TECHNICAL CALCULATION AND ESTIMATOR'S MAN-HOUR MANUAL Marko BuliéMarko Buli¢ TECHNICAL CALCULATION AND ESTIMATOR'S MAN-HOUR MANUAL ERECTION OF PROCESS OR CHEMICAL PLANTS II. Il. Vv. VL. vu. VIL IX. XL. XI. XI. XIV, xv. PIPING ABOVE GROUND PIPELINES STEEL STRUCTURES PROCESS EQUIPMENT STORAGE TANKS CYLINDRICAL AND SPHEROIDAL WELDING AND FLAME CUTTING CORROSION PROTECTION THERMAL INSULATION ESTIMATES PIPING ABOVE GROUND ESTIMATE POINTS FOR BUILD-IN ITEMS WEIGHT FACTORS TECHNICAL CALCULATION MANNER OF DATAS COMPILING MAN HOURS FOR OVERHAULS IN PETROCHEMICAL PLANTS FACTORS AND MAN HOURS FOR PIPING AND ‘STEEL STRUCTURE WORKS IN CALL FOR TENDERS OF “TECHNIP” COMPANY APPENDIX ZAGREB, 2003. (Completed edition) All right reserved. This book, or parts thereof, may not be reproduced in any form without permission of the author.‘Thank you for showing interest in buying our book TECHNICAL CALCULATION AND ESTIMATOR'S MANHOURS MANUAL You can buy the electronic version of the Manual containing all the figurest and other related data at the following prices: Individuals Legal entity 1, COMPLETE MANUAL (239 pages) Us$ 600 uss 1000 2, EACH CHAPTER I PIPING ABOVE GROUND - 36 pages + 20* Us$ 180 Uss 300 Il PIPELINES - 7 pages + 20* US$ 75 Uss 120 IIl STEEL STRUCTURES - 7 pages + 20* Us$ 80 Uss 130 IV __ PROCESS EQUIPMENT - 10 pages + 20* uss 70 Uss 110 V___ STORAGE TANKS - CYLINDRICAL & SPHERICAL - 11 pages + 20* us$ 80 Uss 130 VI. WELDING AND FLAME CUTTING - 18 pages + 20* Us$ 75 Uss 120 VIL_ CORROSION PROTECTION - 3 pages + 20* uUs§ 35 US$ 55 VIII THERMAL INSULATION - 3 pages + 20* US$ 35 Uss 55 IX _ ESTIMATES - 11 pages + 20* us$ 100 Uss 165 X PIPING ABOVE GROUND - ESTIMATE POINTS FOR BUILD-IN ITEMS - 76 pages + 20* Us$ 130 uss 215 XI WEIGHT FACTORS - 7 pages Us$ 15 uss 25 XII TECHNICAL CALCULATION MANNER OF DATA COMPILING - 4 pages uss 6 Uss 10 XIII MANHOURS FOR OVERHAULS IN PETROCHEMICAL PLANTS - 16 pages + 20* Us$ 80 Uss 130 XIV FACTORS AND MANHOURS FOR PIPING AND STEEL STRUCTURE WORKS IN CALL FOR TENDERS: OF “TECHNIP” COMPANY - 3 pages + 20* US$ 60 uss 100 NOTE: +20* = THE FIRST 13 PAGES OF THE MANUAL AND 7 PAGES OF THE APPENDIX 3. APERSONALISED ANALOGUE VERSION OF THE MANUAL COULD BE ORDERED AS WELL. Please, email us your full address and indicate the purchase option you have decided for. We shall send you the electronic manual immediately. AAs soon as your payment is received we shall send you the password that will enable you to open and use the e-manual. We congratulate you on your choice and thank you for buying our electronic Manual.PREFACE AIl40 years of my working life, I spent on erection of different process plants most of which were ol industry projects in the country and abroad, in Europe and North Africa. Since 1978 with occasional interruptions because of simultaneous involvement in several different projects, I worked mostly on technical calculations. I have made hundreds and hundreds calculations based on all kinds of tenders and erection of mechanical equipment, The tenders were written in various foreign languages and alphabet, even in Cyrillic. I am