Conceptual Cost Estimating Manual, Second Edition PDF

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CONCEPTUAL COST
ESTIMATING
MANUAL
SECOND EDITION
JOHN S. PAGE
An Imprint ofElsevier
Conceptual Cost
Estimating
Manual
2nd Edition
Copyright 1984, 1996 by Elsevier. All rights reserved.

Printed in the United States of America. This book,
or parts thereof, may not be reproduced in any form without
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Library of Congress Cataloging-in-Publication Data

Page, John S.
Conceptual cost estimating manual / John S.
Page. 2nd ed.
p. cm.
ISBN 0-88415-267-7
1. Chemical plantsDesign and construction
EstimatesHandbooks, manuals, etc. I. Title.
TH4524.P34 1996
690'.54dc20 95-52313
CIP
Printed in the United States of America.
Printed on acid-free paper (oo).
Contents
Preface .................................................................................... xv
The Human Factor in Estimating .................................................. xv
Introduction .............................................................................. xvi
Section 1. Disciplines of Work .......................................... 1

Section Introduction ....................................................................... 1
Direct Cost Items ........................................................................... 1
Construction Equipment ................................................................ 3
Overhead and Indirects ................................................................. 3
Home Office Cost .......................................................................... 10
Section 2. Process Equipment ......................................... 11

Acid Coolers with Pump and Motor .............................................. 12
Equipment Cost ............................................................... 12
Erection Manhours .......................................................... 13
Activators Vibrating Bin .............................................................. 14
Equipment Cost ............................................................... 14
Erection Manhours .......................................................... 15
Aerators Mechanical .................................................................. 16
High-speed Equipment Cost ......................................... 16
High-speed Erection Manhours .................................... 17
Low-speed Equipment Cost .......................................... 18
Low-speed Erection Manhours ..................................... 19
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vi Contents
Compressors ................................................................................. 20
Air Power Synchronous Motor Driven Equipment
Cost ........................................................................ 20
Air Power Induction Motor Driven Equipment
Cost ........................................................................ 21
Air Power Synchronous and Induction Motor Driven
Erection Manhours ............................................... 22
Automotive and Industrial Service Air Equipment
Cost ........................................................................ 23
Automotive and Industrial Service Air Erection
Manhours ................................................................ 24
Centrifugal Air Plant and High-pressure
Equipment Cost ...................................................... 25
Centrifugal Air Plant and High-pressure Erection
Manhours ................................................................ 26
Industrial Air Air-cooled, Two-stage Equipment
Cost ........................................................................ 27
Industrial Air Air-cooled, Two-stage Erection
Manhours ................................................................ 28
Integral Gas Engine Four Cylinder Equipment
Cost ........................................................................ 29
Integral Gas Engine Four Cylinder Erection
Manhours ................................................................ 30
Packaged Air Single-stage, Water-cooled
Equipment Cost ...................................................... 31
Packaged Air Single-stage, Water-cooled Erection
Manhours ................................................................ 32
Reciprocating Electric Motor Driven Equipment
Cost ........................................................................ 33
Reciprocating Electric Motor Driven Erection
Manhours ................................................................ 34
This page has been reformatted by Knovel to provide easier navigation.

Contents vii
Two-stage, Two-cylinder, Water-cooled Equipment

Cost ........................................................................ 35
Two-stage, Two-cylinder, Water-cooled Equipment
Cost ........................................................................ 36
Two-stage, Two-cylinder, Water-cooled Erection
Manhours ................................................................ 37
Dryers Air .................................................................................... 38
Automatic, Refrigerated Equipment Cost ...................... 38
Automatic, Refrigerated Equipment Cost ...................... 39
Automatic, Refrigerated Erection Manhours ................. 40
Automatic, Refrigerated Erection Manhours ................. 41
Chiller Equipment Cost ................................................. 42
Chiller Erection Manhours ............................................ 43
Surge Arresters ............................................................................. 44
Hydrocarbon and Water Service Equipment Cost ......... 44
Hydrocarbon, Water, and Sewage Service
Equipment Cost ...................................................... 45
Hydrocarbon, Water, and Sewage Service Erection
Manhours ................................................................ 46
Blenders, Mixers, Packers, and Feeders ...................................... 47
Dry Material Auger and Rotary Drum Blenders
Equipment Cost ...................................................... 47
Dry Material Auger and Rotary Drum Blenders
Erection Manhours .................................................. 48
Fixed Side Mounted Mixers with Top Motors
Equipment Cost ...................................................... 49
Fixed Side Mounted Mixers with Top Motors
Plate Mounted Open Tank Mixers Equipment Cost ...... 51

viii Contents
Portable Clamp and Flanged Mounted Mixers

Equipment Cost ...................................................... 52
Flanged Top Tank Mounted and Plate Mounted Open
Tank Mixers Erection Manhours ........................... 53
Gearmotor Mixers Equipment Cost ............................... 54
Gearmotor Mixers Erection Manhours .......................... 55
Batch and Pipeline Homogenizer Mixers Equipment
Cost ........................................................................ 56
Batch and Pipeline Homogenizer Mixers Erection
Manhours ................................................................ 57
High-intensity Mixers Equipment Cost .......................... 58
High-intensity Mixers Erection Manhours ...................... 59
Bag and Rigid Container Vibrating Packers
Equipment Cost ...................................................... 60
Bag and Rigid Container Vibrating Packers Erection
Manhours ................................................................ 61
Boilers ............................................................................................ 62
Package Type Equipment Cost .................................... 62
Package Type Erection Manhours ................................ 63
Boiler Stacks Equipment Cost ...................................... 64
Boiler Stacks Erection Manhours .................................. 66
Classification Equipment ............................................................... 67
Cone Pelletizers Equipment Cost ................................. 67
Cone Pelletizers Erection Manhours ............................. 68
Turbo-screen Cyclone and Pressure Sifter
Equipment Cost ...................................................... 69
Turbo-screen Cyclone and Pressure Sifter Erection
Manhours ................................................................ 70
Rotary Screens Equipment Cost ................................... 71
Rotary Screens Erection Manhours .............................. 72

Contents ix
Condensers and Receivers ........................................................... 73

Vertical Tube Surface Equipment Cost ......................... 73
Vertical Tube Surface Erection Manhours .................... 74
Conveying Equipment ................................................................... 75
Conveyors Open Belt Equipment Cost ...................... 75
Conveyors Open Belt Erection Manhours .................. 76
Conveyors Belt Enclosed with Walkway
Equipment Cost ...................................................... 77
Conveyors Belt Enclosed with Walkway Erection
Manhours ................................................................ 78
Conveyors Spaced, Bucket Elevators, Belt-driven
Equipment Cost ...................................................... 79
Conveyors Spaced, Bucket Elevators, Chain Driven
Equipment Cost ...................................................... 80
Conveyors Spaced, Bucket Elevators, Chain- or
Belt-driven Erection Manhours ............................. 81
Conveyors Continuous, Bucket Elevators, Belt-
driven Equipment Cost ......................................... 82
Conveyors Continuous, Bucket Elevators, Chain-
driven Equipment Cost ......................................... 83
Conveyors Continuous, Bucket Elevators, Belt- or
Chain-driven Erection Manhours .......................... 84
Screw Conveyors Equipment Cost ............................... 85
Screw Conveyors Erection Manhours ........................... 86
Dryers Drum ............................................................................... 87
Atmospheric Single Drum Type Equipment Cost .......... 87
Atmospheric Double and Twin Drum Types
Equipment Cost ...................................................... 88
Atmospheric Single, Double, and Twin Drum Types

x Contents
Dryers Vacuum ........................................................................... 90

Conical Rotating Equipment Cost ................................. 90
Double Drum and Rotary Equipment Cost .................... 91
Conical Rotating and Double Drum Erection
Manhours ................................................................ 92
Rotary Carbon and Stainless Steel Erection
Manhours ................................................................ 93
Dust Collectors .............................................................................. 94
Centrifugal Scrubbers High Capacity, Hot-rolled
Steel Equipment Cost .......................................... 94
Centrifugal Scrubbers Medium Capacity, Hot-rolled
Centrifugal Scrubbers High Capacity, Stainless
Centrifugal Scrubbers Medium Capacity, Stainless
Centrifugal Scrubbers High- and Medium-capacity,
Hot-rolled and Stainless Steel Erection
Manhours ................................................................ 98
Cyclones Hot-rolled Steel Equipment Cost ................ 99
Cyclones Stainless Steel Equipment Cost ................. 100
Cyclones Hot-rolled and Stainless Steel Erection
Manhours ................................................................ 101
Filter Cartridge or Tube House Filters Equipment
Cost ........................................................................ 102
Filter Cartridge or Tube House Filters Erection
Manhours ................................................................ 103
Packaged Motor Operated Blowers Equipment Cost .... 104
Packaged Motor Operated Blowers Erection
Manhours ................................................................ 105

Contents xi
Fans and Blowers .......................................................................... 106

Blowers Rotary Equipment Cost ................................ 106
Blowers Rotary Erection Manhours ........................... 107
Centrifugal Fans Equipment Cost ................................. 108
Centrifugal Fans Erection Manhours ............................ 109
Cast Iron Industrial Fans Equipment Cost .................... 110
Cast Iron Industrial Fans Erection Manhours ................ 111
Heavy Sheet Steel Industrial Fans Equipment Cost ...... 112
Heavy Sheet Steel Industrial Fans Erection
Manhours ................................................................ 113
Feeders ......................................................................................... 114
Heavy Duty Belt Equipment Cost .................................. 114
Heavy Duty Belt Erection Manhours ............................. 115
Pre-wetting Dry Chemical Equipment Cost ................... 116
Pre-wetting Dry Chemical Erection Manhours .............. 117
Pre-wetting Dry Chemical, Package Units Equipment
Cost ........................................................................ 118
Pre-wetting Dry Chemical, Package Units Erection
Manhours ................................................................ 119
Dry Material, Vibrating Equipment Cost ........................ 120
Dry Material, Vibrating Erection Manhours ................... 121
Dry Material, Volumetric and Gravimetric Equipment
Cost ........................................................................ 122
Dry Material, Volumetric and Gravimetric Erection
Manhours ................................................................ 123
Dry Material, Wing and Conveyor Equipment Cost ....... 124
Dry Material, Wing and Conveyor Erection
Manhours ................................................................ 125
Filters ............................................................................................. 126
Gravity Filtration Units Total Material Cost .................... 126

xii Contents
Gravity Filtration Units Total Unit Installation

Manhours ................................................................ 127
Pressure Type Equipment Cost .................................... 128
Pressure Type Erection Manhours ............................... 129
Rubber-lined Equipment Cost ....................................... 130
Rubber-lined Erection Manhours .................................. 131
Vibrating Screens Equipment Cost ............................... 132
Vibrating Screens Erection Manhours ........................... 133
Flakers ........................................................................................... 134
Cooling Drum Equipment Cost ..................................... 134
Cooling Drum Erection Manhours ................................. 135
Generators ..................................................................................... 136
Inert Gas Equipment Cost ............................................ 136
Inert Gas Erection Manhours ........................................ 137
Gas Pulsation Dampers ................................................................ 138
Dampers Equipment Cost ............................................. 138
Dampers Erection Manhours ........................................ 139
Heaters .......................................................................................... 140
Deaerating Feedwater Equipment Cost ........................ 140
Deaerating Feedwater Erection Manhours ................... 141
Gas-, Oil-, and Dual-fired Equipment Cost .................... 142
Gas-, Oil-, and Dual-fired Erection Manhours ............... 143
Heat Exchangers ........................................................................... 144
Hairpin Type Equipment Cost ....................................... 144
Hairpin Type Erection Manhours .................................. 145
Shell and Tube, Fixed Tube, and U-tube Equipment
Cost ........................................................................ 146
Shell and Tube, Fixed Tube, and U-tube Erection
Manhours ................................................................ 147

Contents xiii
For Heating Water Equipment Cost .............................. 148

For Heating Water Equipment Cost .............................. 149
For Heating Water Erection Manhours .......................... 150
Pumps ........................................................................................... 151
Centrifugal Single-stage, Vertical Split Case
Equipment Cost ...................................................... 151
Centrifugal Single-stage, Horizontal Split Case
Equipment Cost ...................................................... 152
Centrifugal Single-stage, ANSI and API 610
Equipment Cost ...................................................... 153
Centrifugal Two-stage and Multi-stage Equipment
Cost ........................................................................ 154
Centrifugal Single-stage, in-line Equipment Cost ....... 155
Gear Light and Heavy Duty Equipment Cost ............. 156
Sewage Horizontal and Vertical, 1,750 rpm
Equipment Cost ...................................................... 157
Sewage Horizontal, 1,750 rpm Equipment Cost ......... 158
Sewage Horizontal and Vertical, 1,150 rpm
Equipment Cost ...................................................... 159
Sump and Plunger Equipment Cost .............................. 160
Vertical Turbine Single and Multi-stage Equipment
Cost ........................................................................ 161
Centrifugal Single, Two, Multi, and in-line Single
Stage Erection Manhours ..................................... 162
Gear Light and Heavy Duty Erection Manhours ......... 163
Sewage Horizontal and Vertical Erection
Manhours ................................................................ 164
Sump and Plunger Erection Manhours ......................... 165
Vertical Turbine Single and Multi-stage Erection
Manhours ................................................................ 166

xiv Contents
Reactors ........................................................................................ 167

Glass-lined, Agitated, Jacketed Equipment Cost .......... 167
Glass-lined, Agitated, Jacketed Erection Manhours ...... 168
Steam Jet Ejectors ........................................................................ 169
Single-stage Equipment Cost ....................................... 169
Single-stage Erection Manhours ................................... 170
Gas Scrubbers .............................................................................. 171
High-energy Venturi Type Equipment Cost ................... 171
High-energy Venturi Type Erection Manhours .............. 172
Separators ..................................................................................... 173
Vane Type Equipment Cost .......................................... 173
Vane Type Equipment Cost .......................................... 174
Vane Type Erection Manhours ..................................... 175
Vibrating Equipment Cost ............................................. 176
Vibrating Erection Manhours ........................................ 177
API Type Oil/Water Equipment Cost ............................. 178
API Type Oil/Water Erection Manhours ......................... 179
Size Reduction Equipment ............................................................ 180
Crushers Equipment Cost ............................................. 180
Crushers Erection Manhours ........................................ 181
Impact Breakers Equipment Cost ................................. 182
Impact Breakers Erection Manhours ............................. 183
Reversible and Non-reversible Hammermills
Equipment Cost ...................................................... 184
Reversible and Non-reversible Hammermills Erection
Manhours ................................................................ 185
Ring Type Granulators Equipment Cost ....................... 186
Ring Type Granulators Erection Manhours ................... 187

Contents xv
Water Softener System ................................................................. 188

Hot Process Water Total Process Material and
Equipment Cost ...................................................... 188
Hot Process Water Total System Installation
Manhours ................................................................ 189
Tanks ............................................................................................. 190
API Cone Roof Storage Subcontract Installed Price ..... 190
API Cone Roof Storage Subcontract Installed Price ..... 191
API Floating Roof Storage Subcontract Installed
Price ....................................................................... 192
ASME Spheres Subcontract Installed Price .................. 193
Fintube Heating Coils Equipment Cost ......................... 194
Fintube Heating Coils Erection Manhours ..................... 195
Fired Heaters, Fintube Type Equipment Cost ............... 196
Fired Heaters, Fintube Type Erection Manhours .......... 197
Suction and Line Type Fuel Oil Heaters Equipment
Cost ........................................................................ 198
Suction and Line Type Fuel Oil Heaters Erection
Manhours ................................................................ 199
Propane Storage Equipment Cost ................................ 200
Propane Storage Erection Manhours ............................ 201
Vessels .......................................................................................... 202
Shop Fabricated Average Weight, Pounds per
Linear Foot .............................................................. 202
Horizontal, Shop Fabricated Cost per Ton .................... 203
Vertical with Angle Legs, Shop Fabricated Cost per
Ton ......................................................................... 204
Vertical with Anchor Ring and Skirts, Shop Fabricated
Cost per Ton ........................................................ 205
Tray Rings, Shop Fabricated Cost Each ....................... 206

xvi Contents
Column Trays, Shop Installation Cost Each .................. 207

Demisting Pads, Shop Installation Cost Each ............... 208
Shop Stress Relief Cost per Ton .................................. 209
Removable Type Trays Material Cost Each .................. 210
Removable Type Trays Material Cost Each .................. 211
Demisting Pads Material Cost Each ............................. 212
Demisting Pads Material Cost Each ............................. 213
Vessels Field Erection Manhours per Ton .................... 214
Tray Installation Field Erection Manhours Each ............ 215
Demisting Pads Field Erection Manhours Each ............ 216
Section 3. Site Preparation ............................................... 217

Area Clear and Grub Manhours per Acre .................................. 217
Area Cuts and Fills Manhours and Material Cost per Acre ....... 218
Section 4. Site Improvements ........................................... 219

Security Fencing ............................................................................ 219
Railroad and Spurs ........................................................................ 219
Tank Dikes ..................................................................................... 220
Concrete Trenches ........................................................................ 220
Drainage ........................................................................................ 221
Catch Basins and Manholes ......................................................... 221
Road Culverts ................................................................................ 221
Section 5. Concrete ........................................................... 222

Earth Backfill Materials Cubic Yards .......................................... 223
Excavation and Backfill Labor Manhours .................................. 224

