Industrial Piping and Equipment Estimating Manual [2 ed.] 0443239193, 9780443239199

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Industrial Piping and Equipment Estimating Manual

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Industrial Piping and Equipment Estimating Manual Second Edition

Kenneth Storm California General Engineering, Mathematical Association of America, Washington, D.C., United States

Elsevier Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom 50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States Copyright © 2024 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. ISBN: 978-0-443-23919-9 For information on all Elsevier publications visit our website at https://www.elsevier.com/books-and-journals Publisher: Megan R. Ball Acquisitions Editor: Fran Kennedy-Ellis Editorial Project Manager: Teddy A. Lewis Production Project Manager: Surya Narayanan Jayachandran Cover Designer: Mark Rogers

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Contents

Preface Introduction

xiii xv

1

Process piping 1.1 Section introductiondpiping schedules and tables 1.2 Piping section general notes 1.3 Schedule Adcombined cycle power plant piping 1.4 Schedule Bdsimple cycle power plant piping 1.5 Schedule Cdrefinery plant piping 1.6 Schedule Ddpetroleum tank farm piping 1.7 Schedule Edbrewery, food processing plants 1.8 Schedule Fdpump and compressor station piping 1.9 Schedule Gdcoal and gas fired power plant 1.10 Schedule Hdpulp and paper plant 1.11 Schedule Idindustrial package boiler 1.12 Schedule Jdhydrogen plant pipping 1.13 Schedule Kddiesel power plant piping 1.14 Schedule ldsolar power plant 1.15 Schedule Mdbiomass plant 1.16 Schedule Ndethanol plant 1.17 Schedule Odwater treatment plant 1.18 Schedule Pdgeothermal plant 1.19 Schedule Qdindustrial plant piping 1.20 Schedule Idunderground drainage piping for industrial plants 1.21 Schedule Sdsimple foundations for industrial plants 1.22 Schedule Tdpipe supports and hangers 1.23 Schedule Udalloy and nonferrous weld factors 1.24 Sample process piping estimates 1.25 Standard and line pipedwall thickness

1 1 2 3 11 16 23 29 34 41 48 55 62 69 76 83 90 97 102 109 114 118 119 120 121 128

2

Combined cycle power plant equipment 2.1 Scope of field work for each F class CTG 2.2 F class CTG estimating data 2.3 F class CTG installation estimate 2.4 F class CTGdequipment installation man-hours

129 129 131 133 136

vi

Contents

2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 2.30 2.31 2.32 2.33 2.34 3

Reheat double flow STGS, sheet 1 Reheat double flow STGS, sheet 2 Double flow STG estimating data Double flow STG installation estimate Reheat double flow STG installation man-hours Scope of field work for each three-wide HRSG HRSGdtriple pressure, three-wide estimate data HRSGdtriple pressure, three-wide estimate HRSGdtriple pressure; three-wide installation man-hours Scope of field work for each double wide HRSG HRSGdtriple pressure double wide estimate data HRSGdtriple pressure, double wide estimate HRSGdtriple pressure; double wide installation man-hours Scope of field work for each single wide HRSG HRSG double pressure single wide estimate data HRSG double pressure single wide estimate Single wide installation man-hours Scope of work for each single pressure MAWP HRSG HRSG single pressure double wide estimate data HRSGdsingle pressure, double wide estimate HRSGdsingle pressure; double wide installation man-hours Scope of field work for each air-cooled condenser Air-cooled condenser estimate data Air-cooled condenser installation estimate Air-cooled condenser installation man-hours Scope of field work for each surface condenser Surface condenser estimate data Surface condenser installation estimate Surface condenserdequipment installation man-hours Structural steel man hour table

Simple cycle power plant equipment 3.1 LM 6000 gas turbine generator set and SCR 3.2 Scope of field work for LM 6000 gas turbine generator 3.3 LM 6000 turbine generator estimate data 3.4 LM 6000 turbine generator installation estimate 3.5 LM 6000 turbine generator installation man-hours 3.6 Scope of field work for each selective catalytic reduction 3.7 Selective catalytic reduction estimate data 3.8 Selective catalytic reduction installation estimate 3.9 Selective catalytic reduction installation man-hours 3.10 Chiller and cooling tower estimate data 3.11 Chiller and cooling tower installation estimate 3.12 Chiller and cooling tower installation man-hours 3.13 Balance of plant equipment estimate data