fully avare of the problems an estimator encounters when working on technical calculations for specific technologies. Very often tenders were not complete and not detailed enough, and the time required for a good technical calculation is getting every day shorter. It is not easy to present exact technical figures and quantities for the equipment or operations not fully defined, hard to comprehend, or even unknown to the estimator. Technical terms and expressions written in different languages and dialects are often incorrect and specific for individual branches. Enormous experience is needed, an ability to assess and estimate, and even the courage to write down the technical quantities and figures. That was the reason for collecting various technical bibliography, standards, catalogues, man hours and rates from the European and USA countries, I have made the analyses, comparisons, simulations, new measures, and manhour tables. A great deal of that was verified in practice during the plant erection. I surveyed the results and analyses of as-built designs. On many occasions, T sought a compromise between different opinions and standpoints. Too many things collected on too many places. Finally, I decided to write this manual for discriminative estimators. It is important to understand that there are no identical projects or jobs in this business, that each project is specific and that no automatism or copying is possible. Approach to any job should be serious and professional and a technical calculation should be made with the assistance of this Manual. Many people try to include the man hours from the tables into the computer systems, which I oppose. Those are the people, which instead of using a computer, a computer uses them. An estimator himself must choose the values and define the man hours taking into account all the elements that might have any influence on them, Only when the relevant man hours are estimated and selected, ‘@ computer can be used. A saying "Switch on your brain before switching on the computer” should be followed. The most complex work in developing these man hours was the work on the man hours for piping above ground. A basis I used was a system for estimating the value of erection works of a German Company LINDE, which I completed and modified. Generally, for elaboration of the man hours for erection/installation of process equipment, used the English man hours of the Oil and Chemical Plant Constructors Association, but I used other sources as well. The source or the author was noted for other tables and if I modified them, I provided the modification basis. Where there are no such notes, Iam the only author A complete edition of this manual in the Croatian language and its sections were published in 1997 and 2000. Thisis why I have not given a unified percentage of the production efficiency but each chapter has its own, Marko Bulié Zagreb Croatia, 2003PREFACE. 