Contents xvii
Earthwork for Equipment Structures, Pipe Racks, and

Sleepers Labor Manhours ................................................ 225
Concrete Required for Equipment, Equipment Structures,
Pipe Racks and Sleepers Cubic Yards ............................ 226
Forms, Reinforcing, Embedments and Concrete Material
Cost ...................................................................................... 227
Forms, Reinforcing, Embedments and Concrete Installation
Manhours ............................................................................. 228
Nonshrink, Nonmetallic Grout Average Square Feet ................ 229
Nonshrink, Nonmetallic Grout Material Cost ............................. 230
Nonshrink, Nonmetallic Grout Installation Manhours ................ 231
Fireproofing Structural Steel Total Material Cost ....................... 232
Fireproofing Structural Steel Installation Manhours .................. 233
Fireproofing Vessel Skirts Material Cost .................................... 234
Fireproofing Vessel Skirts Erection Manhours .......................... 235
Section 6. Structural Steel and Miscellaneous Iron ........ 236

Structural Steel Tons Required .................................................. 237
Miscellaneous Iron Tons Required ........................................... 238
Pipe Rack Steel Tons Required ................................................. 239
Structural Steel Equipment Supports and Structures
Material Cost ........................................................................ 240
Structural Steel for Pipe Racks Miscellaneous Iron for
Equipment Material Cost ................................................... 241
Structural Steel and Miscellaneous Iron Equipment,
Equipment Supports and Structures, and Pipe Racks
Erection Manhours ............................................................... 242

xviii Contents
Section 7. Buildings ........................................................... 243

Building Types and Descriptions ................................................... 243
Building Materials Cost per Square Foot ................................... 245
Building Erection Manhours per Square Foot ............................ 246
Section 8. Piping ................................................................ 247

Shop Furnish and Fabricate Pipe and Fittings ............................. 248
Quantities Required for Pieces of Equipment .................. 248
Cost for Pieces of Equipment .......................................... 249
Field Furnish, Fabricate and Erect Pipe, Fittings and Valves ...... 251
Quantities Required for Pieces of Equipment .................. 251
Material Cost for Pieces of Equipment ............................. 252
Field Erect Shop Fabricated Spools Manhours for Pieces of
Equipment ............................................................................ 256
Field Furnish, Fabricate and Erect Pipe, Fittings, and Valves
Labor Manhours for Pieces of Equipment ........................ 257
Miscellaneous Pipe Items Material Cost for Pieces of
Equipment ............................................................................ 259
Miscellaneous Pipe Items Total Manhours for Pieces of
Equipment ............................................................................ 260
X-ray and Stress Relieving Total Subcontract Cost for
Pieces of Equipment ............................................................ 261
Section 9. Electrical ........................................................... 262

Electrical Power Material Cost ................................................... 263
Electrical Power Installation Manhours ...................................... 264
Electrical Lighting Material Cost ................................................. 265

Contents xix
Electrical Lighting Installation Manhours ................................... 266

Miscellaneous Instrumentation Material Cost ............................ 267
Miscellaneous Instrumentation Installation Manhours .............. 268
Section 10. Instrumentation ................................................ 269

Instruments Total Number of Instruments Required ................. 270
Instruments Total Material Cost ................................................. 271
Instruments Total Instrument Installation Manhours ................. 272
Control Valves Total Material Cost ............................................ 273
Standards, Tray Supports, Trays, Tubes, and Tube Bundles
Total Material Cost ............................................................ 274
Standards, Tray Supports, Trays, Tubes, and Tube Bundles
Total Installation Manhours ............................................... 275
Section 11. Insulation .......................................................... 276

Insulating Material Total Square Feet ........................................ 277
Insulating Material for Equipment Total Material Cost ............... 278
Insulating Material for Piping Total Material Cost ..................... 279
Insulating Labor for Piping and Equipment Total
Manhours ............................................................................. 280
Section 12. Painting ............................................................. 281

Painting Equipment Square Feet Area ................................... 282
Painting Structural Steel and Piping Square Feet Area ......... 283
Painting Miscellaneous and Pipe Rack Steel Square Feet
Area ...................................................................................... 284
Painting Equipment Total Material Cost ................................. 285

xx Contents
Painting Equipment Total Manhours ...................................... 286

Painting Structural Steel Total Material Cost .......................... 287
Painting Structural Steel Total Manhours ............................... 288
Painting Piping Total Material Cost ......................................... 289
Painting Piping Total Manhours .............................................. 290
Painting Miscellaneous and Pipe Rack Steel Total
Material Cost ........................................................................ 291
Painting Miscellaneous and Pipe Rack Steel Total
Manhours ............................................................................. 292
Section 13. Paving ............................................................... 293

Asphalt Pavement Total Subcontract Price ............................... 294
Concrete and Gravel Pavements Total Material Cost ............... 295
Concrete and Gravel Pavements Total Manhours .................... 296
Section 14. Proratables ....................................................... 297

Proratable Materials Total Material Cost ................................... 298
Proratable Labor Total Manhours .............................................. 299
Section 15. Construction Equipment ................................. 300

Equipment Base Rental or Purchase Cost Fuel, Oil, Grease
and Supplies Cost ................................................................ 301
Equipment Service Labor Total Manhours ................................ 302
Section 16. Overhead and Indirects ................................... 303

Engineering and Supervision Personnel Total Manhours ......... 304

Contents xxi
Office Personnel Total Manhours .............................................. 305

Other Indirect and Temporary Construction Labor Total
Manhours ............................................................................. 306
Temporary Construction Materials Total Cost ........................... 307
Payroll Burdens and Benefits and Other Indirect Materials
Total Cost ............................................................................. 308
Section 17. Home Office Cost ............................................. 309

Engineering Design Manhour Range Allowance per Piece
of Equipment ........................................................................ 310
Engineering Design Other Cost as a Percent of
Engineering Labor Dollars ................................................... 314
Engineering Design Manhour Spread Percentages .................. 315
Section 18. Ratio Estimating Factors ................................. 316

Refinery Process Systems Direct Cost Percentages ................ 318
Liquid Type Chemical Plant Direct Cost Percentages .............. 319
Solid Type Chemical Plants Direct Cost Percentages .............. 320
Liquid/Solid Type Chemical Plants Direct Cost
Percentages ......................................................................... 321
Liquid High-pressure Chemical Plants Direct Cost
Percentages ......................................................................... 322
Liquid High-alloy Chemical Plants Direct Cost
Percentages ......................................................................... 323
Construction Equipment as a Percent of Direct Field Labor ........ 324
Overhead and Indirects as a Percent of Direct Field Labor ......... 324
Home Office Services as a Percent of Total Cost and Indirect
Cost ...................................................................................... 324

xxii Contents
Section 19. Estimate Adjustments ..................................... 325

Design Allowance .......................................................................... 325
Quantity Allowance ........................................................................ 325
Escalation ...................................................................................... 325
Contingencies ................................................................................ 326
Risk ................................................................................................ 326
Fees ............................................................................................... 326

PREFACE
Long has been the need for a manual on conceptual cost estimating that allows
the construction industry and the engineering/management staff of chemical, refin-
ery, and industrial plants to arrive at a reasonable cost for a specified facility. Sim-
ply to rely on past records and say that a certain type plant will cost ten dollars per
pound produced, and the product can be sold for fifteen dollars per pound, by no
means justifies the construction cost of the plant. Management of all organizations
concerned demands more reasoning and is certainly within its rights to do so.
When a project is in its planning and evaluating stages, the cost of a complete
design and definitive estimate would be, in most cases, too great to justify the
design and estimate. Therefore, it becomes apparent that a less expensive method
is needed to determine the feasibility of the plant in mind. By using a very moder-
ate flow sheet design, specifications, and/or equipment lists, by properly applying
man-hours, dollars, percentage values (as are shown throughout this manual in
graph and table form), and construction indexes, and by considering other items
outlined in the Introduction, a total cost very close to the as-built cost of a com-
plete plant should be obtainable for any location in the world.
The Human Factor in Estimating

In this high-tech world of sophisticated software packages, including several for
labor and cost estimating, you might wonder what an estimating manual offers that
a computer program does not. The answer is the human factor. In preparing a com-
plete estimate for a refinery, petrochemical, or other heavy industrial project one
often confronts 12-18 major accounts, and each account has 5-100 or more sub-
accounts, depending on the project and its engineering design. While it would seem
that such numerous variables provide the perfect opportunity for computerized
algorithmic solution, accurate, cost-effective, realistic estimating is still largely a
function of human insight and expertise. Each project has unique aspects that still
require the seasoned consideration of an experienced professional, such as gener-
al economy, projects supervision, labor relations, job conditions, construction
equipment, and weather, to name a few.
Computers are wonderful tools. They can solve problems as no human can, but
I do not believe construction estimating is their forte. I have reviewed several con-
struction estimating software packages and have yet to find one that I would com-
pletely rely on. Construction estimating is an art, a science, and a craft, and I rec-
ommend that it be done by those who understand and appreciate all three of these
facets. This manual is intended for those individuals.
John S. Page
INTRODUCTION
This manual contains two methods of conceptual estimating for determining the bud-
get amount or estimated cost to design and construct refineries, chemical/petrochemi-
cal, and some other types of industrial plants.
Method one, when properly applied, produces a semi-definitive conceptual estimate
with an accuracy of 10%.
Method two uses conceptual ratio estimating, and based on the known equipment
material dollar value and the application of weighted percentage costs for all other
items, it produces an estimate with an accuracy of 30%.
The information required and procedures to follow for using these two methods of
estimating are defined later in this introduction.
All equipment and material dollar graph and tables throughout this manual are based
on average cost as of January 1,1996.
Due to the ever-changing economic conditions, the use of what is known throughout
the industry as indices must be considered and applied against all equipment and mate-
rial graphs and tables. This will result in a more realistic equipment and material value
for a project to be designed and constructed at some future date. Indices are simply
numbers for a time frame indicating a percentage of change in regard to a relative cost
of a base time frame. There have been many pro and con discussions as to the use of
indices; however, they are still the only means for achieving an acceptable estimate
where limited information and time are available.
There are several indices from which one might choose. I favor the Nelson Refinery
(Inflation) Index, which appears in the first weekly edition of each month in the Oil and
Gas Journal. The engineer/estimator may wish to use other indices that he is more
familiar with and has more confidence in. Should this be the case, it is to be recognized
that as far as this manual is concerned January 1, 1996 is equal to 100.
All labor manhour graphs and tables are based on an average productivity of 70%. The
engineer/estimator must determine the labor productivity he feels he can achieve for
each project and may acjjust the graph and table manhours as may be required. Major
items that one should consider in determining productivity are:
1. General Economy
2. Project Supervision
3. Labor Relations
4. Job Conditions
5. Construction Equipment
6. Weather
In determining the dollar rate to apply against the estimated manhours the engi-
neer/estimator should first establish weighted composite crew rates. This is simply the
listing by craft of the various personnel required for a crewsuch as general foreman,
foreman, craftsmen, and apprentices/helpersand the weighted percentage of their
time that will be devoted to the crew. The weighted percentage of each classification
multiplied by the hourly rate for that classification will result in the weighted hourly rate
for each. The sum of all weighted rates will equal the composite crew hourly rate. The
total percent of all crew personnel is to equal 100. Using the composite crews and rates,
activity crews and rates are to be formed. List the composite crew rates and the weight-
ed percent of time each crew will be devoted to the activity. The weighted percent of
each composite crew multiplied by the weighted composite crew rate will result in the
weighted hourly activity rate for that crew. The sum of all weighted crew rates for the
activity will equal the hourly weighted activity rate. The total percent of all composite
crew personnel is to equal 100. See Section One for description of disciplines of work
to determine activity crew personnel needed.
All manhour tables and graphs include the total manhours, based on 70% productivi-
ty, to complete the unit of work as listed.
All equipment and material dollar graphs and tables are based on cost as of January
1, 1996, and include the total unit equipment or material cost as outlined.
All graphs and tables that reflect shop fabrication, packaged units, and subcontract-
ed items include the total cost of labor, material, overhead and profit of the supplier, and
vendor or subcontractor.
If the project under consideration is to be located in an area outside the continental
forty-eight states, the engineer/estimator must consider other items not covered in this
manual. Additives for any or all of the following items may be required and since their
costs vary widely for different parts of the world, they must be researched individually
for each foreign project.
1. Mobilization and demobilization of personnel and equipment
2. Foreign differential labor pay
3. Permits, licenses, fees, duties
4. Load out, tie down and material handling
5. Transportation and ocean or air freight
6. Camp, family quarters,fieldoffice, and storage facilities
7. Rest and recreation for personnel
Method OneAccuracy Level of 10%

A method one, semi-definitive conceptual estimate is defined as one that will produce
major discipline quantities, manhours and labor, material, subcontract and total dollars
for their cost. As an example, using concrete as a major discipline of work, and apply-
ing this method, the total cubic yards of concrete for equipment foundations would be
the result. Based on the total cubic yards of concrete, all inclusive of foundation earth-
work, forms, reinforcing steel, embedments,finishing,etc., the total manhours and cost
would be achieved. With the overall results of all major disciplines of work the project
can be scheduled and fast-track cost-controlled until such time as a total definitive esti-
mate is available.
To achieve a degree of accuracy of 10% the following information will be required.
1. Plant capacity, product form, basic process, and raw material
2. Total general specifications
3. Plant location (site conditions)
4. Preliminary soils report with foundation recommendations
5. Plot plan and equipment arrangements.
6. P. & I.D.'s. (mechanical flow sheets)
7. Equipment list
8. Buildings listing type, size, and description
This same type estimate can be assembled with far less information than that listed
above but the degree of accuracy, in all probability would be less than that stated.
Method TwoAccuracy Level of 30%

A method two, ratio conceptual estimate is defined as one that is based on the known
total process equipment material cost and that applies weighted percentages against
that cost to achieve the cost of all other major disciplines of work.
Once the cost of all major disciplines of work has been established, quantities and
manhours can be achieved by dividing the material dollars by the pre-established unit
dollar rate, as outlined in the graphs and tables, and the labor dollars by a pre-estab-
lished composite activity rate.
With the established quantities and manhours the project can be scheduled and fast-
track cost-controlled until such time as a more definitive type estimate is available.
To achieve a degree of accuracy of 30%, the following information will be required.
1. Plant capacity, product form, basic process, and raw material
2. Knowledge of general specifications
3. Plant location (site conditions)
4. Equipment list (priced out)
In assembling a method one or two estimate it should be recognized that in the round-
ing off and averaging of material and labor cost and the application of average indices,
a certain degree of accuracy is lost insofar as the individual item costs are concerned.
However, it is believed that the overall estimate is not seriously affected by this because
the items tend to average each other out.
I sincerely hope the foregoing will enable the engineer/estimator engaged in this type
work to turn out more realistic conceptual estimates and assist in the elimination of
much guesswork.
Section 1
DISCIPLINES OF WORK
The following is a broad description of the major items included in the

various disciplines of work as outlined within this manual.
It should be recognized that all items listed will not necessarily be re-
quired for a given project. There may also be other items for a specific
project that are not included. Should this occur, the estimator should give
consideration to these items and add or deduct accordingly.
Direct Cost Items
1. Process EquipmentThe equipment cost, labor, material and subcon-

tracts necessary to set and erect or install the process equipment in
the final position and condition for mechanical operation.
2. Site PreparationAU general preparation of the plant site for con-
struction including, but not necessarily limited to, clearing, rough
grading, cut, fill, borrow, disposal, soil stabilization and finish grad-
ing.
3. Site ImprovementsIncludes items of work that provide permanent
improvements to the plant site, such as drainage ditches, culverts,
storm drain pipe, canals, dikes, all base materials for roads, parking
lots, and railroads including ballast, railroads, and fencing. Pave-
ments for roads, process areas and parking areas are included under
"Discipline, Paving."
4. ConcreteAll earthwork, forms, reinforcing steel, miscellaneous
embedded items and placing, finishing and curing of concrete for
equipment foundations and equipment structures are included here.
All building concrete including foundations is included under "Disci-
pline, Buildings."
5. Structural SteelAll cost of procuring, fabricating, and erecting
structural and miscellaneous steel, not embedded, for framed struc-
tures, equipment supports, equipment platforms, walkways, ladders,
handrails and pipe supports. Steel for buildings is included under
"Discipline, Buildings"
6. BuildingsAU cost of buildings including earthwork, foundations and
other concrete, total superstructure, HVAC, plumbing and utility pip-
ing to five feet outside of building, insulation, electrical, painting, and
all architectual finishes.
7. Underground PipingAU project underground piping serving the
project including fire water loops and their components, water lines
and special process lines.
8. Above Ground PipingIncludes the fabrication and erection of all
above ground process pipe, valves and fittings required for plant op-
eration. Installation only of relief valves, control valves, and orifice
fittings for instrumentation are also included. The material cost of
these items is included under "Discipline, Instrumentation."
9. Underground ElectricalAll labor and material for underground
power and lighting, ducts, conduit, wire, cable, etc. Also includes
earthwork and concrete for embedments.
10. Above Ground ElectricalAU items required for the complete above
ground power and lighting systems for the total project, excluding
buildings. Also includes the installation of all electrical instruments
and their hook-up.
11. InstrumentationIncludes material and labor cost of instrumenta-
tion work delineated as follows:
Material cost includes instruments, control valves, relief valves,

control panels, meter runs, orifice fittings and all other instrument
items plus the tubing, tube bundles, and tray materials required to
install these items.
Labor cost includes the installation of the above except as noted.
Labor cost to install relief and control valves and orifice fittings is
included under Above Ground Piping. Labor cost to install electri-
cal hook-up is included under "Above Ground Electrical."
All header piping labor and material costs are included under
"Above Ground Piping."
12. InsulationAU labor and material cost of insulation, refractories, and

linings for process equipment and piping. Building insulation is in-
cluded with buildings.
13. PaintingIncludes all preparation and protective coating of surfaces
with paint and/or epoxy for the total project excluding buildings.
14. PavingIncludes the furnishing and placing of concrete, asphalt, or
gravel used for the final surfacing of roads, sidewalks, parking areas,
and process work areas as required.
15. ProratablesIncludes the labor and material cost for daily area clean
up, all required scaffolding and final test, startup, and pre-commis-
sioning assistance.
Construction Equipment
1. Rental or PurchaseCost of rental or purchase of construction equip-

ment required to construct the project. Does not include small tools.
2. Service LaborAU labor required to service and maintain the con-
struction equipment. Does not include the operation of the equipment
when working. Operators are included in the Direct Account Labor.
3. Fuel, Oil, Grease, SuppliesIncludes the cost of all fuels, lubricants,
and supplies required to operate and maintain the construction equip-
ment.
Overhead and Indirects
The following is a comprehensive list of inclusions, and the scope of the

individual project will dictate the actual item requirements.
Indirect Labor (Except for Temporary Facilities Labor)

