foundation estimate, using Excel forms (Continued) labor cost craft supervision, calculation of, 86 labor cost direct and indirect craft, calculation of, 8485 labor cost project staff, calculation of, 87 material cost, 8990 quantity takeoff detailed work-up sheet, 84 subcontractor cost, 9091 Shell construction estimate, 176 Shell plate erection, 181 Small bore code piping, 3133 SP-01 AIG piping, 37, 130 Spray dryer bid breakdown, 194 labor hours, 194195 Standard to metric, 241242 Statistical and mathematical formulas, 231236 STG and STG-related foundations, 103106 STG piping, 137 lube oil supply piping installation manhours, 219 vendor piping, 3841, 135137 STG utility bridge steel, verification of, 226 field estimate, 226227 least squares regression model, 226227, 226f structural steel quantity MTO, 226 Structural and miscellaneous steel quantity (combined cycle power plant), 59 Structural database, for combined cycle power plant, 52 Structural steel, 145146 estimate, 145146 installation man-hour estimate, 145 quantity MTO, 226 Subcontractor cost, 8283, 9091 Subcontractor quotes, 57

T Tank construction estimate, 174175, 180182 Tank farm boltup flanged joints, database development for, 219223 field data report, 220 least squares regression model150 lb/300 lb field boltup, 220221, 221f least squares regression model600 lb field boltup, 222223 verification of, 223 Tank testing, 182 Tube heat exchanger, 176

U Unbalanced bidding strategy, 203204 Underground piping verification of cast iron, by regression analysis, 49 man-hours, 146147 Unit man-hour database, benefits of, 4445 Unit method, 810 correlation, 10 regression model, 9 RP piping and supports average man-hour, calculation of, 89, 10f unit-quantity model, 1013 Unit-quantity model, 1012, 58 boiler foundations—HRSG Stack and HRSG (combined cycle power plant), 58 detailed estimate using, to erect gasifier, 163170 detailed estimating, 95 to excel estimate sheet, conversion of, 1213 gasifier—feedstock bunker A and B, 61 illustration of, 11 refinery—vessels/columns, 6061 regression model, 1112, 12f structural and miscellaneous steel quantity (combined cycle power plant), 59 work estimates, 100115 CTG and CTG-related foundations, 101103 Excel estimate spreadsheet for boiler foundations, 100101 plant mechanical system-related foundations, 106110 STG and STG-related foundations, 103106 utility distribution plant electrical controls foundations, 111115 Utility distribution plant electrical controls foundations, 111115

V Vessels/columns construction estimate, 173175 Vessels/columns material takeoff, 2425

W Welding, 6466 lube oil supply piping, 216 sequence, 181