137 138 139 143 148 149 150 155 161 162 163 168 173 174 175 179 183 184 185 188 192 193 194 199 206 207 208 211 214 215 217 217 218 219 221 224 224 225 228 230 231 231 232 232

Contents

3.14 3.15 4

vii

Balance of plant equipment installation estimate Balance of plant equipment installation man-hours

233 234

Refinery and hydrogen plant equipment 4.1 Steam methane reformer and pressure swing adsorbers 4.2 Scope of field work for steam methane reformer 4.3 Steam methane reformer estimate data 4.4 Steam methane reformer installation estimate 4.5 96 MMSCFD steam methane reformerdequipment installation man-hours 4.6 General scope of field work required for each pressure swing adsorbers 4.7 Pressure swing adsorber estimate data 4.8 Pressure swing adsorber equipment installation estimate 4.9 Pressure swing adsorber 4.10 Structural steel man-hour table 4.11 WHR structural steel installation estimate 4.12 WHR structural steeldstructural steel installation man-hours 4.13 Scope of field work for waste heat recovery equipment 4.14 Waste heat recovery equipment estimate data 4.15 Waste heat recovery equipment installation estimate 4.16 Equipment installation man-hours 4.17 Hydrogen plant equipment man-hour breakdown 4.18 Scope of field work for each electric static precipitator 4.19 Electric static precipitator equipment estimate data 4.20 Electric static precipitator equipment installation estimate 4.21 Electric static precipitator equipment man-hours 4.22 Oil refinery section introduction 4.23 Scope of field work for stripper unit 4.24 Stripper unit estimating data 4.25 Stripper unit installation estimate 4.26 Stripper unitdequipment installation man-hours

235 235 236 237 246

5

Compressor station 5.1 Compressor station estimate data 5.2 Compressor station installation estimate data 5.3 Compressor station equipment installation man-hours

283 284 285 286

6

Biomass plant 6.1 Equipment descriptions 6.2 Scope of field work for each 400,000 lb./hr. waste heat boiler 400,000 lb./hr. membrane wall boiler with superheater Scope of work-field erection 6.3 400,000 lb./hr. waste heat boiler estimate data 6.4 Waste heat boiler installation estimate

287 287

255 256 256 257 258 258 259 259 260 260 261 262 262 263 264 269 275 276 277 278 280 282

293 294 296

viii

Contents

6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.28 6.29 6.30 6.31 6.32 6.33 6.34 6.35 6.36 6.37 6.38 6.39 6.40 6.41 6.42 6.43 6.44 6.45 6.46 6.47 6.48 6.49

Waste heat boilerdequipment installation man-hours Scope of field work for each stoker Stoker estimate data Stoker equipment installation estimate Stokerdequipment installation man-hours Scope of field work for each economizer Economizer estimate data Economizer equipment installation estimate Economizerdequipment installation man-hours Scope of field work for each precipitator Precipitator estimate data Equipment installation estimate Precipitatordequipment installation man-hours Scope of field work for each mechanical collector Mechanical collector estimate data Equipment installation estimate Mechanical collectordinstallation man-hours Scope of field work for CO and Nox removal system CO and Nox estimate data Equipment installation estimate CO and Nox removal systemdinstallation man-hours Scope of field work for each wet scrubber Wet scrubber estimate data Wet scrubber installation estimate Wet scrubberdinstallation man-hours Scope of field work for tabular air heater modules Tubular air heater estimate data Equipment installation estimate Tubular air heater modulesdinstallation man-hours Scope of field work for stack Stack estimate data Equipment installation estimate Stackdinstallation man-hours Scope of field work for fuel feeding equipment Fuel feeding equipment estimate data Equipment installation estimate Fuel feedingdequipment installation man-hours Scope of field work for bottom ash drag system Bottom ash drag system estimate data Equipment installation estimate Bottom ash drag systemdinstallation man-hours Scope of field work for ID, OFA, FD, and spout air fan ID, OFA, FD, and spout air fan estimate data Equipment installation estimate ID, OFA, FD, and spout air fan sheet 2