AU or part of the items described below are used to establish costs for:
Salaried indirect
Office hourly indirects
Field hourly indirects
The distribution will vary depending upon the type of project, local la-
bor practices, and contractor preferences.
Description To Include
Engineering salaries- Civil, cost, electrical, general, mechani-
estimating cal and structural estimating salaries.
Engineering salaries- Project chief engineer; assistant project
field technical support chief engineer; chief field engineer; civil,
electrical, mechanical, structural, field,
staff, office, piping, instrument engi-
neers; coordinators; engineering drafts-
men; party chiefs, instrument men,
chainmen, rodmen, and laborers tempo-
rarily assigned to a field party perform-
ing general layout work.
Watchmen and Security supervisor, security coordina-
Janitorslabor tor, guards, watchmen, janitors, labor
for supplying drinking water. Note: Does
not include contract security personnel.
Holiday pay Pay for holidays not worked. Personnel
covered by overhead and indirect esti-
mate only.
Salariesoffice clerical Administrative clerks, office clerks, and
secretaries.
Quality assurancelabor Chief construction inspector, construc-
tion inspectors, welding inspector, piping
inspector, electrical inspector, boiler in-
spector and civil inspector.
Salariessubcontract Salaries for subcontract coordinators.
administration
Salariescost engineering Salaries for cost/schedule supervisor,
chief field cost engineer and cost engi-
neers.
Salariesscheduling and Salaries for chief field scheduler and
planning planner/schedulers.
Salariestechnical clerks Salaries for technical clerical personnel.
Material control labor Material control coordinators and mate-
rial control personnel assigned to imple-
ment and follow-up the material control
program.
Job payroll labor for loading, unloading,
and transporting from facilities to proj-
ect construction area tools and construc-
tion equipment, temporary facilities, etc.
Move in/outlabor Move-in is defined as assembly of tools
and construction equipment at jobsite.
Move-out is the return of tools and con-
struction equipment to other approved
destination, in the immediate area of the
project.
Wages paid to hourly employees during a
temporary period when work is stopped.
Also wages paid to craftsmen for voting
Non-productive labor
in accordance with union or government
regulations. Welding test labor and jury
pay differential. Note: Work stoppage
due to weather and show-up time are
considered in productivity factors used
elsewhere.
Safety and medical Safety supervisor, safety inspectors, and
expenselabor medics.
Salariesoffice Chief accountant, accountants, book-
keepers, invoice auditors, expeditors,
chief timekeeper, timekeepers, person-
nel manager, assistant personnel man-
ager, personnel interviewer, data con-
trollers, data entry operators, purchas-
ing agents, and buyers.
Salariessupervision Project manager, general superinten-
dent, craft superintendents, area super-
intendents, assistant project manager,
assistant superintendents, administra-
tive manager, office manager, area coor-
dinators and master mechanic.
Sick pay Wages paid overhead and indirect em-
ployees only for authorized absence due
to personal illness, as approved by proj-
ect construction manager.
Warehouse salaries Warehouse supervisor, assistant ware-
house supervisor, warehousemen, tool-
room attendants, warehouse laborers-
assigned full time to warehouse opera-
tion. Note: Must be on job payroll only.
Temporary Construction Facilities (Labor and Material)
Temporary buildings and Labor only for construction or erection,
utilitieslabor maintenance and dismantling of the tem-
porary facilities, in accordance with but
not limited to the following: Roads,
ditches, bridges, storage areas, parking
lots, fencing, buildings, water system,
sanitary system, power distribution, tel-
ephone and communications systems,
and plant air system. Note: Does not in-
clude construction camp, quartering or
catering facilities.
Temporary buildings and Material and supplies and maintenance
utilitiesmaterial and for construction and dismantling of the
supplies temporary facilities in accordance with
but not limited to the following. Also in-
cludes rental of temporary field offices
and warehouses, roads, ditches, bridges,
storage areas, parking lots, fencing,
buildings, water system, sanitary sys-
tem, power distribution, telephone and
communications systems, and plant air
system. Note: Does not include construc-
tion camp, quartering or catering facili-
Labor Burdens and Overhead Personnel Benefits

Description Tb Include
Retirement and savings Actual cost fixed by the appropriate ac-
plan (for overhead and counting office. Note: Does not include
indirect personnel only) any like or similar item which is a part of
a union fringe benefit.
Insuranceemployees' Direct premium charges only. Note: Does
life and hospitalization (for not include any like or similar item
overhead and indirect which is a part of a union fringe benefit.
personnel only)
InsuranceW/C, B/I, and Premium expense based on payrolls.
P/D Limits conform to the requirements for
the state as specified in the contract.
Taxespayroll FICA and Medicare, state unemploy-
ment insurance and federal unemploy-
ment insurance.
Vacation pay (for Actual cost for overhead and indirect
overhead and indirect personnel only based on gross payroll as
personnel only) billed by the appropriate Accounting Of-
fice. Note: Does not include any like or
similar item which is a part of a union
fringe benefit.
Small Tool and Consumables
Description TD Include
Construction supplies This account should include items that

are consumed and, by their use, directly
related to construction; for example,
sandpaper, rope, chalk, soapstone,
emery paper grinding wheels, moil
points, saw blades, padlocks, threading
dies, drill bits and reamers, rags, brooms
and mops, air and water hose for general
use.
Small tools (in accordance Purchase or rental of hand tools, power
with contract limits) operated hand tools, etc. Rental or re-
pair parts for such tools will be included
in this account. This account includes mi-
nor equipment such as small pumps to
3", vibrators, light plants (800 watt-
3,000 watt), chain saws, pipe threaders,
tar pots, small, sand blasting machines,
air and chain hoists.
Workmen's supplies This cost will include items that are, by
their use, directly beneficial to and for
the convenience of workmen; for exam-
ple, towels, toilet paper, drinking cups,
ice drinking water, hard hats, protective
clothing, gloves, boots, salt tablets, soap,
drinking water barrels or containers,
safety shoes, and work shoes. Credit is
to be received for sales by payroll deduc-
tion for items charged here.
Other Indirects
Advertising Classified ads, public advertisements.
Bond premiums Bid bonds, performance bonds, mainte-
nance bonds, and fidelity bonds.
Communications and Telephone, telegraph, teletype, postage,
postage radio rental or communications system
rented from a third party. Include data
lines and couplers.
Containers Deposits for returnable containers and
reels.
Dues Membership dues for clubs and profes-
sional organizations, for overhead and in-
direct personnel only. Note: Does not in-
clude union dues.
Engineering supplies Surveying instruments (purchase or
rental) drafting supplies, surveying sup-
plies, blueprint or photostat work,
progress photos.
Expediting Cost for services supplied by expeditors
who are not on the job payroll.
Heat, light, water, and Public utility charges and heating fuels
power for job buildings. Cost for water not
used for construction purposes.
Insurancegeneral Premiums for builder's risk, fire and ex-
tended coverage, equipment floater cov-
erage, non-owned automotive liability,
independent contractors' liability, con-
tractual liability, special risk coverage,
such as war risk and heavy lift, hull and
P&I, umbrella.
Legal Abstracts, lawyers fees, court costs, no-
tary fees, sign-up expense.
Licenses and permits Business permits, construction permits,
export/import licenses, government in-
spection fees, hauling permits.
Move in/outsupplies and Transportation of tools, and construction
services equipment by others to project construc-
tion area, and miscellaneous supplies
consumed and services used, for move-in
and -out purposes.
Office supplies Stationery supplies, printing, office
equipment purchase, rental or repair, of-
fice and warehouse forms and supplies,
jobsite reproduction costs and furniture.
Safety and medical Medical examination fees, medical sup-
expense, material plies, safety signs and literature, first-
aid equipment, fire extinguishers, and
refills.
Testing and laboratory Soil surveys, concrete cylinder tests, in-
analysis dependent inspectors. Lab charges to
test welders.
Transportation and subsistence expense
of overhead and indirect employees on
Traveling
business trips (excluding quality assur-
ance personnel travel).
All material, supplies, and tools required
Welding supplies by a welder, i.e., acetylene, oxygen, flux,
welding rods, lighters, flints, chipping,
hammers, wire brushes, stingers, hel-
mets, lenses, asbestos gloves, goggles,
gauges, welding qualification test mate-
rial, etc.
Unclassified Flowers, weather reports and forecasts,
and bank service charges.
Data processing services Cost for data processing services for the
project. Terminal rental, supplies, com-
puter charges from outside jobsite
sources, etc.
Consulting services Cost for outside consulting services
which might be required in connection
with the projects which are not a part of
engineering.
Trade journals, books, Cost of books or subscriptions.
publications, and
subscriptions
Contract Guard Service Cost of subcontract guard service
Quality Assurance- Normally includes travel costs for qual-
Material and Supplies ity control personnel.
Employee Educational Cost of employee educational assistance,
Assistance for overhead and indirect personnel only.
Home Office Cost
1. Engineering/Design ServicesTotal labor and material cost for the

complete engineering and design of the project including engineering
fee.
2. Construction ServicesServices furnished by various home office de-
partments such as estimating, scheduling, expediting, etc., as may be
required to assist the project. Services are charged to the project only
for time actually spent on the project.
3. Project General ManagementIncludes the portion of time that the
contractor's management staff applies in regard to overall direction of
the project.
Section 2
PROCESS EQUIPMENT
The most important component of physical plant cost is that of process

equipment. From it the prime basis can be formed for the estimation of
the entire plant.
Once the production rate has been established and a rough flow sheet
presented, an equipment list can be compiled noting the type, size, capac-
ity and material of construction. From the logarithmic graphs that appear
on the following pages, an average cost of equipment material and instal-
lation manhours can be computed.
Inasmuch as it is not practical within the scope of this manual to ade-
quately describe each piece of equipment beyond the very minor descrip-
tion as appears on the individual graphs, I rely on the estimator's ability
to realize that the items covered are of a standard nature for chemical
plants, refineries, and industrial plants.
All installation manhours include offloading equipment at job site, haul-
ing up to 2,000 feet and rigging, picking, setting, and aligning of the
equipment.
The equipment graphs include the total cost of the equipment, but do
not include structural steel or miscellaneous iron such as supports, lad-
ders, walkways, platforms, or handrails. See other sections for these
items.
AU shop fabricated equipment graphs, as in the case of vessels, include
the total shop cost, overhead, and profit for fabricating and furnishing of
all material and components required for that piece of equipment.
Packaged unit graphs include the total skid-mounted cost of the equip-
ment and piping, electrical components and instrumentation, which may
be an integral part of the package.
Sub-contract equipment graphs include the total sub-contractors cost
and profit for the furnishing and installing of the equipment.
All equipment graphs include an average allowance for freight cost
within the continental forty-eight states.
I caution the engineer/estimator to be thoroughly familiar with the in-
troduction to this manual before applying this information.
ACID CCX)LERS WITH PUMP
AND MOTOR
Equipment Cost
Equipment Cost
Heat Exchanger Area Square Feet

ACID COOLERS WITH PUMP
AND MOTOR
Erection Manhours
Erection Manhours
Heat Exchanger Area Square Feet

VIBRATING BIN ACTIVATORS
Equipment Cost
Equipment Cost
Diameter Inches
VIBRATING BIN ACTIVATORS
Erection Manhours
Manhours
Erection
Diameter Inches
HIGH-SPEED MECHANICAL
AERATORS
Equipment Cost
Equipment Cost
Motor Horsepower
(D Basic unitductile iron/carbon steel
Basic unitstainless steel
HIGH-SPEED MECHANICAL
AERATORS
Erection Manhours
Manhours
Erection
Motor Horsepower
LOW-SPEED MECHANICAL
SURFACE AERATORS
Equipment Cost
Equipment Cost
Motor Horsepower
Fixed low-speed unit
Floating low-speed unit
Next Page
LOW-SPEED MECHANICAL
SURFACE AERATORS
Erection Manhours
Erection Manhours
Motor Horsepower
Fixed low-speed unit
Floating low-speed unit
Previous Page
AIR POWER COMPRESSORS

Synchronous Motor Driven
Rated for Sea Level to 3,300 Feet
Altitude at 125 psig Maximum
Discharge Pressure
Equipment Cost
Equipment Cost
Motor Horsepower
0)460,575, or 480 volts
2300 or 4160 volts
Induction Motor Driven
Rated for Sea Level to 3,300-Fbot
Altitude at 125 psig Maximum
Discharge Pressure
Equipment Cost
Equipment Cost
Motor Horsepower
460,575, or 230-volt
480or2,300-volt
Synchronous and Induction Motor
Driven Rated for Sea Level to
3,300-Foot Altitude at 125 psig
Maximum Discharge Pressure
Erection Manhours
Manhours
Erection
Motor Horsepower
AUTOMOTIVE AND
INDUSTRIAL SERVICE AIR
COMPRESSORS
Equipment Cost
Equipment Cost
Motor Horsepower
(D Single-stage, air-cooledcapacity 7.9 to 37.0 acfin @ 80 psig.
Two-stage, air-cooledcapacity 5.0 to 97.2 acfin @ 175 psig.
AUTOMOTIVE AND
INDUSTRIAL SERVICE AIR
COMPRESSORS
Erection Manhours
Erection Manhours
Motor Horsepower
(D Single-stage, air-cooledcapacity 7.9 to 37.0 acftn @ 80 psig.
Two-stage, air-cooledcapacity 5.0 to 97.2 acftn @ 175 psig.
CENTRIFUGAL AIR COMPRESSORS
Plant and High-Pressure
(Soot Blower) Types
100 to 350 psig Discharge
Pressure
Equipment Cost
Equipment Cost
Nominal Motor Horsepower

0 Plant air compressors
(2) High-Pressure (soot blower) compressors
CENTRIFUGAL AIB COMPRESSORS
Plant and High-Pressure
(Soot Blower) Types
Pressure
Erection Manhours
Erection Manhours
Nominal Motor Horsepower

INDUSTRIAL AIR
COMPRESSORS
Air-Cooled, Two-Stage50 to
250psig
Equipment Cost
Equipment Cost
Motor Horsepower
(D Two-stage50 to 125 psig,
Two-stage-150 to 250 psig.
INDUSTRIAL AIR
COMPRESSORS
Air-Cooled, Two-Stage50 to
250psig
Erection Manhours
Erection Manhours
Motor Horsepower
INTEGRAL GAS ENGINE
COMPRESSOR
Fbur-Cylinder Type
Equipment Cost
Equipment Cost
Rated Hp. (BHP)

(D Cast iron cylinders, 1,000 psig discharge
(2) Nodular cylinders, 1,500 psig discharge
Forged steel cylinders, 2,500 psig discharge
Forged steel cylinders, 6,000 psig discharge
INTEGRAL GAS ENGINE
COMPRESSORS
Fbur-Cylinder Type
1,CXX) TO 6,000 psig Discharge
Erection Manhours
Erection Manhours
Rated Horsepower (BHP)

PACKAGED AIR COMPRESSOR
UNITS
Single-Stage, Water-Cooled
Oil-Lubricated and Nonlubricated
Types
Equipment Cost
Equipment Cost
Motor Horsepower
(DOil-lubricated-208, 230, or 460-volt.
Nonlubricated-208, 230, or 460-volt.
PACKAGED AIR COMPRESSOR UNITS
Single-Stage, Water-Cooled
Types
Erection Manhours
Erection Manhours
Motor Horsepower
For 208-, 230-, or 460-volt units.
RECIPROCATING
COMPRESSORS
Electric Motor Driven
Equipment Cost
Equipment Cost
Compressor Horsepower
1) Cast Iron Cylinders 1000 PSI Discharge
2) Nodular Iron Cylinders 1500 PSI Discharge
3) Steel Cylinders 2500 PSI Discharge
4) Steel Cylinders 6000 PSI Discharge
RECIPROCATING
COMPRESSORS
Electric Motor Driven
1,000 to 6,000 psi Discharge
Erection Manhours
Erection Manhours
Compressor Horsepower
TWO-STAGE, TWO-CYLINDER,
WATER-COOLED AIR COMPRESSORS
150 to 350 psi Discharge
Pressure
Equipment Cost
Equipment Cost
Motor Horsepower
0 Oil-lubricated
Nonlubricated
Pressure
Eauimnent Cost
Equipment Cost
Motor Horsepower
(D Oil-Lubricated
(D Nonlubricated
Next Page
Pressure
Erection Manhours
Manhours
Erection
Motor Horsepower
Previous Page
REFRIGERATED AIR DRYERS