2... INTRODUCTION... ABBREVIATIONS & UNITS. CHAPTER da 12 24 22 23 23.1 23.2 24 da 12 13 14 15 16 2a 22 23 24 34 3.2 33 34 35 3.6 41 4.2 43 44 CONTENTS I. PIPING ABOVE GROUND... DERIVED OPERATING TIME STANDARD FOR TABLES FACTOR OF BASIC ASSEMBLY 1, PIPES (ANSI B. 36.10). PIPE - INSTALLATION ON PROCESS PLANT. PIPE - INSTALLATION ON PIPE RACK OR SLEEPER WAY. FITTINGS (ANSI B. 16.9). ELBOWS.. CAPS. TEES, STRAIGHT TEE. REDUCED TEE. REDUCERS ~ CONCENTRIC AND ECCENTRI 1, PIPES (DIN 2448/2458). PIPE - INSTALLATION IN PROCESS PLAN’ PIPE - INSTALLATION ON PIPE RACK OR SLEEPER WAY. STEAM TRACING (ANSI & DIN)... INSTRUMENT AND CONTROL PIPING.... ‘STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS FABRICATED FROM PIPES AND FITTINGS... ‘STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS FABRICATED FROM READY MADE DISTRIBUTORS FOR 4 CONNECTIONS. 2, FITTINGS (DIN).... ELBOWS... CAPS. TEES. REDUCERS ~ CONCENTRIC AND ECCENTRI: 3. FLANGES.. WELDING NECKS. SLIP - ON... SOCKET WELDING... LAP JOINT + STUB END. BLIND... ORIFICE COMPLETE. 4, SMALL FITTING: WELDOLETS, SOCKOLETS, NIPOLETS, etc. HALF COUPLINGS FOR WELDINGS..... FITTINGS WITH SOCKET ENDS THREADED FITTINGS.51 5.2 53 54 55 CHAPTER 1 Noawswn 8.2 83 84 85 8.6 87 10. 5. VALVES... VALVES WITH FLANGED ENDS VALVES WITH WELDING ENDS.. VALVES FOR THREADED ENDS.. PRESSURE GAUGES. THERMOMETERS... RATES FOR TENDER CALCULATIONS... MANHOUR ESTIMATE FOR INSTALLATION OF PIPING.. EFFECT ASSESSMENT FOR QUICK CALCULATION. PIPING IN PROCESS PLANT... . PIPES (CARBON STEEL - Nor INSULATED) - MEAN VALUE. FITTINGS (CARBON STEEL) - MEAN VALUE... VALVES - MEAN VALUE. PIPE SUPPORTS... AVERAGE DIAMETER - Manner of Calculation... RATES FOR INSTALLATION OF POLYETHYLENE PIPING. RATES FOR ERECTION OF PVC & FRP PIPING... CARBON STEEL PIPING CEMENT LINED INSIDE. PIPING MADE OF STEEL AND GREY CAST-IRON... RATES FOR PIPING BASED ON INCH-DIAMETER (ID). RATES FOR UNITS OF OPERATION ~- BASED ON INCH-DIAMETER (ID) RATES FOR PIPING WELDING... MAN HOURS FOR WELDING OF PIPING..... WORK CALCULATION - MAN HOURS FOR PIPING MODIFICATION AT SITE. INSTALLATION OF PIPING ABOVE - GROUND, Prefabrication and installation breakdown... Il, PIPELINES... PIPE TRANSPORT. PIPE STRINGING.. BENDING OF PIPES... PIPE JOINTING.. WELDING...... WRAPPING... LAYING IN TRENCH. SPECIAL POINTS... BORING UNDER ROADS AND RAILROADS... BREAK OUT OF ROADS....esss CONNECTING PIPELINE SECTIONS.. CROSSING WATERCOURSES....... INSTALATION OF CLEANING STATIONS PUTTING UP PIPELINE MARKERS.. OTHER SPECIAL POINTS..... PRESSURE TESTS... PRELIMINARY AND FINISHING WORKS.. BeeSsCHAPTER 1a 12 13 14 15 16 17 18 19 24 41 42 43 44 45 5a 52 53 CHAPTER da 12 13 14 15 16 17 18 19 24 214 21.2 21.3 22 224 2.2.2 III. STEEL STRUCTURE ERECTION 1, BASIC MAN HOURS - UNIT...... SORTING THE STRUCTURE. PRE-ERECTION OF STRUCTURE.. TRANSPORT OF STRUCTURE TO ERECTION PLACE. INSTALLATION OF ANCHOR BOLTS... STRUCTURE ERECTION... INSTALLATION OF LOST FORMWORK. INSTALLATION OF WIRE ROPE CLAMPS. REAMING OF HOLES... . BOLTING FROM SCAFFOLDING... 2, ERECTION OF MISCELLANEOUS STEEL STRUCTURES. BASIC MANHOUR RATES. 3. CORRECTION FACTORS..... 4, STEEL STRUCTURES IN OIL REFINERIES AND PETROCHEMICAL PLANTS. LIGHT STRUCTURE (to 30 ka/m MEDIUM-WEIGHT STRUCTURE (31 + HEAVY STRUCTURE (above 60 kg/m)... MISCELLANEOUS STRUCTURES... PIPE HANGERS AND SUPPORTS... 