298 299 299 300 301 302 302 303 303 304 304 305 305 305 306 306 306 307 307 308 308 309 309 309 310 310 310 311 311 312 312 312 312 313 313 314 314 315 315 316 316 316 318 319 320

Contents

6.50 6.51 6.52 6.53 6.54 6.55 6.56 6.57 6.58 6.59 6.60 7

ix

ID, OFA, FD, and spout air fandinstallation man-hours Scope of field work for ductwork ID, OAF, FD, under fire, and over fire ductwork estimate data Equipment installation estimate ID, OFA, FD, under fire, and over fire ductworkdinstallation man-hours Scope of field work for structural steel and boiler casing Structural steel and boiler casing estimate data Equipment installation estimate Structural steel and boiler casingdinstallation man-hours Structural steel & miscellaneous iron Biomass plant major equipment man-hour breakdown

Ethanol plant 7.1 Scope of field work for biomass handling and bagasse storage 7.2 Biomass handling and bagasse storage estimate data 7.3 Equipment installation estimate 7.4 Biomass handling and bagasse storagedequipment installation man-hours 7.5 Scope of field work for pretreatment 7.6 Pretreatment estimate data 7.7 Equipment installation estimate 7.8 Pretreatment installation man-hours 7.9 Scope of field work for viscosity reduction 7.10 Viscosity reduction estimate data 7.11 Equipment installation estimate 7.12 Viscosity reductiondequipment installation man-hours 7.13 Scope of field work for fermentation 7.14 Fermentation estimate data 7.15 Equipment installation estimate 7.16 Fermentation-equipment installation man hours 7.17 Scope of field work for distillation and dehydration sheet 1 7.18 Scope of field work for distillation and dehydration sheet 2 7.19 Distillation and dehydration estimate data 7.20 Equipment installation estimate 7.21 Scope of field work for ethanol storage and loading 7.22 Ethanol storage and loading estimate data 7.23 Equipment installation estimate 7.24 Ethanol storage and loading installation man hours 7.25 Scope of field work for chemical storage 7.26 Chemical storage estimate data 7.27 Equipment installation estimate 7.28 Chemical storage-equipment installation man hours 7.29 Scope of field work for lignin separation 7.30 Equipment installation estimate

320 320 321 321 322 323 323 324 325 325 326 327 327 327 328 328 328 330 331 332 333 333 334 334 335 336 337 338 338 339 340 342 344 345 346 346 347 348 349 350 350 350

x

Contents

7.31 7.32 7.33 7.34 7.35 7.36 7.37 7.38 7.39 7.40 7.41 7.42 7.43 7.44 7.45 7.46 7.47

Lignin separation installation man hours Scope of field work for lignin storage and handling Lignin storage and handling estimate data Equipment installation estimate Lignin storage and handling installation man hours Scope of field work for wastewater treatment Wastewater treatment estimate data Equipment installation estimate Wastewater treatment installation man hours Scope of field work for utilities Utilities estimate data Equipment installation estimate Utilities-equipment installation man hours Scope of field work for package boiler Equipment installation estimate Package boiler-equipment installation man hours Ethanol plant major equipment man hour breakdown

350 351 351 352 352 353 353 354 354 355 356 357 358 358 359 360 360

8

Geothermal power plant 8.1 Geothermal steam power plant 8.2 Scope of field work for surface condenser 8.3 Surface condenser estimate data 8.4 Surface condenser installation estimate 8.5 Surface condenser equipment installation man-hours

361 361 361 362 364 367

9

Wastewater treatment plant 9.1 Wastewater treatment plant 9.2 Screening headworks estimate data 9.3 Plant equipment installation estimate 9.4 Pumps and mixers estimating data 9.5 Pumps and mixers installation estimate 9.6 Treatment plant equipment estimate data 9.7 Treatment plant equipment installation estimate 9.8 Piping estimate data 9.9 Piping installation estimate 9.10 Concrete estimate data 9.11 Concrete installation estimate 9.12 Weir beam estimate data 9.13 Weir beam installation estimate