Automatic Type 15 to 1000 scfm
Equipment Cost
Equipment Cost
Capacity SCFM
Automatic Type 1,200 to 15,000
scfm
Equipment Cost
Equipment Cost
Capacity scfm
REFRIGEBATED AIR DRYERS
Automatic Type 15 to I9OOO scfm
Erection Manhours
Erection Manhours
Capacity SCFM
Automatic Type 1,200 to IS9OOO
scfm
Erection Manhours
Erection Manhours
Capacity SCFM
CHILLER AIR DRYERS
Capacity 3,000 to 28,000 scfm at
lOOpsig
Equipment Cost
Equipment Cost
Capacity SCFM At 100 PSIG

Next Page
CHILLER AIR DRYERS

Capacity 3,000 to 28,000 scfm at
lOOpsig
Erection Manhours
Erection Manhours
C a p a c i t y SCFM At 100 PSIG

Previous Page
SURGE ARRESTORS
Hydrocarbon and Water Service
500 psi Design Operating Pressure
ASME CodeSection VIII
Division I
Equipment Cost
Equipment Cost
Nominal Size Gallons

Hydrocarbon Service
Water Service
SURGE ARRESTORS
Hydrocarbon, Water and Sewage Service
275 psi Design Operating Pressure
Division I
Equipment Cost
Equipment Cost

Hydrocarbon service
Water service
Sewage service
SURGE ABBESTORS
Hydrocarbon, Water and Sewage Service
275 and 500 psi Design Operating Pressures
Division I
Erection Manhours
Erection Manhours

DRY MATERIAL BLENDERS,
PACKERS9 AND FEEDERS
Auger Blenders
Rotary Drum Blenders
Equipment Cost
Equipment Cost
iuaximum Mixing Cubic Feet Per Hour

(D Auger blenders
Rotary drum blenders
DRY MATERIAL BLENDERS9
Auger Blenders
Rotary Drum Blenders
Erection Manhours
Erection Manhours
Maximum Mixing Cubic Feet Per Hour

Auger blenders
Rotary drum blenders
MIXERS AND BLENDERS
Fixed Side Mounted Mixers with
Top Motors
Equipment Cost
Equipment Cost
Rating Hors epower

MIXERS AND BLENDERS
Fixed Side Mounted Mixers
with Top Motors
Erection Manhours
Erection Manhours
Rating Horsepower
MIXERS AND BLENDERS
Plate Mounted Open Tank Mixers
Equipment Cost
Equipment Cost
Rating Horsepower
(D Plate-mounted, open tank mixersdirect drive.
Plate-mounted, open tank mixersgear drive.
MIXERS AND BLENDERS
Portable Clamp and Flanged
Mounted Mixers
Equipment Cost
Equipment Cost
Rating Horsepower
Portable clamp mounted mixersdirect drive.
Portable clamp mounted mixersgear drive.
Flanged top tank mounted mixersdirect drive
Flanged top tank mounted mixersgear drive.
MIXERS AND BLENDERS
Flanged Top Tank Mounted and
Plate Mounted Open Tank Mixers
Erection Manhours
Manhours
Erection
Rating Horsepower
Portable clamp mounted mixersDirect And Gear
Drive.
Flanged top tank and plate mounted open tank mix-
ersdirect and gear drives.
MIXERS AND BLENDERS
Gearmotor Mixers
Equipment Cost
Cost
Equipment
Approximate Weight - Pounds
(D For mounting on structural steel support above open tank

For mounting on closed tank with stuffing box/shaft seal
For mounting on closed tank with end face mechani cal seals
Note: Motor horsepower range 2-200, shaft length
range 100"-23O*, impeller range 29"-75".
MIXERS AND BLENDERS
Gearmotor Mixers
Erection Manhours
Approximate Weight - Pounds

(D For mounting on structural steel support above
open tank
For mounting on closed tank with stuffing box/shaft
seals or end face mechanical seals
Note: Motor horsepower range 2-200, shaft length
range 100"-23O*, impeller range 29"-75".
MIXERS AND BLENDERS
Batch and Pipeline Homogenizer
Mixers
Equipment Cost
Cost
Equipment
Horsepower
(D Batch homogenizer mixers
Pipeline homogenizer mixers
MIXERS AND BLENDERS
Batch and Pipeline Homogenizer
Mixers
Erection Manhours
Erection Manhours
Horsepower
MIXERS
High-Intensity
Equipment Cost
Cost
Equipment
Working Capacity Cubic Feet

MIXERS
High-Intensity
Erection Manhours
Manhours
Erection
Working Capacity Cubic Feet

Bag Vibrating Packers
Rigid Container Vibrating
Packers
Equipment Cost
Cost
Equipment
Maximum Bag Width Or Container Diameter Inches

Bag vibrating paekers
Rigid container vibrating packers
Bag Vibrating Packers
Rigid Container Vibrating
Packers
Erection Manhours
Erection Manhours
Maximum Bag Width Or Container Diameter Inches

(D Bag vibrating packers
(2) Rigid container vibrating packers
BOILERS
Package Type
Equipment Cost
Cost
Equipment
Pounds Per Hour

Note: Cost is for total boiler including forced draft fan
assembly. Boiler capacity pounds per hour-satu-
rated steam at 100 to 235 psig.
BOILERS
Package Type
Erection Manhours
Manhours
Erection
Pounds Per Hour

Note: Manhours are for installation of boiler including
forced draft fan. Boiler capacity pounds per
hour-saturated steam at 100 to 235 psig.
BOILER STACKS
1
M-InCh Plate
Equipment Cost
Cost
Equipment
Linear Feet Of Stack

(D 24-inch diameter (3) 42 to 48-inch diameter
30-inch diameter 54 to 60-inch diameter
36-inch diameter
Note: Cost includes stack, cable, and clamps.
BOILER STACKS
5
/ie- and 3/s-Inch Plate
Equipment Cost
Cost
Equipment

%>-inch plate 42- to 48-inch diameter
%3-inch plate 54- to 60-inch diameter
%-inch plate 54- to 60-inch diameter
Note: Cost includes stack, cable, and clamps.
Next Page
BOILEB STACKS
1
Ai-, 5/i6-, 3/8-Inch Plate
Erection Manhours
Erection Manhours

24-inch diameter (D 42- to 48-inch diameter
30-inch diameter 54- to 60-inch diameter
36-inch diameter
Previous Page
CLASSIFICATION EQUIPMENT
Cone Pelletizers
Equipment Cost
Cost
Equipment
Cone Size Feet

Cone Pelletizers
Erection Manhours
Manhours
Erection
Cone Size Feet

Turbo-Screen Cyclone and
48"-Pressure Sifter (3-Screens)
Equipment Cost
Cost
Equipment
Diameter Inches
Stainless steel turbo-screen cyclone
Carbon steel turbo-screen cyclone
48-inch pressure sifter (3-screens)
Turbo-Screen Cyclone and
48"-Pressure Sifter (3-Screens)
Erection Manhours
Manhours
Erection
Diameter Inches
Carbon or stainless steel cyclone
48-inch pressure sifter (3-screens)
Rotary Screens
Equipment Cost
Cost
Equipment
Capacity Screen Area Square Feet

Rotary Screens
Erection Manhours
Manhours
Erection
Capacity Screen Area Square Feet

VERTICAL TUBE SURFACE
CONDENSERS AND
RECEIVERS
Equipment Cost
Cost
Equipment
Cooling Surface Square Feet

VERTICAL TUBE SURFACE
CONDENSERS AND
RECEIVERS
Erection Manhours
Erection Manhours
Cooling Surface Square Feet

CONVEYING EQUIPMENT
ConveyorsOpen Belt
Equipment Cost
Cost
Equipment
Linear Feet
(D 18-inch belt <D 36-inch belt
24-inch belt 42-inch belt
30-inch belt
Note: See structural steel account for bents.
CONVEYING EQUIPMENT
ConveyorsOpen Belt
Erection Manhours
Erection Manhours
Linear Feet
(S) 30-inch belt
CONVEYING EQUIPMENT
ConveyorsBelt Enclosed
with Walkway
Equipment Cost
Cost
Equipment
Linear Feet
(D 18-inch belt 36-inch belt
<) 30-inch belt
CONVEYING EQUIPMENT
ConveyorsBelt Enclosed
with Walkway
Erection Manhours
Erection Manhours
Linear Feet
18-inch belt (D 36-inch belt
(E) 30-inch belt
CONVEYING EQUIPMENT
ConveyorsSpaced, Bucket
Elevators, Belt-Driven
Equipment Cost
Equipment
Linear Feet
6-x 4-inch buckets
(2) 12-x 7-inch buckets
16- x 8-inch buckets
CONVEYING EQUIPMENT
Elevators, Chain-Driven
Equipment Cost
Cost
Equipment
Linear Feet
(D 6-x 4-inch buckets
(S) 16-x 8-inch buckets
CONVEYING EQUIPMENT
Elevators,
Chain- or Belt-Driven
Erection Manhours
Manhours
Erection
Linear Feet
6-x 4-inch buckets
16- x 8-inch buckets
CONVEYING EQUIPMENT
ConveyorsContinuous, Bucket
Elevators,
Belt-Driven
Equipment Cost
Cost
Equipment
Linear Feet
0 8- x 5-inch buckets
20-x 8-inch buckets
CONVEYING EQUIPMENT
Elevators,
Chain-Driven
Equipment Cost
Cost
Equipment
Linear Feet
20-x 8-inch buckets
CONVEYING EQUIPMENT
Elevator,
Chain- or Belt-Driven
Erection Manhours
Manhours
Erection
Linear Feet
8-x 5-inch buckets
20-x 8-inch buckets
SCREW CONVEYORS
Equipment Cost
Overall Conveyor Length-Linear Feet

Screw Diameter:
(D 6-inch 16-inch
9-inch 18-inch
(E) 12-inch CD 20-inch
014-inch 24-inch
SCREW CONVEYORS
Erection Manhours
Erection Manhours
Overall Conveyor Length-Linear Feet

Screw Diameter:
6-inch 16-inch
9-inch 18-inch
12-inch 20-inch
(D 14-inch 24-inch
DRYERSDRUM
Atmospheric Single Drum Type
Equipment Cost
Cost
Equipment
Approximate Weight Pounds

DRYERSDRUM
Atmospheric Double and Twin
Drum Types
Equipment Cost
Equipment Cost

(D Double drum
Twin drum
Next Page
DRYERSDRUM
Atmospheric Single, Double, and
Twin Drum Types
Erection Manhours
Erection Manhours

(D Single Drum
Double Drum
Twin Drum
Previous Page
DRYERSVACUUM
Conical Rotating Type
Equipment Cost
Equipment Cost

DRYERSVACUUM
Double Drum and Rotary Types
Equipment Cost
Cost
Equipment

0 Double drum
Rotarystainless steel
(H) Rotarycarbon steel
DRYERSVACUUM
Conical Rotating and Double
Drum Types
Erection Manhours
Erection Manhours

Conical rotating
Double drum
DRYERSVACUUM
Rotary Types Carbon Steel and
Stainless Steel
Erection Manhours
Erection Manhours

Carbon Steel
Stainless Steel
DUST COLLECTORS
CENTRIFUGAL SCRUBBERS
High Capacity, Low Energy
Loss Type
Hot-Rolled Steel Construction
Equipment Cost
Equipment Cost
Capacity CFM At 4.5 V Pressure Drop

(D 12-gauge %6-inch plate
(2) 10-gauge V4-inch plate
Note: Cfin capacity at 2.0-inch pressure drop will equal
approximately 67% of above cftn.
DUST COLLECTORS
Medium Capacity, Medium
Energy Loss
Hot-Rolled Steel
Equipment Cost
Equipment Cost
Capacity CFM At 4.5" Pressure Drop

12-gauge (E) %6-inch plate
<2) 10-gauge (D V4-inch plate
Note: Cfm capacity at 2.0-inch pressure drop will equal
approximately 71% of above cfm.
DUST COLLECTORS
High Capacity, Low Energy
Loss Type
T304-2B Stainless Steel Construction
Equipment Cost
Equipment Cost
Capacity CFK At 4.4" Pressure Drop

12-gauge ^16-inch plate
10-gauge V4-inch plate
Note: Cfm capacity at 2.0-inch pressure drop will equal
DUST COLLECTORS
Medium Capacity, Medium
Energy Loss Type
T304-2B Stainless Steel Construction
Equipment Cost
Equipment Cost
Capacity CFK At 4.5" Pressure Drop

12-gauge %6-inch plate
(2) 10-gauge (D V4-inch plate
Note: Cfrn capacity at 2.0-inch pressure drop will equal
DUST COLLECTORS
High- and Medium-Capacity Units
Hot-Rolled Steel and T304-2B
Stainless Steel
Erection Manhours
Erection Manhours

Hot-rolled steelall thicknesses
T304-2B stainless steel-all thicknesses
DUST COLLECTORS
Hot-Rolled SteelCyclones
Equipment Cost
Equipment Cost

(D 16-gauge (g) 12-gauge %6-inch plate
(2) 14-gauge 0 10-gauge
Note: Cfin capacity at 2.5-inch pressure drop will equal
approximately two-thirds of above cfin.
DUST COLLECTORS
304 Stainless Steel Cyclones
Equipment Cost
Equipment Cost
Capacity CFM At 6,O" P r e s s u r e Drop

16-gauge 12-gauge %6-inch plate
14-gauge (D 10-gauge
Note: Cftn capacity at 2.5-inch pressure drop will equal
approximately two-thirds of above cfin.
DUST COLLECTORS
Hot-Rolled Steel and 304
Stainless Steel Cyclones
Erection Manhours
Erection Manhours

Hot-rolled steelall thicknesses
304 stainless steelall thicknesses
DUST COLLECTORS
Filter Cartridge or Tube House
Filters
Equipment Cost
C os t
Equipment
Filter Cartridge Or Fabric Filter Square Feet Area

(D Filter cartridge
Fabric filtertube house
DUST COLLECTORS
Filter Cartridge or Tube House
Filters
Erection Manhours
Manhours
Erection
Filter Cartridge Or Fabric Filter Square Feet Area

Filter cartridge
Fabric filtertube house
DUST COLLECTORS
Packaged Motor Operated
Blowers for Filter Cartridge
and Tube House Dust Collectors
Equipment Cost
Cost
Equipment
Motor Horsepower
DUST COLLECTORS
Packaged Motor Operated
Blowers for Filter Cartridge
and Tube House Dust Collectors
Erection Manhours
Manhours
Erection
Motor Horsepower
FANS AND BLOWERS
BlowersRotary to 15 psi
Equipment Cost
Cost
Equiproe nt
InletCFM
FANS AND BLOWERS
BlowersRotary to 15 psi
Erection Manhours
Manhours
Erection
InletCFM
FANS AND BLOWERS
Centrifugal Fans with
Backwardly Inclined Blades
Equipment Cost
Equipment Cost
Maximum Volume - CFM

5-inches @ 2,300 fpm to 2^-inches @ 3,200 fpm
(D 8^-inches @ 3,000 fpm to 4^-inches @ 4,175 fpm
13^-inches @ 3,780 fpm to 6%-inches @ 5,260 fpm
(D Above Class Three specification
Note: Performance range designations are indicated by
static pressure (inches of water) at fan outlet ve-
locity (feet per minute). Performance range-sin-
gle width-fan class.
FANS AND BLOWERS
Centrifugal Fans with
Backwardly Inclined Blades
Erection Manhours
Erection Manhours
Maximum Volume - CFM
Note: Manhours are for all classes

FANS AND BLOWERS
Cast Iron Industrial Fans
Equipment Cost
Cost
Equipment
Maximum Volume-CFM
FANS AND BLOWERS
Cast Iron Industrial Fans
Erection Manhours
Manhours
Erection
Maximum Volume-CFM
FANS AND BLOWERS
Heavy Sheet Steel Industrial Fans
Equipment Cost
Equipment Cost
Max imum Vo1ume-CFM

Next Page
FANS AND BLOWERS

Heavy Sheet Steel Industrial Fans
Erection Manhours
Erection Manhours
Maximum Volume-CFM
Previous Page
HEAVY DUTY BELT FEEDERS

Equipment Cost
Cost
Equipment
Capacity Cubic Feet Per Hour

HEAVY DUTY BELT FEEDERS
Erection Manhours
Manhours
Erection
Capacity Cubic Feet Per Hour

PRE-WETTING DRY CHEMICAL
FEEDERS
Equipment Cost
Equipment Cost
Hopper Cubic Feet

FEEDERS
Erection Manhours
Manhours
Erection
Hopper Cubic Feet

Note: Manhours are for mounting on drum or tank or
placed on stand or shelf above tank.
PRJS-WETTING DRY CHEMICAL
Package Units
Equipment Cost
Cost
Equipment
Tank Gallons
(D Single-tank system
Two-tank system
FEEDERS
Package Units
Erection Manhours
Manhours
Erection
Tank Gallons
Single-tank system
Two-tank system
DRY MATERIAL FEEDER
EQUIPMENT
Vibrating Feeders
Equipment Cost
Equipment Cost
Tons Per Hour