5. ERECTION AND DISMANTLING OF MISCELLANEOUS STEEL STRUCTURES... ERECTION OF STEEL STRUCTURES - ACC. TO THE WEIGHT. MISCELLANEOUS STRUCTURES... REMOVAL OF STEEL STRUCTURE AND MISCELLANEOUS ITEMS... 60 kg/m). IV, ERECTION OF EQUIPMENT IN PETROCHEMICAL INDUSTRY. 1, STATIONARY EQUIPMENT. ALL EQUIPMENT TO 0,5 TO! TOWERS above 0,5 TON.. TOWERS CONSISTING OF MORE PIECES PACKAGE UNIT. OTHER EQUIPMENT.. BRIDGE CRANES. UFTS... ELECTROSTATIC PRECIPITATORS... MARINE LOADING ARVS.... 2. ROTARY EQUIPMENT. CENTRIFUGAL PUMPS... MAN HOURS BASED ON POWER [KW]. MAN HOURS BASED ON WEIGHT [ka] MAN HOURS BASED ON THE CAPACITY, COMPRESSORS... COMPRESSORS DRIVEN BY ELECTRIC MOTOR, COMPRESSORS DRIVEN BY GAS TURBINE...34 3.2 33 34 41 42 CHAPTER 1 da 24 22 23 24 25 26 27 28 29 2.10 CHAPTER 1 wawn CHAPTER 1 2 3 CHAPTER 1 2 3. TOWERS & VESSELS - INSTALLATION OF INTERIOR COMPONENTS & EQUIPMENT... INSTALLATION OF TRAYS AND DEMISTERING PADS.... VESSELS & TOWER PACKINGS... OPENING AND CLOSING OF MANHOLES.. ERECTION OF PLATFORMS, LADDERS AND FLOOR GRIDS 4. EQUIPMENT SCAFFOLDING. TUBULAR SCAFFOLD... PATENT SCAFFOLDING. V. STORAGE TANKS - CYLINDRICAL AND SPHEROIDAL.. APPROX. WEIGHTS AND ERECTION EFFECTS OF CYLINDRICAL STORAGE TANKS. STATISTICAL PARTICIPATION OF STORAGE TANK COMPONENTS IN TOTAL WEIGHT.....+.s ERECTION OF CYLINDRICAL STORAGE TANKS - DETAILS. PRELIMINARY WORKS.... STORAGE TANK BOTTOM STORAGE TANK SHELL. WIND BINDINGS - RINGS FOR SHELL STIFFENING.. FIXED ROOF... FLOATING ROOF... AUXILIARY STRUCTURE CONNECTIONS AND OPENINGS. STORAGE TANK EQUIPMENT. FINISHING WORKS... ERECTION OF SPHERICAL AND SPHEROIDAL STORAGE TANKS 85 85 90 95 VI. WELDING AND FLAME CUTTING. MANUAL ARC WELDING OF CYLINDRICAL TANKS - SMAW, SUBMERGED ARC WELDING...... WELDING WITH SEMIAUTOMATIC (GMAW). WELDING OF SPHERICAL STORAGE TANKS... 100 MANUAL GAS CUTTING AND GAS CONSUMPTION, 102 VII. CORROSION PROTECTION... 103 SAND BLASTING AND PAINTING OF PIPING... 103 SAND BLASTING AND PAINTING OF STEEL STRUCTURES. 104 SAND BLASTING AND PAINTING OF STORAGE TANKS.... 105 VIII. THERMAL INSULATION... 106 THERMAL INSULATION FOR PIPING.. 106 THERMAL INSULATION OF VESSELS AND KILNS..... 108CHAPTER awn 91 9.2 93 94 95 96 97 10.1 10.2 10.3 10.4 IX, ESTIMATES. 1, ESTIMATE OF SCAFFOLDS... ESTIMATES OF SCAFFOLDING WHEN CONTRACTED TO A SPECIALIST FIRM... ESTIMATE OF SCAFFOLDING WHEN DONE BY AN ERECTION COMPANY. 2. ESTIMATE OF WELDING ROD CONSUMPTION AND ADDITIONAL WELDING MATERIAL. .. PIPING... STEEL STRUCTURES. CYLINDRICAL STORAGE TANKS... EQUIPMENT IN PETROCHEMICAL INDUSTR) 3, ESTIMATE OF CONSUMPTION OF TECHNICAL GAS AND GRINDING PLATE............. 4, ESTIMATE OF ELECTRICITY CONSUMPTION.. 5, ESTIMATE OF CONSUMPTION OF FUEL AND LUBRICANT. FUEL CONSUMPTION..... LUBRICANT CONSUMPTION. 6, TOOL COST ESTIMATE AT THE JOB SITE. 7, ESTIMATE OF SAFETY AT WORK MEANS. 8, ESTIMATE OF ERECTION TIME.... 9, SELECTION OF HOISTING MACHINERY. SELECTION OF THE LARGEST CRANE. PIPING IN PLANTS... PIPING BETWEEN PLANTS. PIPELINES..... ERECTION OF STEEL STRUCTURE..... INSTALLATION OF PROCESS EQUIPMENT. ERECTION OF CYLINDRICAL STORAGE TANKS... 