369 369 370 370 371 374 377 380 383 384 385 387 391 393

Equipment estimates and statistical applications to construction 10.1 Section introduction 10.2 Scope of field work for each single wide HRSG 10.3 Field erect HRSG double pressure single wide 10.4 HRSG double pressure; single wide installation man-hours

397 397 398 399 403

10

Contents

10.5 10.6 10.7 10.8

xi

Scope of field work for each 400,000 lb./h waste heat boiler Waste heat boiler installation estimate Waste heat boilerdequipment installation man-hours Statistical applications to construction

Appendix A: Formulasdareas and volumes Appendix B: Metric/standard conversions Glossary of key terms Index

404 405 408 408 419 421 423 427

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Preface

This second edition of Industrial Piping and Equipment Estimating Manual focuses on industrial process plants and enables the estimator to apply the scopes of work, estimate data tables, and estimate sheets to use methods for collecting, organizing, summarizing, presenting, and analyzing historical man-hour data. Industrial construction includes refineries, power generation, and manufacturing plants. These projects are identified by the plant process and vary in size and complexity. The construction business requires estimating methods, indexing, cost analysis, and estimating to provide detailed accurate bid proposal to handle increasing competition. Engineers and contractors use estimating methods, historical data, and man-hour tables, which are entered into the computer, that model the work of construction. The purpose of this manual is to provide a comprehensive and accurate method for compiling the piping and equipment man-hour estimates for the following process plants: Combined Cycle Power Plant Simple Cycle Power Plant Refinery and Hydrogen Plant Compressor Station Biomass Plant Ethanol Plant Geothermal Power Plant Water Treatment Plant The estimating methods in this manual will allow the experienced estimator to use the comparison method to estimate similarities and differences between the proposed and previously installed equipment and the unit quantity method will be a final check on actual man hours compared to estimate man hours. This manual does not include cost and man hours for material, equipment usage, indirect craft and supervision, project staff, warehousing, shop fabrication, overheads, and fee. The sample estimates will illustrate how to apply the estimate tables and sheets to prepare detailed direct craft man-hour estimates.

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Introduction Introduction The estimate data in this manual have been verified by measurement, project cost reports from field erection of process piping and equipment, one-cycle time studies, and the data are revised continuously due to construction design, engineering, labor skill, material, equipment, and procedures. Information for man-hour analysis is obtained from the foreman’s report. The foreman’s report is used to find the number of man-hours for a task. The report is used for cost and time control. The cost engineers and welding quality control in the field monitor and verify the work. These reports are collected for the field installed piping and equipment. From the reports and review of the specifications, codes, and drawings the cost engineer and estimator will examine the data for consistency, completeness, and accuracy. Reports are collected for similar work and the data are entered into a spreadsheet. The spread sheet prepares the data for mathematical analysis. The engineer and estimator determine the productivity rate. The rate is used for future cost analysis and estimating similar scopes of work. The estimate data are based on “standard,” which is defined as “forming a basis for comparison.” The standard unit man-hour involves these considerations: the work is being performed by a contractor who is familiar with all conditions at the job site; the project has the proper supervision; the workers are familiar with and skilled in performance of the work task; and there is an adequate supply of labor. There are clarifications and exceptions stated for the application of the data.

xvi

Introduction

Labor productivity and analysis Labor productivity is concerned with direct craft labor. Direct craft labor means the craft is working in the field erection of process piping and equipment. The man hour is defined as the amount of work performed by the average worker in 1 h. Once time values are known for a construction task, they are multiplied by the quantity (Man-Hour ¼ Time  Quantity). Time may be for 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. Examples of man-hour units: (1) HRSGdseal weld side, roof, and floor casing field seams; number of welder man-hours per lineal foot of field welding, 0.35 MH/LF (2) Welding butt weld, carbon steel, arc-uphill, WT1.0; example is 110%. Task time is 1.8 h, then normal time is (1.8  1.10) ¼1.98 h. If the worker is rated 90% then n RF