DRY MATERIAL FEEDER
EQUIPMENT
Vibrating Feeders
Erection Manhours
Erection Manhours
Tons Per Hour

DRY MATERIAL FEEDER
EQUIPMENT
Volumetric and Gravimetric
Feeders
Equipment Cost
Cost
Equipment
Approximate Weight In Pounds

Volumetric feeders
Gravimetric feeders
DRY MATERIAL FEEDER
EQUIPMENT
Volumetric and Gravimetric
Feeders
Erection Manhours
Manhours
Erection
Approximate Weight In Pounds
(D Volumetric feeders
Gravimetric feeders
DRY MATERIAL FEEDERS
Wing and Conveyor Types
Equipment Cost
Cost
Equipment
Maximum Cubic Feet Per Hour

(D Wing-type feeders-ratchet drive
Wing-type feeders-micro master drive
Conveyor type feeders
(3) Sanitary wing-type feeders
DRY MATERIAL FEEDERS
Wing and Conveyor Types
Erection Manhours
Erection Manhours
Maximum Cubic Feet Per Hour

Wing-type feedersratchet drive
Wing-type feedersmicro master drive
Conveyor-type feeders
(D Sanitary wing-type feeders
GRAVITY FILTRATION UNITS
Total Material Cost
Cost
Material
Unit Diameter-Feet
GRAVITY FILTRATION UNITS
Total Unit Installation Manhours
Manhours
Ins tallation
Unit Diameter-Feet
FILTERS
Pressure Type
Equipment Cost
Cost
Equipment
Diameter Feet
FILTERS
Pressure Type
Erection Manhours
Manhours
Erection
Diameter Feet
FILTERS
Rubber-Lined
Equipment Cost
Cost
Equipment
Flow Rate G. P . M.
(D Units on casters with rubber-lined filter and pump.
In addition to above, includes adequate rubber-lined
steel slurry tank, rubber-lined valves, and rubber-
lined steel fittings.
FILTERS
Rubber-Lined
Erection Manhours
Erection Manhours
Flow Rate G. P, M.
(D Units on casters with rubber-lined filter and pump.
In addition to above, includes adequate rubber-lined
steel slurry tank, rubber-lined valves, and rubber-
lined steel fittings.
FILTER EQUIPMENT
Vibrating Screens
Equipment Cost
Cost
Equipment
Square Feet Single Deck Area

One-deck screen
Two-deck screen
Three-deck screen
Note: Costs of all two-and three-deck screens are based
on square feet of single deck area.
FILTER EQUIPMENT
Vibrating Screens
Erection Manhours
HlIlI H JlIlIf iluilllHII44414444-4UuUIII
1'iaiuiv
Q
* vjivii l-
Square Feet Single Deck Screen Area

(D One-deck screen
Two-deck screen
Three-deck screen
Note: Manhours for two- and three-deck screens are
based on square feet of single deck area.
FLAKERS
Cooling Drum Type
Equipment Cost
Equipment Cost

FLAKEBS
Cooling Drum Type
Erection Manhours
Manhours
Erection

INERT GAS GENERATORS
Equipment Cost
Cost
Equipment
Rated Out Put - (SCFM Inerts)

Indoor construction
Outdoor construction
Explosion-proof construction
Note: Add 3% to above for two-point control. Add 5%
to above for automatic output control.
INERT GAS GENERATORS
Erection Manhours
Manhours
Erection
Rated Output (SCFM Inerts)

OD Indoor construction
Outdoor construction
Explosion-proof construction
Note: Add 1% to above for two-point control. Add
1.5% to above for automatic output control.
GAS PULSATION DAMPERS
Equipment Cost
Cost
Equipment
Volume Cubic Inches

Next Page
GAS PULSATION DAMPERS

Erection Manhours
Erection Manhours
Volume Cubic Inches

Previous Page
HEATERS
Deaerating Feedwater Type
Equipment Cost
Cost
Equipment
Outlet Capacity Pounds Per Hour

HEATERS
Deaerating Feedwater Type
Erection Manhours
Erection Manhours
Outlet Capacity Pounds Per Hour

HEATERS
Gas-, Oil, and Dual-Fired Heaters
Equipment Cost
Equipment Cost

Gas-fired
Oil-fired
Dual-fired
HEATERS
Gas-, Oil-, and Dual-Fired Types
Erection Manhours
Erection Manhours

HAIRPIN TYPE
HEAT EXCHANGERS
Equipment Cost
Cost
Equipment
Heat Transfer Surface Square Feet

HAIRPIN TYPE
HEAT EXCHANGERS
Erection Manhours
Manhours
Erection
Heat Transfer Surface Square Feet

HEAT EXCHANGERS
Shell and Tube, Fixed Tube Sheet,
and U-Tube
Equipment Cost
Equipment Cost
Heating Surface Square Feet

150# Rating 300# Rating 600# Rating
Note: Above is for carbon steel, straight tube
exchangers. Add following percent to the above
for:
Straight
Tubes U-Tubes Tube Sheet
Carbon Steel - 6% 10%
Stainless Steel 20% 26% 30%
Copper 10% 16% 20%
HEAT EXCHANGERS
Shell and Tube, Fixed Tube Sheet,
and U-Tube
Erection Manhours
Erection Manhours

Note: Above manhours are for 150# rating.
Increase above for:
300# Rating-10%
600# Rating-20%
HEAT EXCHANGERS FOR
HEATING WATER
Equipment Cost
Equipment Cost

(D Carbon steel shells, copper-lined heads, %-inch cop-
per "U" tubes 18 BWG, two-pass, 150-pound con-
struction.
Carbon steel shells, copper-lined heads, bronze tube
sheet, two-pass, 150-pound construction.
HEAT EXCHANGERS FOR
HEATING WATER
Equipment Cost
Equipment Cost

Carbon steel shell, %-inch O.D. copper "U" tubes 18
BWG, two-pass, 150-pound construction.
(2) Carbon steel shell, bronze tube sheet, two-pass, 150-
pound construction.
Next Page
HEAT EXCHANGERS FOR

HEATING WATER
Erection Manhours
Erection Manhours

Previous Page
CENTRIFUGAL PUMPS
Single-Stage, Vertical Split Case
Equipment Cost
Equipment Cost
Prime Mover Horsepower

(D 3,500 rpmspecific gravity of 1.0.
(2) 1,750 rpmspecific gravity of 1.0.
CENTRIFUGAL PUMPS
Single-Stage, Horizontal Split
Case
Equipment Cost
Cost
Equipment

03,600 rpmspecific gravity of 1.0.
1,750 rpmspecific gravity of 1.0.
CENTRIFUGAL PUMPS
Single-Stage ANSI and API 610
Equipment Cost
Equipment Cost

(D ANSI pumps3,500 rpmspecific gravity of 1.0.
(2) ANSI pumps1,750 rpmspecific gravity of 1.0.
API 610 pumps3,500 rpmspecific gravity of 1.0.
CENTRIFUGAL PUMPS
Two-Stage and Multi-Stage
Horizontal Split Case
Equipment Cost
Equipment Cost

Two-stage, 3,550 rpmspecific gravity of 1.0
Multi-stage, 3,550 rpmspecific gravity of 1.0
CENTRIFUGAL PUMPS
Single-Stage, In-Line
Ductile Iron and Steel Cased
API-610 Standard
Equipment Cost
Equipment Cost
Motor Horsepower
Ductile iron3,550 rpmspecific gravity of 1.0
Steel Cased, API-610 Standard-3,550 r p m -
specific gravity of 1.0
GEAR PUMPS
Light and Heavy Duty
Equipment Cost
Cost
Equipment
Motor Horsepower
Light duty
Heavy duty
SEWAGE PUMPS
Horizontal and Vertical
1,750 rpm
Equipment Cost
Cost
Equipment
Motor Horsepower
(D Horizontall%inch solids (D Vertical 2-inchsolids
<2> Horizontal2-inch solids Vertical 3-inchsolids
Verticall%inch solids
SEWAGE PUMPS
Horizontal1,750 rpm
Equipment Cost
Cost
Equipment
Motor Horsepower
(D Horizontal2%ineh solids
Horizontal3-inch solids
SEWAGE PUMPS
1,150 rpm
Equipment Cost
Equipment Cost
Motor Horsepower
Horizontall%ineh solids
Horizontal2-inch solids
(S) Horizontal2%inch solids
(D Horizontal3-inch solids
Vertical2-inch solids
() Vertical3-inch solids
SUMF AND PLUNGER PUMPS
Equipment Cost
Equipment Cost
Motor Horsepower
Sump pumps3,600 rpmspecific gravity of 1.0
Sump pumps1,750 rpmspecific gravity of 1.0
Plunger pumps10 to 350 gpm
VERTICAL TURBINE PUMPS
Single and Multi-Stage
Equipment Cost
Equipment Cost
Motor Horsepower
(D 3,550 rpmspecific gravity of 1.0
1,750 rpmspecific gravity of 1.0
(2) 1,170 rpmspecific gravity of 1.0
CENTRIFUGAL PUMPS
Single-, Two-, Multi- and In-Line
Single Stage
Erection Manhours
Manhours
Erection
Prime Mover Or Motor Horsepower

(D Single-stage or in-line single-stage
Two-stage
Multi-stage
GEARPUMPS
Light and Heavy Duty
Erection Manhours
Erection Manhours
Motor Horsepower
Light duty
Heavy duty
SEWAGE FUMPS
Erection Manhours
Manhours
Erection
Motor Horsepower
(D Horizontal
Vertical
SUMP AND PLUNGER PUMPS
Erection Manhours
Erection Manhours
Motor Horsepower
(D Sump pumps
Plunger pumps
Next Page
VERTICAL TURBINE PUMPS

Single- and Multi-Stage
Erection Manhours
Manhours
Erection
Motor Horsepower
Previous Page
REACTOBS
Glass Lined, Agitated, Jacketed
25 and 100 psi
Equipment Cost
Cost
Equipment
Capacity-Gallons
(D Glass-lined steel25 psi
Glass-lined steel-100 psi
REACTORS
Glass-Lined, Agitated, Jacketed
25 and 100 psi
Erection Manhours
Manhours
Erection
Capacity-Gallons
Glass-lined steel25 psi
Glass-lined steel-100 psi
STEAM JET EJECTORS
Single-Stage Type
Equipment Cost
Cost
Equipment
Suction And Discharge Size Inches

STEAM JET EJECTORS
Single-Stage Type
Erection Manhours
Manhours
Erection
Suction And Discharge Size Inches

GAS SCRUBBERS
High-Energy Venturi Type
Equipment Cost
Equipment Cost

(T) 12-gauge hot-rolled steel material
(D K-inch plate hot rolled steel material
12-gauge stainless steel material
(D %-inch 304 stainless steel material
GAS SCRUBBERS
High-Energy Venturi Type
Erection Manhours
Erection Manhours

Hot-rolled steel material
(2) 304 stainless steel material
SEPARATORS
Vane Type
Equipment Cost
Cost
Equipment
Line Size Inches

(D 275-pound rating
<2) 720-pound rating
SEPARATORS
Vane Type
Equipment Cost
Cost
Equipment
Unit Diameter Inches

(D Carbon Steel
(2) Stainless Steel
SEPARATORS
Vane TyP 6
Erection Manhours
Manhours
Erection
Line Size Inches

(D 150# or 300# raised face flangedwithout base
150# or 300# raised face flangedwith base
VIBRATING SEPARATORS
Equipment Cost
Cost
Equipment

0 Carbon steel
Stainless steel
VIBRATING SEPABATORS
Carbon or Stainless Steel
Erection Manhours
Manhours
Erection

API TYPE OIL/WATER
SEPARATORS
Packaged Equipment Cost
Cost
Equipment
Gallons Per Minute

Next Page
API TYPE OIL/WATER

SEPARATORS
Packaged Units
Erection Manhours
Manhours
Erection
Gallons Per Minute

Previous Page
SIZE REDUCTION EQUIPMENT

Crushers
Equipment Cost
Equipment Cost
Horsepower
Gyratory
Jaw
Crushers
Erection Manhours
Erection Manhours
Horsepower
(D Gyratory
Jaw
Impact Breakers
Equipment Cost
Cost
Equipment
Horsepower
(D Dual rotary
Single rotary
(E) Twin rotary
Impact Breakers
Erection Manhours
Manhours
Erection
Horsepower
Dual rotary
Single rotary
Twin rotary
Reversible and Non-reversible
Hammermills
Equipment Cost
Cost
Equipment
Horsepower
Reversible
Non-reversible
SIZE REDUCTON EQUIPMENT
Reversible and Non-reversible
Haxnmermills
Erection Manhours
Manhours
Erection
Horsepower
Ring-Type Granulators
Equipment cost
Equipment Cost
Horsepower
Ring-Type Granulators
Erection Manhours
Manhours
Erection
Horsepower
HOT PROCESS
WATER SOFTENER SYSTEM
Total Process Material and Equipment Cost
And Equipment Cost
Total Process material
Softener Diameter-Feet
HOT PROCESS WATER
SOFTENER SYSTEMS
Total System Installation Manhours
Installation Manhours
Total System
Softener Diameter-Feet
API CONE ROOF STORAGE
TANKS
Subcontractor Installed Price
on Foundations by Others
Installed Price
Subcontractor
Capacity-Barrels
API CONE ROOF STORAGE
TANKS
Installed Price
Subcontractor
Capacity-Barrels
API FLOATING ROOF STORAGE
TANKS
Capacity-Barrels
STORAGE TANKS
ASME SPHERES
Capacity-Gallons
(S) %-inch plate

(D V2-inch plate
(H) %-inch plate
@ %-inch plate
TANK HEATING COILS
Fintube Type
Equipment Cost
Cost
Equipment

TANK HEATING COILS
Fintube Type
Erection Manhours
Manhours
Erection

FIRED HEATERS FOR TANKS
Fintube Type
Equipment Cost
Cost
Equipment
BTU Per Hour

Gas-fired
Oil-fired
FIRED HEATERS FOR TANKS
Fintube Type
Erection Manhours
Manhours
Erection
BTU Per Hour

Gas- or oil-fired.
TANK SUCTION AND
LINE TYPE FUEL OIL
HEATERS
Equipment Cost
Equipment Cost
Gallons Per Hour

Tank suction type-heating range 60 to 140 F.
Line typeheating range 80 to 240 F.
TANK SUCTION AND
LINE TYPE FUEL OIL
HEATERS
Erection Manhours
Erection Manhours
Gallons Per Hour

Tank suction typeheating range 60 to 140 F.
Line type-heating range 80 to 240 F.
PROFANE STORAGE TANKS
ASME 250 psi117-Inch I.D.
Equipment Cost
Cost
Equipment
S h e l l Length-Feet
Next Page
PROPANE STORAGE TANKS

ASME 250 psi117-Inch I.D.
Erection Manhours
Manhours
Erection
Shell Length-Feet
Previous Page
SHOP FABRICATED VESSELS

24-Inch Through 144 Inch
Diameter
Average WeightPounds Per Linear Foot
Average Weight Pounds Per Linear Foot
Vessel Diameter-Inches
0 Horizontal vessels
(2) Vertical vessels with legs
Vertical vessels with skirt plates
SHOP FABRICATED
HORIZONTAL VESSELS
24-Inch Through 144-Inch
Diameter
Fabricated Cost Per Ton
Ton
Fabricated Cost Per
Vessel Diameter - Inches

SpotX-Rayed
(2)100%X-Rayed
Note: If drip legs are required, weigh drip legs and
use $2.40 per pound for spot x-rayed and $2.50
per pound for 100 percent x-rayed.
Baffels, draw-off boxes and vortex breakers
estimate weight and price at 20 percent of the
vessel per-ton cost.
SHOP FABRICATED VERTICAL
VESSELS WITH ANGLE LEGS
Diameter

(DSpotX-Rayed
100%X-Rayed
Note: For conical transmission pieces use three lin-
ear feet of the larger vessel diameter weight at
35% of the cost per ton of that diameter vessel.
See other graphs for tray rings, trays, and
demisting pads if required.
SHOP FABRICATED VERTICAL
VESSELS WITH ANCHOR RING
AND SKIRTS
Diameter

(DSpotX-Rayed
100%X-Rayed
Note: For conical transmission pieces use three lin-
ear feet of the larger vessel diameter weight at
35% of the cost per ton of that diameter vessel.
See other graphs for tray rings, trays, and
demisting pads if required.
SHOP FABRICATED TRAY
RINGS
Cost Each
Shop Fabricated Cost Each

Tray rings for single-pass removable trays
(D Tray rings for two-pass removable trays
COLUMN TOAYS
Shop Installation Only
Diameter
Installation Cost Each
Shop Installation Cost Each

Removable type single downflow valve or perfo-
rated type trays
Removable type double downflow valve or perfo-
rated type trays
Note: Includes shop installation only. Does not include
cost of tray.
DEMISTING PADS
Shop Installation
36-Inch Through 144-Inch Vessel
Diameter

2-, 4-, or 6-inch pad with bottom grid only
2-, 4-, or 6-inch pad with bottom and top grid
Note: Above cost includes furnishing and installing bar
support and installation only of pad as outlined.
SHOP STRESS RELIEF OP
VESSEL
Cost Pter Ton
Shop Cost Per Ton
Total Vessel Weight Tons

REMOVABLE TYPE TRAYS
14 Gauge Stainless Steel Valve
Trays With Stainless Steel Valve
Discs 24-Inch Tray Spacing
Material Cost Each
Cost Each
Material
Tray Diameter Feet

Single downflow410 stainless steel
REMOVABLE TYPE TRAYS
14 Gauge Stainless Steel Valve
Trays With Stainless Steel Valve
Discs 24-Inch Tray Spacing
Material Cost Each
Cost Each
Material
Tray Diameter Feet

(D Double downflow410 stainless steel
Double downflow304 stainless steel
(S) Double downflow316 stainless steel
DEMISTING FADS
Four-Inch Thickness
Material Cost Each
Material Cost Each
(D Carbon steel
(2) 410, 304, or 316 stainless steel
Monel
DEMISTING PADS
Pour-Inch Thickness
Top or Bottom Grids only
Material Cost Each
Material Cost Each

0 Carbon Steel
(D 410 or 304 Stainless Steel
316 Stainless Steel
(D Monel
VESSELS
Diameter
Field Erection Manhours Per Ton
Erection Manhours Per Ton
Vessel Weight-Tons
Horizontal vessels
Vertical vessels
Add for following if required:
Remove and replace manway cover1.3 manhours per tray.
Check tray and tighten retaining bolts1.8 manhours per tray.
VESSEL TRAY INSTALLATION
Diameter
Field Erection Manhours Each
Erection Manhours Each
Single downflow valve or perforated tray types
0 Double downflow valve or perforated tray types
DEMISTING PADS
Diameter
Field Erection Manhours Each
Erection Manhours Each
(D 2-, 4-, or 6-inch pad with bottom grid only
2-, 4-, or 6-inch pad with bottom and top grid
Section 3
SITE PREPARATION
General preparation of the plant site for construction is included in this

section.
Items include, but are not necessarily limited to, clearing, rough grad-
ing, cut, fill, borrow, disposal, soil stabilization, and finish grading.
Soil tests are not considered a part of site preparation and are not in-
cluded. If this is to form a part of the estimate, it must be determined
from other sources.
AREA CLEAR AND GRUB

Manhours Per Acre
Manhours Per Acre

On Site Off Site
Site Description Disposal Disposal
Light 30.0 40.0
Medium 40.0 50.0
Medium Heavy 50.0 60.0
Heavy 60.0 70.0
LightLight brush and grass, no trees.