10. UNLOADING, HANDLING AND SORTING OF THE MATERIAL. MATERIAL FOR PIPING... STEEL STRUCTURE PROCESS EQUIPMENT..... CYLINDRICAL STORAGE TANKS.. 11. TEMPORARY WORKS, SPACE REQUIRED AND CONNECTIONS AT THE SITE... TEMPORARY WORKS. AREA NEEDED... CONNECTIONS NEEDED... 12, ESTIMATE OF THE NUMBER OF WELDS AND RADIOGRAMS FOR PIPING.... ESTIMATE OF BUTTWELDS BASED ON A LIST OF MATERIAL - PIPES, FITTINGS AND FLANGES.. ESTIMATE OF BUTTWELDS BASED ON A LIST OF MATERIAL - FITTINGS AND FLANGES ONLY.. ESTIMATE OF BUTTWELDS BASED ON THE PIPING LENGTHS.. ESTIMATE OF TOTAL WELDS (ALL TYPES)... ESTIMATE OF RADIOGRAMS ON THE PIPING. 7CHAPTER 1a 12 13 24 22 23 34 3.2 33 34 35 3.6 37 38 3.9 3.10 4.1443 FLANGED JOINT... 44 45 46 47 48 51 5.2 53 54 55 5.6 57 58 5.9 61 6.2 X, PIPING ABOVE GROUND. EXPLANATION TO THE ERECTION ITEMS... 1.0 PIPING. PIPE INSTALLATION IN PLANT! PIPE INSTALLATION ON PIPERACKS. PIPE DISMANTLING... 2.0 FITTING... ADJUSTMENT OF FITTINGS WITH ONE CONNECTION END... ADJUSTMENT OF FITTINGS WITH TWO CONNECTION ENDS..... ADJUSTMENT OF FITTINGS WITH THREE CONNECTION ENDS... 3.0 PIPEWELD MAKE-ON AND WELDING BUTT WELD MAKE-ON AND WELDING.. FILLET (SOCKET) WELD - PERFORMANCE AND WELDING. MITRE WELD MAKE-ON AND WELD.. NOZZLE WELD MAKE-ON AND WELDING.... WELDOLET, NIPOLET - INSTALLATION AND WELDING. REINFORCEMENT PAD MAKE-ON AND WELDING... SEAL RING MAKE-ON AND WELDING (ACC. TO DIN 2695). INSERT RING (FOR AL ONLY). WELD CUTTING FOR MODIFICATIONS. MATERIAL MULTIPLIER FACTORS (().... 4.0 FLANGED AND THREADED JOINTS, BENDING OF PIPES. wl 27 127 127 127 128 128 128 128 128 129 129 129 129 130 130 130 130 130 130 130 INSTALLATION OF MEASURING ORIFICES, BLANKING PLATES, etc. PIPE BENDING... PREPARATION OF THREADED ENDS. THREADED CONNECTION MAKE-ON. DISASSEMBLING Item 4.1 + 4.4 and 4.7. 5.0 VALVES... . VALVE INSTALLATION (WITH AND WITHOUT HAND DRIVE) VALVE INSTALLATION WITH ACTUATORS (SOLENOID, AIR). BUTTERFLY VALVE INSTALLATION WITH ACTUATOR. BUTTERFLY VALVE INSTALLATION. CONTROL VALVE INSTALLATION. SAFETY VALVE INSTALLATION... HYDRANT INSTALLATION... SPINDLE EXTENSIONS... DISMANTLING OF VALVES.. 6.0 PRESSURE TESTING. 131 131 131 131 131 131 131 131 132 132 132 132 1327A 72 73 74 75 81 B11 8.1.2 8.1.3 8.14 8.15 8.2 8.21 8.2.2 8.2.3 8.2.4 8.2.5 83 8.3.1 8.3.2 8.3.3 8.3.4 84 84.1 85 8.5.1 8.5.2 8.6 87 8.7.1. 8.7.2 8.7.3 88 8.8.1 8.8.2 7,0 MISCELLANEOUS. SUPPORTS - FABRICATION AND WELDING SUPPORT INSTALLATION (WITHOUT FABRICATION)..... INSTALLATION OF SPRING HANGERS AND SUSPENSIONS.. GRINDING OF EXCESS MATERIAL ON WELDING ROOTS.. INSTRUMENT CONNECTION - DRILLING... 8.0 ACTIVITIES DERIVED FROM BASIC ITEMS.. PIPES... PIPE HANDLLING AND CUTTING IN PREFABRICATION... INSTALLATION OF PREFABRICATED SPOOLS.. SPATIAL SHIFTING OF PIPES... MAKE-ON OF OUTSIDE PIPE FOR A DOUBLE WALL PIPING (JACKETED PIPING)...... MAKE-ON AND INSTALLATION OF LINE PIPING DN 20/25 ON JACKETED PIPING, MISCELLANEOUS FITTINGS. . HALF COUPLINGS... WELD COMPENSATOR. WELD METER RUNS... PREFABRICATED OF SPOOLS FOR WELDING. MEASURING ORIFICES - MEASURING FLANGES. WELDING........ ‘TACK WELDING ON VALVE SIMULATORS... LONGITUDINAL WELDS ON PIPE HALF SHELLS. THERMOMETER BRANCH (TI). PREFABRICATED WELDS AT INSTALLATION OF PREFABRICATED SECTIONS (SPOOLS). FLANGED JOINTS. . REPLACEMENT OF BOLTS... VALVES. ROTATING THE VALVE INSTALLATED, EXPANSION JOINTS WITH FLANGED ENDS.. WALL PASS FOR PIPES. MISCELLANEOUS, FABRICATION AND INSTALLATION OF PIPE HOLDERS, HANGERS, AND SUPPORTS (to 100 kg per item)... DISMANTLING OF PIPE HOLDERS, HANGERS, AND SUPPORTS. HOLE DRILLING IN CONCRETE... EXTRAS... CHANGE IN BILL OF QUANTITIES BEFORE THE CLIENT'S APPROVAL FOR FABRICATION..... CHANGE IN ISOMETRY PRIOR TO THE CLIENT'S APPROVAL FOR FABRICATION... 136 21368.8.3 8.8.4 8.8.5 8.8.6 8.8.7 8.8.8 TABLE Item. 3.10 MULTIPL. FACTORS FOR DIFF. KIND OF MATERIALS. FORMS FOR CALCULATION OF MAN HOUR RATES... CHAPTER 1 2 3 4, CHAPTER CHAPTER 1 2. CHAPTER A. B. CHAPTER 1 wawn HAND DRAFTING OF ISOMETRY ACCORDING TO THE CLIENT'S INSTRUCTION... INSTALLATION OF MISSING MATERIAL. PIPING MODIFICATION....... SAND BLASTING HANDLING, PRIMER COAT ON PIPING, AND PIPE SUPPORTS. UNDERGROUND PIPING... FACTORS FOR CALCULATION OF MAN HOURS FOR PREFABRICATION AND INSTALLATION OF PIPING.. 2137 137 137 138 139 eee 142 1.0 PIPES... 142 2.0 FITTINGS. 142 3.0 FLANGES.. 143 4.0 SMALL FITTINGS. 143 5.0 VALVES... 144 6.0 PIPE EXPANSION JOINTS AND FLOWRATE METERS 7.0 OTHER INSTALLATION WORKS........ 8.0 ESTIMATE POINTS FOR BUILD-IN ITEMS OF A. G. PIPING 145 145 147 XI. WEIGHT FACTORS... PIPING. ...o0s STEEL STRUCTURES... PROCESS EQUIPMENT... CYLINDRICAL STORAGE TANKS. 2203 206 208 209 XII. TECHNICAL CALCULATION MANNER OF DATA COMPILING... 210 XIII, MAN HOURS FOR OVERHAULS IN PETROCHEMICAL PLANT: PIPING ERECTION AND DISMANTLING.. MAN HOURS FOR OVERHAUL OF EQUIPMENT IN PETROCHEMICAL PLANT! 214 214 229 XIV, FACTORS AND MAN HOURS FOR PIPING AND STEEL STRUCTURE WORKS IN CALL FOR TENDERS OF "TECHNIP" COMPANY. PIPING BETWEEN PLANTS AND IN PLANTS. STEEL STRUCTURE ERECTION..... 230 230 232 XV. APPENDIX... 1SO R7 DIN 2448/2458 SUMMARY OF PIPE SCHEDULED SIZES.. ANSI B 36.10 SUMMARY OF PIPE SCHEDULED SIZES... PIPE AND FITTINGS DIMENSIONS - TABLE MANUAL. STEEL STRUCTURE - SURFACES OF SECTIONS in m2/m: CONVERSIONS BETWEEN ENGLISH AND (SI) STANDARDS UNITS... 2233 233 236 237 2238 10INTRODUCTION With proper and conscientious application of these data for making estimates, the estimator will calculate hourly time requirements i.e. the man hours required for the erection. The man hours (Mhr) do not refer to any condition or PRODUCTIVITY EFFICIENCY PERCENTAGES (PEP, Leistungsféhigkeit - Prozentsatz), but to precisely determined below stated PEPs. ‘The standard ranges of productivity efficiency percentages are! 1. Verylow 10240% 2. Low 41+60% 3. Average 61+80% 4.Verygood 81.90% 5. Excellent 91+100% 6. Extraordinary 101+120% Man hours in this Manual refer to the following Productivity Efficiency Percentages: 1, PIPING ABOVE GROUND IN PLANTS 1.1Calculation based on the estimate points of basic erection items and man hours and effects derived thereby PEP igh average 80% 1.2Calculation