MediumConsiderable brush of larger size.
Medium HeavyLarge brush and small trees.
HeavyMuch small brush, many small trees and occasional large trees.
All manhours include cutting, stacking or piling.

On site disposal manhours include hauling to on site disposal area or on site burning.
Off site disposal manhours include hauling to off site disposal area within five mile radius of
site.
Cost of all small tools and construction equipment is included under their respective ac-
counts.
AREA CUTS AND FILLS
Manhours and Material Cost Per Acre
Land Average C.Y./AC. Average M.H./AC. Purchase

Description Cut Fill Cut Fill Fill/AC.
Level 1,080 532 40.0 5.0 $ 9,400
Slightly Rolling 1,613 1,080 60.0 10.0 18,900
Rolling 2,420 1,613 85.0 15.0 28,200
Rough 2,952 1,888 105.0 17.0 33,100
Very Rough 3,870 2,420 135.0 22.0 42,400
LevelSmooth and level no hills.

Slightly RollingLevel with minor contour changes and small hills.
RollingConstant contour changes and small hills.
RoughPartially level with minor contour changes, slues and valleys.
Very RoughConstant changes, major hills, slues and valleys.
If ample fill material is available on the site delete above purchase fill cost.
Manhours include removal and on site stock piling top soil and spoil, area cuts and fills to
grade and minor site drainage.
Cost of all small tools and construction equipment is included under their respective ac-
counts.
Fine Grading: Use 1.3 manhours per 100 square yards.
Soil Stabilization:
MaterialUse $1.30 per square yard.
LaborUse 0.05 manhours per square yard.
Section 4
SITE IMPROVEMENTS
This section includes items of work that provide permanent improve-

ments to the plant site, such as security fencing, railroads or spurs includ-
ing ballast, tank dikes and all sub-base materials for roads, parking areas,
paved areas and railroads, concrete trenches, drainage piping, catch ba-
sins, manholes and road culverts.
Pavements for roads, parking areas and process areas are included un-
der "Discipline, Paving "
Site improvements will vary depending on site location, conditions, and
project requirements. For these reasons I have listed unit costs for vari-
ous items that may be required.
The scope of work or plot plan will dictate the items required for site
improvements.
troduction of this manual before applying this information.
Security Fencing
Fencing is usually listed as a subcontract price in the estimate and as

such includes his overhead and profit.
A six-foot-high chain link fence with three strands of barbwire, line and
corner post embedded in concrete, top rail and traffic and personnel gates
will cost an average of $15.50 per linear foot. Included in this price is instal-
lation labor at an average of 0.35 manhours per linear foot.
Railroad and Spurs
Railroads including ballast, ties, tracks, switches, stops, etc., are usu-
ally carried in the estimate as a subcontract item. The sub-base material
is usually furnished in place by the earth subcontractor or the general
contractor.
1. Sub-base material will average 0.75 cubic yards per linear foot of
track (2-rails) at:
Material$22.00 per cubic yard
Labor0.60 manhours per cubic yard
2. Railroad and appurtenances subcontracted price including overhead
and profit will average:
Labor and Material$88.00 per linear foot of track (2-rails).
Included in this subcontract price is the cost of 1.06 manhours per lin-
ear foot of track.
Tank Dikes
Earth type dikes include the furnishing, placing, and compaction of all
earth materials. Concrete type dikes include all operations for the form-
ing and placing of concrete.
1. Earth type dikes material will average 1.60 cubic yards per linear
foot of dike at the average cost of:
2. Concrete type dikes material will average 1.4 cubic yards of concrete
per linear foot of dike at the average cost of:
Concrete Trenches
Concrete trenches two feet wide by two feet deep, with standard sumps
and basins and grated cover including all earthwork, concrete and related
items will average:
Material$35.00 per linear foot
Labor2.50 manhours per linear foot
Drainage
Drainage items such as raw water, oily water, and pressurized systems
will vary depending on pipe size, elevations, etc. The following represents
an average cost of all items involved:
Catch Basins and Manholes

Catch basins and manhole size and length will vary depending on capac-
ity and bottom elevation. The following are average for this type installa-
tion and include all costs for earthwork, concrete, concrete related items,
frames and solid or grated covers:
Material$700.00 each
Labor25.00 manhours each
Road Culverts
Road culverts will vary in size depending on volume requirements. The

following costs are based on using 24-inch reinforced concrete pipe which
seems to be predominant for this item:
Section 5
CONCRETE
Logarithmic graphs in this section indicate the value of labor in man-

hours and materials in dollars of earthwork, concrete, fireproofing and
grout for equipment foundations and equipment structure foundations.
Earthwork and concrete for buildings are included with the buildings
and are not to be considered here.
The earth and concrete graphs are average and are based on the total
equipment count, even though some pieces of equipment may not require
foundations.
Earthwork graphs include labor in manhours for all hand and machine
excavation and backfill. There is also a graph showing average quantities
of required backfill in the event special fill material is required. Should
special fill material be required it should be priced at the current material
value for that particular type of fill.
Concrete graphs include the furnishing, fabricating, and placing of
forms, reinforcing steel; miscellaneous embedments; concrete and curing;
protecting and finishing concrete. There is also a graph showing esti-
mated cubic yards of concrete for cost control and reporting purpose.
Piling as such has been excluded. The graphs represent the use of
spread type footings and reflect enough manhour and material values to
include this item if required.
Graphs are included for fireproofing vessel skirts and structural steel.
Should this not be required, simply disregard these graphs.
The graphs for grouting show average square feet required, for labor
manhours and material value based on total equipment count for equip-
ment support and total tons of steel for base plates.
CONCRETE FOUNDATIONS
Earth Backfill Materials
Cubic Yards
Cubic Yards Of Backfill
Pieces Of Equipment
Equipment foundations
Equipment structure foundations
Pipe rack or sleeper foundations
Excavation and Backfill
for Equipment Foundations
Labor Manhours
Labor Manhours
Pieces Of Equipment
(D Hand excavation
Machine excavation
(H) Hand backfill
Machine backfill
For Equipment Structures
and Pipe Rack and Sleepers
Labor Manhours
Labor Manhours
Pieces Of Equipment
Equipment Structures Pipe Rack And Sleepers
(D Hand Excavation Hand Excavation
Machine Excavation Machine Excavation
Hand Backfill CD Hand Backfill
(D Machine Backfill Machine Backfill
Concrete Quantities
Cubic Yards
Cubic Yards Of Concrete
Pieces Of Equipment
(D Equipment foundations
Pipe rack and sleeper foundations
Forms, Reinforcing, Embedments,
Concrete
Material Cost
Total Material Cost
Pieces Of Equipment
0 Equipment foundations
(D Equipment structure foundations
Forms, Reinforcing, Embedments,
Concrete
Pieces Of Equipment
Equipment foundations
NonshrinkNonmetallic Grout
Average Square Feet
Feet
Square
Pieces Of Equipment Or Tons Of S t e e l

Equipment
Material Cost
Material Cost

Equipment
Steel

Equipment
Steel
Fireproofing Structural Steel
Total Material Cost
Total Material Cost
Tons Of S t e e l
Fireproofing Structural Steel
Tons Of S t e e l
Fireproofing Vessel Skirts
Material Cost
Total Material Cost
Pieces Of Equipment With Skirts

Fireproofing Vessel Skirts
Erection Manhours
Manhours
Erection
Pieces Of Equipment With Skirts

Section 6
STRUCTURAL STEEL AND

MISCELLANEOUS IRON
The curves in this section represent the material cost in dollars and the
erection manhours required for equipment supports, equipment struc-
tures and piperacks, and miscellaneous steel and iron for equipment plat-
forms, walkways, and ladders.
All steel items are based on the total pieces of equipment even though
some pieces will require no steel.
If pipe racks are not required, delete these curves from the estimate.
All building steel is included with the buildings and is not a part of this
section.
STRUCTURAL STEEL
Tons Required
Tons Required
Pieces Of Equipment
MISCELLANEOUS IRON
Tons Required
Tons Required
Pieces Of Equipment
PIPE RACK STEEL
Tons Required
Tons Required
Pieces Of Equipment
STRUCTURAL STEEL
Equipment Supports and
Structures
Material Cost
Material Cost
Pieces Of Equipment
STRUCTURAL STEEL FOR
PIPE RACKS
Miscellaneous Iron for Equipment
Material Cost
Material Cost
Pieces Of Equipment
Miscellaneous iron
Pipe racks
STRUCTURAL STEEL AND
MISCELLANEOUS IRON
Equipment, Equipment Supports
and Structures, and Pipe Racks
Erection Manhours
Erection Manhours
Pieces Of Equipment
Structural steel
Miscellaneous iron
Pipe racks
Section 7
BUILDINGS
The scope of work, for a proposed project should include information as

to type and size of buildings required.
The logarithmic graphs included in this section show average labor in
manhours and material dollar cost per square foot of floor area for vari-
ous types of one-story buildings that are more or less standard.
All buildings listed include building earthwork, concrete foundations,
concrete ground floor slabs, structural framing, exterior and interior
finishes, sprinkler system, plumbing, HVAC, and electrical power and
lighting. AU utilities extend five feet outside of building.
Following is a listing of buildings with a brief description of their types
and inclusions.
Building Types and Descriptions
Office Building
StructureClear span steel framing.
Exterior WallsMasonry and curtain wall with aluminum entrance.
Interior WallsMetal studs and drywall with hollow metal doors and
frames.
CeilingsSuspended and insulated.
RoofMetal deck with built-up roof, roof ventilators, gutters and drains.
Dining FacilitiesCoffee bar and dining area.
PlumbingWater, utility lines, toilets, drains and sprinklers.
HYkC-Ample for size of structure.
ElectricalLighting and power.
Note: No furniture is included.
Laboratory Building:
Same type construction as office building with additional plumbing and
electrical outlets for laboratory equipment.
Note: No laboratory equipment or furniture is included.
Control Building
StructureStructural steel framing.
Exterior WallsConcrete block, hollow metal frames and doors and steel
sash.
Interior WallsOffice and toilet with metal studs and drywall, hollow
metal frames and doors.
RoofPre-cast concrete slabs with insulation and built up roof.
CeilingsExposed.
PlumbingToilet utilities and drinking fountain.
HVACAmple for size of structure.
ElectricalLighting and power.
Note: No instrumentation included.
Warehouse Building:
StructureStructural steel framing.
Exterior WallsCorrugated asbestos or insulated metal siding with hol-
low metal doors and frames, truck doors and steel sash.
Interior WallsOffice and toilet room partitions of metal studs and dry-
wall with hollow metal doors and frames, storage shelv-
ing and bins included.
RoofSame as exterior wall siding.
CeilingsExposed except office and toilet area with same type construc-
tion as interior partitions.
PlumbingToilet utilities and drinking fountains.
HVAC-Office area only.
ElectricalPower and lighting.
Maintenance Shop Building

Same type construction as warehouse with additional foundations for
shop equipment and including an overhead crane.
Note: No shop equipment is included.
Change House Building

Same type construction as control building with concrete locker bases,
lockers and additional toilet and shower facilities for men and women.
BUILDING MATERIALS
Cost Per Square Foot
Materials Only
Material Cost Per Square Foot
Square Feet Of Floor Area

(D Office building Warehouse building
(D Laboratory building Maintenance shop building
(E) Control building Change house building
BUILDING ERECTION
Manhours Per Square Foot
Manhours Per Square Foot
Square Feet Of Floor Area

(D Office building (D Warehouse building
Laboratory building Maintenance shop building
Control building Change house building
Section 8
PIPING
In the absence of plot plans, piping and instrument diagrams, and flow
sheets the cost of process piping can be determined from the following
logarithmic graphs.
The graphs are based on total equipment count.
All dollar costs on the material graphs are average and include the costs
of all pipe, valves, and fittings that should be required. Control valve ma-
terial cost is included in the instrumentation section.
Labor manhour graphs are average and include all necessary installa-
tion operations. Installation of control valves furnished under the instru-
mentation section is included here.
The offsite fabrication graphs include all labor, material, and shop costs
for furnishing and fabricating pipe spools and delivery within reasonable
distance of job site.
Graphs for underground potable water, fire loops, etc., include all mate-
rial and labor operations to five feet outside of buildings.
The field x-ray and stress relief graphs are to be considered as subcon-
tract work.
Building piping for plumbing, etc., to five feet outside the building, is
included under the building section and is not to be considered here.
SHOP FURNISH AND
FABRICATE PIPE AND
FITTINGS
Linear Feet of Pipe For Pieces Of Equipment
Linear Feet Of Pipe
Pieces Of Equipment
Alloy 2V2" and over
Carbon steel 2V2" and over
Alloy 2" and under
SHOP FURNISH AND
FABRICATE PIPE AND
FITTINGS
Cost For Pieces Of Equipment
Shop Furnish And Fabricate Total Cost
Pieces Of Equipment
OAlloy2J/2" and over
Carbon steel 2Vz" and over
Alloy 2" and under
SHOP FURNISH AND
FABRICATE PIPE AND
FITTINGS
Cost For Pieces of Equipment
Shop Furnish And Fabricate Total Cost
Pieces Of Equipment
Alloy 2 ^ " and over

Carbon steel 2te" and over
Alloy 2" and under
FIELD FURNISH, FABRICATE9
AND ERECT PIPE, FITTINGS,
AND VALVES
Linear Feet Of Pipe For Pieces Of Equipment
Linear Peet Of Pipe
Pieces Of Equipment
1
(D Carbon steel 2 ^" and over
(E) Carbon steel 2" and under
(S) Steam tracing
(D Underground
Alloy 2" and under
FIELD FURNISH9 FABRICATE9
AND ERECT PIPE9 FITTINGS9
AND VALVES
Material Cost For Pieces Of Equipment
Material Cast
Pieces Of Equipment
Carbon steel 2W and over
Carbon steel 2" and under
Carbon steel underground
AND VALVES
Pieces Of Equipment
Carbon steel 2%" and over
Carbon steel underground
FIELD FURNISH, FABRICATE,
AND ERECT STEAM TRACING
PIPE, FTTTINGS, AND VALVES
Pieces Of Equipment
FIELD FUBNISH 9 FABRICATE9
AND ERECT PIPE9 FITTINGS9
AND VALVES
Material Cost
Pieces Of Equipment
0 Alloy 2" and under
FIELD ERECT SHOP
FABRICATED SPOOLS
PIPE, FITTINGS, AND VALVES
Labor Manhours For Pieces Of Equipment
Erection Manhours
Pieces Of Equipment
Note: All items include installation of control valves.
Alloy 2Mz" and Over
Carbon Steel 2te" And Over
Alloy 2" And Under
AND VALVES
Erection Manhours
Pieces Of Equipment
Carbon steel 2 1 ^" and over
AND ERECT
PIPE, FITTINGS, AND VALVES
Erection Manhours
Pieces Of Equipment
(D Carbon steel underground
Steam tracing
Alloy 2" and under
FIELD FURNISH9 FABRICATE9
AND ERECT
MISCELLANEOUS PIPING
ITEMS
Material Cost
Pieces Of Equipment
(D Hangers and supports