based on man hours and ef fects for quick calculation and special man hours PEP = igh average 75% 1.3Calculation based on man hou rs for piping per inch - diameter (ID) PEP = high average 80% 1.4Calculation based on man hours f or units of operation PEP = very good 85% 2.PIPELINES PEP = high average 75 % 3,STEEL STRUCTURES PEP average 75% 4.PROCESS EQUIPMENT IN PLANTS PEP = average 70% S5,CYLINDRICAL ST ORAGE TANKS PEP = very good 85% 6.WELDING AND CUT TING PEP = average 70% 7. CORROSION PROTECTION PEP = high average 80% 8, THERMAL INSULATION PEP = very good 85 % uwFor each project, before the labour value is calculated, the Productivity Efficiency Percentage should be determined. This is done by the project manager with the assistance of his collaborators. John S, Page (USA) stated six production elements that have an impact on PEP determination, They are: 1. Project Management and Supervision 2, Labour Conditions: 3. Job Conditions 4, Machinery and Equipment 5, Weather Conditions 6, General Economy (for J. S. P. thisisa leading element, which I shall not consider) . Project Management and Supervision Has the company already executed such projects? How often? What is the calibre of your supervision? Are skilled and experienced staff available? What can you afford to pay them? Will they be satisfied with the accommodation? Will they be satisfied with the salaries? Will you have enough money at the site (down payments)? After evaluating these questions, estimate the percentage according to the PEP table. 2, Labour Conditions Does the company have a good labour relations man? Has the company sufficient number of skilled and trained labour? What are the foremen like? Will they be satisfied with their salaries? Will they be satisfied with accommodation, food, transport? How often will they be able to visit their families? Estimate the percentage according to the PEP table. 3, Job Conditions ‘What is the scope of the work and just what is involved in the job? What is the schedule? Is it tight, or do you have ample time to complete the work? What is the condition of the site? Is it low and muddy, and hard to drain, or is it high and dry? Does it involve a plant already in operation? Wil there be tie-ins to the existing systems? What will the relationship be between the production personnel and office personnel? Will most of the operations be manual or mechanized? What kind of material procurement will you have? Estimate the percentage according to the PEP table. 4, Machinery and Equipment Do you have ample equipment to finish your job? What kind of shape is it in, and will you have good maintenance and repair help? The qualifications and experience of crane and other operators? The plant-hire company for the machinery? Past experience? Estimate the percentage according to the PEP table. 