Testing pipe and fittings
Testing welders
AND ERECT
MISCELLANEOUS PIPING
ITEMS
Total Manhours For Pieces Of Equipment
Total Manhours
Pieces Of Equipment
(D Hangers and supports
(2) Testing pipe and fittings
Testing welders
AND ERECT
X-RAY AND STRESS
RELIEVING
Total Subcontract Cost For Pieces Of Equipment
Total Subcontract Cost
Pieces Of Equipment
Section 9
ELECTRICAL
Logarithmic graphs in this section reflect the average cost of project

power and lighting excluding building electrical that is included with the
building section.
Power and lighting graphs for material in dollars and labor in manhours
are included for the battery limit requirements and are based on total
pieces of equipment.
Instrumentation graphs are included for the cost of miscellaneous hook-
up materials in dollars and installation of this material in manhours. In-
struments, instrument standards, tray supports, trays, tubes and tube
bundles are discussed in Section 10, "Instrumentation."
ELECTRICAL POWER
Power Material Cost
Electrical Power Material Cost
Pieces Of Equipment
ELECTRICAL POWER
Pieces Of Equipment
ELECTRICAL LIGHTING
Lighting Material Cost
Lighting Material Cost
Pieces Of Equipment
ELECTRICAL LIGHTING
Pieces Of Equipment
ELECTRICAL
INSTRUMENTATION
Total Miscellaneous Instrumentation Material Cost
Miscellaneous Electrical Instrument Material Cost
Pieces Of Equipment
Note: Pneumatic instruments and other instrument
materials are included under "Instruments."
ELECTRICAL
INSTRUMENTATION
Miscellaneous Electrical Instrument Manhours
Pieces Of Equipment
Note: Manhours for installation of electrical instrument

materials only. All other instrument manhours
included under "Instruments"
Section 10
INSTRUMENTATION
The following graphs represent the average number of instruments re-

quired, their material value in dollars and installation in manhours based
on total pieces of equipment.
Included with the instrument graphs are dollars and manhours for the
furnishing and installation of panel boards.
Other graphs are included for the cost and installation of standards,
tray supports, trays, tubes, and tube bundles.
Material value of control valves is included under this section. The in-
stallation of these valves is discussed in Section 8, "Piping."
Furnishing and installation of miscellaneous electrical hook-up materi-
als is discussed in Section 9, "Electrical".
INSTRUMENTS
Total Number Of Instruments Required
Number Of Instruments
Pieces Of Equipment
INSTRUMENTS
Total Material Cost
Cost Of Instruments
Pieces Of Equipment
INSTRUMENTS
Total Instrument Installation Manhours
Pieces Of Equipment
CONTROL VALVES
Total Material Cost
Control Valves Material Cost
Pieces Of Equipment
Note: Installation manhours included under "Piping."
STANDARDS, TRAY SUPPORTS,
TRAYS, TUBES, AND TUBE
BUNDLES
Total Material Cost
Total Material Cost
Pieces Of Equipment
STANDARDS, TRAY SUPPORTS,
TRAYS, TUBES, AND TUBE
BUNDLES
Total Installation Manhours
Pieces Of Equipment
Section 11
INSULATION
The following piping and equipment insulation graphs are based on to-
tal pieces of equipment for a project and are average for various types
and thickness that are more or less standard for refinery and petrochemi-
cal work.
All building insulation is discussed in Section 7, "Buildings."
Refractories and linings are considered a minor operation for this type
construction and can be estimated on the same basis as insulation.
INSULATING MATERIAL
Total Square Feet
Total Square Feet
Pieces Of Equipment
Pipe
Equipment
INSULATING MATERIAL
FOR EQUIPMENT
Total Material Cost
Total Material Cost
Pieces Of Equipment
INSULATING MATERIAL
FOR PIPING
Total Material Cost
Total Material Cost
Pieces Of Equipment
INSULATING LABOR FOB
PIPING AND EQUIPMENT
Total Manhours
Pieces Of Equipment
Pipe
Equipment
Section 12
PAINTING
Based on total pieces of equipment the following graphs are average

cost of materials in dollars and labor in manhours for painting.
Material cost includes sandblasting materials as required and protec-
tive coating materials of paint and/or epoxy.
Labor manhours include time required for sandblasting and painting.
Building painting is discussed in Section 7, "Buildings."
PAINTINGEQUIPMENT
Square Feet Area
Square Feet Area
Pieces Of Equipment
PAINTINGSTRUCTURAL
STEEL AND PIPING
Square Feet Area
Square Feet Area
Pieces Of Equipment
(D Structural steel
Piping
PAINTINGMISCELLANEOUS
AND PIPE RACK STEEL
Square Feet Area
Square Feet Area
Pieces Of Equipment
0 Miscellaneous iron
Pipe rack steel
PAINTINGEQUIPMENT
Total Material Cost
Total Material Cost
Pieces Of Equipment
PAINTINGEQUIPMENT
Total Manhours
Painting Manhours
Pieces Of Equipment
PAINTINGSTRUCTURAL
STEEL
Total Material Cost
Total Material Cost
Pieces Of Equipment
PAINTINGSTRUCTURAL
STEEL
Total Manhours
Painting Manhours
Pieces Of Equipment
PAINTINGPIPING
Total Material Cost
Total Material Cost
Pieces Of Equipment
PAINTINGPIPING
Total Manhours
Painting Manhours
Pieces Of Equipment
AND PIPE RACK STEEL
Total Material Cost
Total Material Cost
Pieces Of Equipment
Miscellaneous iron
Pipe rack steel
AND PIPE RACK STEEL
Total Manhours
Painting Manhours
Pieces Of Equipment
Miscellaneous iron
Pipe rack steel
Section 13
PAVING
This section includes items of work for the installation of road, parking
area and yard pavements.
The placement of sub-base materials for these items is described in Sec-
tion 4, "Site improvement." The furnishing and placing of finish base and
asphalt, concrete or gravel pavement is included.
The scope of work or other proposal documents should indicate the
pavement requirements. In the absence of this information, the following
allowances can be added based on the total equipment count.
1. Asphalt Pavement40.0 square yards per piece of equipment.

2. Concrete Pavement4.5 square yards per piece of equipment.

ASPHALT PAVEMENT
6-Inch Base2 Inches Asphalt
Total Subcontract Price
Total Subcontract Price
Square Yards
CONCRETE AND GRAVEL
PAVEMENTS
Total Material Cost
Total Material Cost
Square Yards
012-inch base material and 6-inch reinforced concrete

6-inch gravel pavement
CONCRETE AND GRAVEL
PAVEMENTS
Total Manhours
Total Manhours
Square Yards
(D 12-inch base material and 6-inch reinforced concrete
6-inch gravel pavement
Section 14
PRORATABLES
Materials costs in dollars and labor in manhours on the following graphs

reflect the average cost and time required for daily area clean-up, all proj-
ect scaffolding and final test, start-up, and pre-commissioning assistance.
PRORATABLE MATERIAL
Total Material Cost
Total Material Cost
Pieces Of Equipment
PRORATABLE LABOR
Total Manhours
Manhours
Total
Pieces Of Equipment
Section 15
CONSTRUCTION EQUIPMENT
The average cost of equipment to construct a project can be estimated

from the following logarithmic graphs.
The rental or purchase curve represents the average cost of rental or
purchase of construction equipment to construct the project. This does
not include small tools.
The fuel, oil, grease, and supply curve includes the cost of these items
to operate and maintain the equipment.
The equipment service labor curve represents all labor required to ser-
vice and maintain the construction equipment. This does not include the
operating labor of the equipment when working. Operators are included
in the direct account labor.
BASE RENTAL OR PURCHASE COST
FUEL, OIL, GREASE, AND
SUPPLIES COST
Cost
Total
Total Direct Field Labor Cost In Million Dollars

(D Rental or puchase cost
Fuel, oil, grease and supplies cost
SERVICE LABOR
Total Manhours
Total Manhours
Equipment Rental Or Purchase Cost

In Hundred Thousand Dollars
Section 16
OVERHEADS AND INDIRECTS
Included in this section are logarithmic graphs reflecting average cost

of labor, materials, temporary facilities, small tools, consumable supplies,
burdens and benefits, etc., required to supervise and construct a project.
Various items have been grouped together on the following graphs for
ease of listing and application. For a comprehensive listing of total cover-
age of items under this section refer to the overhead and indirect listings
under Section 1 "Disciplines of Work."
troducton to this manual before applying this information.
INDIRECT LABOR
Engineering and Supervision
Personnel
Total Manhours
Total Manhours
Total Direct Labor In Hundred Thousand Dollars

(D Engineering personnel
Supervision personnel
INDIRECT LABOR
Office Personnel
Total Manhours
Total Manhours

OTHER INDIRECT AND
TEMPORARY CONSTRUCTION
LABOR
Total Manhours
Total Manhours

Other Indirect Labor
(D Temporary Construction Labor
PAYROLL BURDENS AND
BENEFITS
Other Indirect and
Temporary Construction
Materials
Total Cost
Total Cost

Payroll burdens and benefits
(2) Other indirect materials
(H) Temporary construction materials
Note: See next page for continuation of these items.
PAYROLL BURDENS AND
BENEFITS
OTHER INDIRECT MATERIALS
Total Cost
Cost
Total
Total Direct Labor In Million Dollars

(D Payroll burdens and benefits
(E) Other indirect materials
Section 17
HOME OFFICE COST
Total engineering design, including construction services such as esti-

mating, scheduling, expediting, etc., project general management, design
allowance, and fee are included as a part of home office cost and as such
are considered under this section.
Manhour range tables listing manhour ranges for single and duplicate
pieces of equipment are included to establish the total home office man-
hours required.
After total manhours are established they are to be spread, on a per-
centage basis, to the various personnel disciplines, as outlined in the fol-
lowing manhour spread percentage table.
Simply by multiplying the established discipline manhours by your es-
tablished discipline rates a total labor manhour and dollar cost is ob-
tained.
Other cost such as blueprints, reproductions, computer use, miscellane-
ous expenses, travel expenses, telephone, telex, postage, and burdens
and benefits are to be established as a percent of the total labor dollars in
accordance with the following percentage spread table for these items.
After the total labor and material dollars are established, the estimator
need only apply a cost for design allowance and fee for a complete home
office engineering design cost.
See Section 19, "Definition of Estimate Adjustments," for design allow-
ance and fee definitions.
ENGINEERING DESIGN
Manhour Range Allowance
Per Piece of Equipment
Manhour Allowance For

Single Duplicate
Equipment Classification Unit Range Unit Range
Boilers And Heaters
Packaged Steam Boilers 800-1,000 400-500
Packaged Electric Hydronic Boilers 800-1,000 400-500
Cast Iron Gas Fired Boilers 650-850 350-450
Steel Boiler Stacks 400-500 200-250
Fired Heaters 600-800 300-400
Deaerating Heaters 600-800 300-400
Classification Equipment
Cone Type Pelletizers 400-600 200-400
Pressure Sifters 450-650 225-325
Rotary Screens 400-600 200-400
Turbo-Screen Classifiers 500-700 250-350
Compressors And Air Dryers
Reciprocating Gas Engine Compressors 1,000-1,200 600-700
Reciprocating Electric Compressors 1,000-1,200 600-700
Centrifugal Package Unit Compressors 850-1,000 425-500
Air Cooled Service Compressors 600-800 300-400
Air DryerRefrigerated Type 650-850 325-425
Air DryerChiller Type 650-850 325-425
Conveyors And Bucket Elevators
ConveyorOpen Belt 800-1,000 400-500
ConveyorBelt Enclosed With Walkway 1,000-1,200 500-600
ConveyorSteel Screw 850-1,000 400-500
ConveyorReciprocating 800-1,000 400-500
ConveyorScroll 800-1,000 400-500
ConveyorSpaced Bucket Elevator 800-1,000 400-500
ConveyorContinuous Bucket Elevator 800-1,000 400-500
Crystallizers
Batch Vacuum 650-850 325-425
Mechanical 700-900 350-450
Dow Therm Units 750-850 300-400
ENGINEERING DESIGN

Single Duplicate
Dry Material Blenders And Feeders
Blenders 50-100 20-40
Vibrating Packers 50-100 20-40
Electric Vibrating Feeders 50-100 20-40
Gravimetric Feeders 50-100 20-40
Volumetric Feeders 50-100 20-40
Wing-Type Feeders 50-100 20-40
Conveyor Type Feeders 80-150 30-70
Sanitary Type Feeders 80-150 30-70
Dry Polymer Feeders 70-120 30-50
Dryers And Flakers
Atmospheric Drum Dryer 700-900 350-450
Vacuum Drum Dryer 700-900 350-400
Twin Drum Dryer 800-1,000 400-500
Tray Atmospheric Dryer 800-1,000 400-500
Tray Vacuum Dryer 800-1,000 400-500
Rotary Dryer 800-900 400-450
Spray Dryer 800-900 400-450
Cooling Drum Flakers 700-900 350-450
Dust Collectors
Cyclone 700-900 350-450
Multi Cyclones 800-1,000 400-500
Washers 800-1,000 400-500
Automatic Cloth Filters 800-1,000 400-500
Centrifugal Precipitators 1,000-1,200 500-600
Electrical Precipitators 1,000-1,200 500-600
Feeder Valves 300-400 150-200
Ejectors
Single-Stage Noncondensing 200-400 100-200
Two-Stage Barometric Intercondenser 200-400 100-200
Extractors
Continuous Centrifugal 200-500 100-200
ENGINEERING DESIGN

Single Duplicate
Fans And Blowers
Heavy Gauge Centrifugal Fans 600-800 300-400
Motors And V-BeIt Drive For Fans 100-150 50-60
Rotary Blowers 400-600 200-300
Centrifugal Turbo Blowers 600-800 300-400
Filters
Pressure Type 200-300 100-150
Oil Mist Collectors 200-300 100-150
Plate And Frame Type 200-400 100-200
Sparkler 200-300 100-150
Leaf 200-300 100-150
Sewage And Rotary 300-400 150-200
Screen Vibrating 400-600 200-300
Flotation Machines 400-600 200-250
Gas Holders 150-200 50-70
Generators
Steam Turbine Units 5,000-8,000 2,000-3,500
Inert Gas Generators 2,000-4,000 800-1,500
Skid MountedDiesel Engine Driven 1,000-2,000 300-500
Heat Exchangers, Evaporators And Condensers
Shell And Tube, Floating Head Exchangers 600-800 300-400
Shell And Tube, Fixed-Tube Sheet, U-Tube
Exchangers 600-800 300-400
Steel Fin Tubes, Steel ReBoilers And
Jacketed Pipe 600-800 300-400
Long Tube Vertical Evaporators 800-900 400-450
Horizontal Tube Evaporators 800-1,000 400-500
Jacketed, Glass Lined Steel Vessel Evaporators 850-1,050 425-525
CondensersBarometric 650-850 325-425
ENGINEERING DESIGN

Single Duplicate
Mixers And Blenders For Liquid And Liquid Solids

Propeller Mixers 50-150 20-60
Blender Type Mixers 50-150 20-60
Pan And Sigma Mixers 50-150 20-60
Homogenizers 60-150 25-60
High Intensity Mixers 60-150 25-60
Pumps
Centrifugal 700-900 350-450
Vertical Turbine And Sump 850-1,100 425-550
Power And Internal Gear Rotary 700-900 350-450
Vacuum 400-600 200-300
Sewage Nonclog 700-900 350-450
Scales And Weighing Equipment
Mechanical Lever Truck Scales 1,000-1,200 500-600
Electronic Load Cell Truck Scales 1,000-1,200 500-600
Built In Industrial Scales 200-300 100-150
Automatic Bagging Scales 200-300 100-150
Bulk Weighing Scales 300-400 150-200
Separators
Centrifugal Batch Top Suspended 600-800 300-400
Centrifugal Batch Bottom Driven 600-800 300-400
Centrifugal Batch Automatic 700-900 350-450
Centrifugal High Speed 700-900 350-450
Size Reduction Equipment
Size Reduction Crushers 400-600 200-300
Size Reduction Mills, Cutters, Pulverizers 400-600 200-300
Ball Mills 500-700 250-350
Thickeners
Continuous Type 400-600 200-300
ENGINEERING DESIGN

Single Duplicate
Vessels, Reactors And Tanks
Horizontal Pressure Vessels 800-1,000 400-500
Vertical Pressure Vessels (Towers) 1,000-1,200 500-600
Agitated, Jacketed Reactors 1,000-1,200 500-600
Vacuum Receiver Tanks 800-1,000 400-500
Agitated Tanks 700-900 350-450
Storage Tanks 600-1,000 300-500
Waste Treatment Equipment
Sewage Treatment Plant Package 600-800 300-400
IncineratorsLiquid Waste 500-800 250-400
IncineratorsSolid Waste 500-800 250-400
Solid Waste Shredders 400-600 200-300
Wastewater Treatment Package System 600-800 300-400
Water Treating Equipment
Mechanical Surface Aerators 850-1,000 425-500
Ion Exchanger Demineralizers 600-800 300-400
Water Stills 200-300 100-200
ENGINEERING DESIGN
Other Cost as a Percent of
Total Engineering Design Labor Dollars
Item Percent
Blue Prints And Reproduction 14.0
Computer Use 12.0
Miscellaneous Expense 10.0
Travel Expense 3.0
Telephone, Telex And Postage 4.0
Burdens And Benefits 32.0
Total 75.0
ENGINEERING DESIGN
Manhour Spread Percentages
Per Cent
Discipline 1 2 3__
Operations Management 0.1 0.1 0.1
Project Management 1.5 1.6 1.9
Project Engineer 5.5 6.1 7.0
Design Supervisor 0.9 1.0 1.0
Civil/Structural 5.2 8.7 6.3
Vessels 2.6 2.8 3.1
Electrical 5.9 6.5 7.2
Plant Design 19.7 17.0 23.8
Piping 3.0 2.3 3.8
Administration 4.3 4.7 5.0
P & Fs Flow Diagrams 2.1 2.0 2.7
Mechanical Supervision 0.4 0.4 0.4
Instrument Engineering 3.6 5.0 4.4
Instrument Drafting 4.9 6.4 5.8
Rotating Equipment 0.8 0.8 0.9
Special Equipment 1.2 1.3 1.4
Heat Transfer 0.5 0.5 0.6
Process 4.2 4.6 5.1
Estimating 1.0 1.0 1.1
Cost Engineering 1.7 1.3 1.4
Computer 2.5 2.5 2.8
Initial Operations 0.1 0.2 0.2
Technical Information 0.1 0.1 0.1
Scheduling 2.2 1.5 1.4
Purchasing 3.9 3.8 0.0
Inspection/Expediting 3.9 3.8 0.0
Stenographic 3.8 4.1 4.6
Accounting 8.8 5.8 5.8
Office Services 1.5 1.6 1.7
Contract Legal 0.1 0.1 0.1
Home Office Construction 2.0 LO OO
Total 100.0 100.0 100.0
Code:
1Engineering, Procurement And Construction Contract
2Engineering And Procurement Contract
3Engineering Only Contract
Section 18
RATIO ESTIMATING FACTORS
Ratio estimating factors are simply the relationship, in percentage

ranges, between two or more things and are the transformation of statis-
tical data into combinations of variables that are usually not correlated.
The minimum basic information required to assemble an estimate of
this type is:
1. Information regarding plant capacity, product form, basic process

and raw material.
2. A complete process equipment list with individual shipping dates
and total material dollar cost.
3. The general plant location.
The accuracy of this type estimate should fall in the range of + 30% to
- 30%.
Accuracy Definition
+ % = Add to total cost excluding contingency for highest cost.

- % = Deduct from total cost excluding contingency for lowest cost.
The direct cost percent ranges in the following tables are to be applied
against the total material dollar value of the process equipment. The con-
struction equipment and overhead and indirects percent ranges are a per-
cent of the direct field labor dollar value. The home office percent range is
applied against the total direct and indirect cost of the project.
The percentages for the various disciplines of work are averages of
many projects located in the Gulf Coast Area. When determining a per-
centage to be applied for a specific project from the percentage range ta-
bles consideration should be given to this fact.
The percentages for labor are for open or merit shop type operations. If
closed shop methods are to be employed additional consideration should
be given and applied against the labor dollar value.
Manhours for the various disciplines of work can be obtained by divid-
ing the labor percentage dollars by the established hourly activity rate.
A construction schedule can be executed utilizing the discipline man-
hours coupled with equipment shipping dates.
For a description of items included under the various disciplines of work
see Section 1, "Disciplines of Work."
Ratio Estimating Factors
The Refinery Process Systems table is based on any one or all of the
following process systems and includes all discipline requirements.
1. Atmosphere and vacuum crude distillation

2. Saturates gas plant
3. Naphtha hydrodesulphurization
4. Distillate hydrotreater
5. Flexicoker
6. Heavy oil hydrodesulphurization
7. Fluid catalytic cracker
8. Unsaturates gas plant
9. Cycle oils hydrodesulphurization
10. C5, C6 isomerization
11. Catalytic reformer
12. Aromatics extractions
13. Steam reforming hydrogen plant
14. Butane alkylation
15. Olifin poly plant
16. H2S recovery and sulphur manufacturing
Tables on Chemical Plants are self-explanatory.

REFINERY PROCESS SYSTEMS
Ratio Percentages
Direct Cost
Average
Percent
Percentage Ratio Ranges of Totals
Discipline I II HI IV V VI VII
1. Process Equipment 100.00 44.30-44.60 7.70-7.80 55.83 92.82 10.03 49.97
2. Site Preparation 0.02-0.05 0.25-0.30 2.75-2.85 0.01 0.55 3.59 1.01
3. Site Improvements 0.95-1.10 * 1.10-1.12 0.55 * 1.43 0.69
4. Concrete 4.25-4.75 0.10-0.12 12.70-12.90 2.41 0.22 16.42 5.63
5. Structural Steel 8.00-8.30 * 3.70-3.75 4.53 * 4.82 3.90
6. Buildings 1.10-1.25 2.20-2.40 1.70-1.75 0.66 4.81 2.21 1.71
7. Underground Piping 1.10-1.20 * 1.40-1.48 0.62 * 1.84 0.83
8. Above-ground Piping 32.00-35.00 0.75-0.80 21.30-22.40 18.59 1.60 27.51 18.19
9. Underground Electric 0.30-0.50 * 0.65-0.70 0.16 * 0.87 0.32
10. Above-ground Electric 11.50-12.00 * 6.10-6.25 6.47 * 7.90 5.81
11. Instrumentation 10.30-10.70 * 3.20-3.50 5.82 * 4.16 4.48
12. Insulation 4.50-5.00 * 7.40-7.50 2.55 * 9.57 3.94
13. Painting 1.50-1.70 * 3.90-4.00 0.93 * 5.06 1.84
14. Paving 0.40-0.60 * 0.60-0.70 0.27 * 0.81 0.36
15. Proratables 1.00-1.10 * 2.80-2.95 0.60 * 3.79 1.32
** lbtal Direct Cost 176.9-183.3 47.6-48.2 77.0-79.7 100.0 100.0 100.0 100.0
* Not applicable or no significant trend data available.

Roman Numeral Codes:
I. Discipline, Other Materials as a percent of Process Equipment costs. (1,1)
II. Discipline, Subcontracts as a percent of Process Equipment costs. (1,1)
III. Discipline, Direct Labor as a percent of Process Equipment costs. (1,1)
IV. Discipline, Material cost as a percent of Total Material costs. (IV**)
V. Discipline, Subcontract cost as a percent of Total Subcontract costs. (V**)
VI. Discipline, Labor cost as a percent of Total Labor cost. (VI**)
VII. Discipline, Total cost as a percent of Total Direct cost. (VII**)
LIQUID TYPE CHEMICAL PLANT
Ratio Percentages
Direct Cost
Average
Percent
3. Site Improvements 2.75-3.50 0.60-0.75 1.50-2.25 1.30 1.74 2.95 1.70
4. Concrete 7.50-8.75 2.00-3.00 9.00-12.00 3.58 6.30 15.04 6.39
6. Buildings 4.00-5.00 3.00-3.50 3.50-4.50 1.90 8.23 6.08 3.55
7. Underground Piping 4.00-5.00 0.01-0.02 2.75-3.25 2.00 0.02 4.04 2.17
12. Insulation 7.50-8.50 * 4.50-5.25 3.60 * 6.44 3.74
13. Painting 2.50-3.25 * 2.75-2.90 6.30 * 3.93 1.70
14. Paving 1.00-1.50 0.30-0.40 0.50-1.00 0.50 0.85 1.05 0.66
15. Proratables 1.00-1.50 * 2.00-2.40 0.60 * 3.09 1.04
** Total Direct Cost 217.9-237.5 32.57-36.43 68.7-85.7 100.0 100.0 100.0 100.0

SOLID TYPE CHEMICAL PLANTS
Ratio Percentages
Direct Cost
Average
Percent
Discipline I II IH IV V VI VlT
4. Concrete 8.75-10.25 2.50-3.00 12.00-13.75 4.33 7.37 17.08 7.59
6. Buildings 5.00-5.50 3.75-4.25 4.00-5.25 2.34 10.99 6.51 4.22
12. Insulation 5.50-6.50 * 3.00-4.00 2.47 * 4.03 2.56
13. Painting 2.00-2.75 * 1.75-2.25 0.91 * 2.46 1.17
14. Paving 1.10-1.80 0.30-0.40 0.75-1.00 0.52 0.98 0.98 0.68
15. Proratables 1.40-1.75 * 2.25-2.50 0.65 * 3.09 1.15
** Tbtal Direct Cost 220.8-232.8 36.12-38.07 74.30-85.50 100.0 100.0 100.0 100.0

LIQUID/SOLID TYPE CHEMICAL PLANTS
Ratio Percentages
Direct Cost
Average
Percent
4. Concrete 9.25-10.50 2.75-3.50 12.50-14.00 3.94 7.16 16.15 7.01
6. Buildings 5.00-5.50 3.75-4.25 4.75-5.25 2.13 10.67 6.16 3.90
12. Insulation 8.00-9.00 * 4.50-5.50 3.37 * 5.72 3.55
13. Painting 3.00-3.50 * 2.80-3.10 2.14 * 3.49 1.62
14. Paving 1.25-1.75 0.30-0.50 0.75-1.25 0.47 0.96 0.94 0.63
15. Proratables 1.50-2.00 * 2.25-2.50 0.58 * 2.86 1.04

CHEMICAL PLANTLIQUID HIGH PRESSURE TYPE
4000 TO 5000 PSI
Ratio Percentages
Direct Cost
Average
Percent
Discipline I II III IV V VI VII
4. Concrete 6.50-7.25 1.75-2.00 9.25-10.00 2.92 5.30 12.62 5.26
6. Buildings 3.25-4.00 2.50-3.00 3.25-3.75 1.48 7.67 4.50 2.75
12. Insulation 8.00-8.50 * 4.50-5.00 3.54 * 6.33 3.79
13. Painting 2.75-3.25 * 2.75-3.00 1.30 * 3.86 1.73
14. Paving 0.75-1.25 0.02-0.04 0.50-0.70 0.37 0.80 0.79 0.51
15. Proratables 1.25-1.50 * 2.00-2.50 0.63 * 3.28 1.15

CHEMICAL PLANTLIQUID HIGH ALLOY TYPE
Ratio Percentages
Direct Cost
Average
Percent
Discipline I II HI IV V VI VlT
4. Concrete 6.25-7.00 1.50-2.00 8.75-10.00 2.95 5.09 12.97 5.31
6. Buildings 3.25-4.00 2.50-3.00 3.25-3.50 1.59 7.84 4.93 2.95
12. Insulation 6.75-7.25 * 3.50-4.00 3.11 * 5.67 3.33
13. Painting 2.50-3.00 * 2.25-2.50 1.14 * 3.46 1.52
14. Paving 0.75-1.00 0.25-0.50 0.50-0.70 0.42 0.81 0.87 0.54
15. Proratables 1.25-1.50 * 2.00-2.50 0.65 * 3.44 1.18

Ratio Percentages
As A Percent Of Direct Field Labor
Percent of
Direct Field Labor
Description Range Average
16. Rental or Purchase 12.0-18.0 15.0
17. Service Labor 2.0-6.0 4.0
18. Fuel, Oil, Grease, Supplies 7.0-15.0 1^0
Tbtal 21.0-39.0 31.0
Note: Fuel percentage based on diesel cost of $1.25 per gallon.
OVERHEAD AND INDIRECTS

Ratio Percentages
As A Percent Of Direct Field Labor
Percent of
Direct Field Labor
19. Salaried Indirect 8.0-12.0 10.0
Office Hourly Indirects 4.0-8.0 16.0
Field Hourly Indirects 3.0-7.0 5.0
20. Temporary Construction 10.0-20.0 15.0
Facilities*
21. Burdens and Benefits 25.0-28.0 27.0
22. Small Tools and Consumables 5.0-10.0 7.0
23. Other Indirects 10.0-20.0 1^0
Tbtal 65.0-105.0 85.0
* Includes Labor for Constructing.
HOME OFFICE SERVICES

Ratio Percentages
As A Percent Of Tbtal Direct And Indirect Cost
Percent of Total
Direct and Indirect
24. Engineering/Design Services 8.0-16.0 12.0
25. Construction Services 0.1-0.4 0.2
26. Project General Management 1.0-1.5 U
Tbtal 9.1-17.9 13.3
Section 19
ESTIMATE ADJUSTMENTS
Each estimate, in all probability, will need some or all of the following
adjustments dependent upon the scope of work, amount of pre-bid infor-
mation available, and the type of estimate to be prepared. The following
are definitions of these adjustments:
Design Allowance. The design allowance is an adjustment to the es-

timated mechanical equipment cost to provide for nominal and routine
changes in equipment design. The design allowance is included in the de-
tails of the estimate and is considered as part of the direct base cost. The
magnitude of the design allowance is a function of the amount of design
information available to the estimator, and it decreases as the accuracy
level of the estimate increases. An example of a design allowance is the
addition of money for routine nozzle and clip changes on a fabricated ves-
sel. It is expected that all design allowance money will be expended dur-
ing the project.
Quantity Allowance. The quantity allowance is an adjustment to

the estimated construction activity take-off quantities to provide for (1)
the difference between neat take-off quantities and in-place quantities
and for (2) consideration of fabrication waste. The quantity allowance is
included in the details of the estimate and is considered as a part of the
direct base cost. The magnitude of the quantity allowance is a function of
the amount of design information available to the estimator and de-
creases as the accuracy level of the estimate increases. An example of a
quantity allowance is adding to the piping take-off an allowed quantity of
small diameter pipe and valves for vents and drains not shown on esti-
mate drawings. It is expected that all quantity allowance money will be
expended during the project.
Escalation. The escalation is the amount of dollars or percentage of

cost added to the estimated base cost to provide for procurement at a fu-
ture date later than the estimate. The magnitude of the escalation is a
function of an appraisal of anticipated market conditions during the de-
sign and construction phases of the project. It is expected that all escala-
tion money will be expended during the project.
Contingencies. A percentage of base cost plus escalation and taxes

or amounts added to same providing coverage for human calculation or
judgement error in accumulation of estimate scope. Contingencies are an-
ticipated to be spent and form a part of the cost of the project. Contingen-
cies vary directly with the accuracy level of the estimate. The more gross
the method of estimating, the higher the contingencies. Contingencies do
not provide any funds for scope changes. Examples of items covered by
contingency are: piping lines missed on take-off, extension errors, dimen-
sion errors, etc.
Bisk. An amount of money or percent of base cost plus lower level ad-
ditives (except fee) normally added to the base cost plus additives to
cover the chances of probabilities that the base cost estimate plus addi-
tives is not ample for financing of the project. Risk is normally associated
with the monies applied by a contractor's management in the case of a
"lump sum" or "guaranteed maximum" or an owner for other contractual
arrangements to cover costs that might occur, but hopefully will not. Risk
monies may or may not be spent. These monies are added to provide fi-
nancial protection and quantify management or executive judgements for
final project cost outcome. Considerations of changes in scope normally
generated by an organization should be covered in these amounts. In rare
cases, risk could be expressed as a deduction from the base cost plus addi-
tives. Examples of items covered by risk are: inclement weather condi-
tions, time extensions of the project, prototype processes, productivity
loss, etc.
Fees. The amount of money anticipated to be recovered by the con-

tractor to provide funds for payments of his non-project overhead and
profit.

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Copyright 1984, 1996 by Elsevier. All rights reserved.

Originally published by Gulf Publishing Company,

For information, please contact:

For information on all Gulf Professional Publishing titles

Library of Congress Cataloging-in-Publication Data

Introduction .............................................................................. xvi

Section 1. Disciplines of Work .......................................... 1

Section 2. Process Equipment ......................................... 11

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Two-stage, Two-cylinder, Water-cooled Equipment

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Portable Clamp and Flanged Mounted Mixers

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Condensers and Receivers ........................................................... 73

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Dryers Vacuum ........................................................................... 90

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Fans and Blowers .......................................................................... 106

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Gravity Filtration Units Total Unit Installation

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For Heating Water Equipment Cost .............................. 148

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Reactors ........................................................................................ 167

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Water Softener System ................................................................. 188

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Column Trays, Shop Installation Cost Each .................. 207

Section 3. Site Preparation ............................................... 217

Section 4. Site Improvements ........................................... 219

Section 5. Concrete ........................................................... 222

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Earthwork for Equipment Structures, Pipe Racks, and

Section 6. Structural Steel and Miscellaneous Iron ........ 236

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Section 7. Buildings ........................................................... 243

Section 8. Piping ................................................................ 247

Section 9. Electrical ........................................................... 262

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Electrical Lighting Installation Manhours ................................... 266

Section 10. Instrumentation ................................................ 269

Section 11. Insulation .......................................................... 276

Section 12. Painting ............................................................. 281

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Painting Equipment Total Manhours ...................................... 286

Section 13. Paving ............................................................... 293

Section 14. Proratables ....................................................... 297

Section 15. Construction Equipment ................................. 300

Section 16. Overhead and Indirects ................................... 303

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Office Personnel Total Manhours .............................................. 305

Section 17. Home Office Cost ............................................. 309

Section 18. Ratio Estimating Factors ................................. 316

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Section 19. Estimate Adjustments ..................................... 325

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The Human Factor in Estimating

Method OneAccuracy Level of 10%

Method TwoAccuracy Level of 30%

The following is a broad description of the major items included in the

Direct Cost Items