5, Weather Conditions What were past weather conditions for the area? If necessary, can they be checked? What future weather forecasts? Will there be much rain or snow? What differences are expected in the weather with regard to Central Europe - Zagreb? Estimate the percentage according to PEP table, When we have considered and analysed all the percentages, we have to divide the total sum by five to arrive at an average percentage of productivity that is the Productivity Efficiency Percentage (PEP). Dividing the PEP declared by the average PEP we obtain a factor. This factor is multiplied by the calculated man hours (MHr) and will give actually needed man, hours (MHr). The number of hours can be either increased or decreased. 2ABBREVIATIONS & UNITS PEP = Producti ‘efficiency percentage Mhr = Man Hours mm = milimeters = 0.03937 inches m= linear meters = 3.281 feet km = kilometers = 0.6214 miles me square meters = 10, 764 feet m= cubicmeters = 35,314 feet ft= linear feet = 0.3048 meters |= liters = 61.023 cu inches = 0.03531 cu feet = 0.2642 u.s. gal kg = kilogram = 2.2046 Ibs lbs = pound = 0.4536 kg tor ton = metrictons = 1000 kg ea =each pe= piece PN = pressure nominal or NP bar = 14.5 psi (Ib/sqin) Dn = diametar nominal OD or de = outer diametar ID = inch diametar MID = meter inch diametar t= thickness mm V=volume max. = maximum min, = minimum ¥= phi (Greek) = round KW = kilowatts = 1.341 horse power kWh = kilowatthours KVA = kilovoltampers ka/Mhr = kilograms per man hour Mhr/m = man hours per meter f= factor k= coefficient Notice: Decimal numbers are listed with a comma (European way). BoT I. PIPING ABOVE GROUND DERIVED OPERATING TIME STANDARD FOR TABLES FACTOR OF BASIC ASSEMBLY POSITION CHAPTER X, ACCORDING TO FORMS ON PAGE 142 + 146 Productivity efficiency percentage (PEP) = 80% FOR PREFABRICATION : 8% 1. PIPES (ANSI B 36.10) FORINSTALLATION : 92% 1:1 PIPE INSTALLATION ON PROCESS PLANT [thm] “CARBON STEEL - NONWRAPBED - ABOVE GROUND, ‘STAINLESS STEEL [einch [Odsmm [Sen 10 [Sch 20 [sen30 | sta [sen 40] scneo [xs [sch80 [sch 100] sch 120) Sch 105 [seh 405 = = Materials: + alloy steetst 4. PIPES (ANSI B. 36.10) FOR PREFABRICATION : 89% 4.2 INSTALLATION ON PIPE RACK OR SLEEPER WAY [Ml /m] FORINSTALLATION : 92% ‘CARBON STEEL NONWRAPPED. SNES SEL Sho] x5 [Sendo] seh 100 | Seizo] Sari 3aS_| SASS] Sch 10S [sch 40s] Sch 805| meat a2 3 ul 1a 7 Sch iO] Sch29 | SABO] Sd AE aa 3) ‘Man hour include the next activities: handling + erection ~on-ste transport -wel + ptefabricatonor 2. FITTINGS (ANSI 36.10) FOR PREFABRICATION : 85% 2A ELBOWS [Hhi/ea] FOR INSTALLATION: 15% CARBON STEEL STRINEESS STEEL | xs _[ sen 80 WHS] SARS sen 105 | Sch 408 a| 8 8 8 3 2.2 CAPS [siefea] x 0) 140 + 1,60 High temp, aly steel 1,00 + 1,80, = Copper aloy 420 ~Aloy steel Ni 1,60a 2. FITTINGS (ANSI 8.36.10) 2.3 TEES 2.3.1 STRAIGHT TEE [Mhv/ea] FOR PREFABRICATION : 85% FORINSTALLATION : 15% : Aa i afd H ‘eines [OD-mm| ‘Sch 20 Sch 30] std] Sch 40 [ Sch 60 ie 3 aa | 23 e eee 3/4" v Tae" Ti" z 2ue"| 73 7 ¥ = o * 10" 3/2/38) 2] 8|8/3/a|3]8|8]o/3] ky i = Cro ally stee! 1,40 + 1,60 High temp. alloy steel = Copper alloy 4,20 ~ Aloy steel Ni - killed CS. 4,00 + 1,25 ~Auminium alloy 400 450 18° 500 20" 550 Ea 00 2 650 26 700 ry 730 = = Em 800 = = 32" 850 = = Em 300 = = 36 (trea] x Materials: ‘st 2. FITTINGS (ANS!) 2.4 REDUCERS - CONCENTRIC AND ECCENTRIC. [Mhr/ea} FOR PREFABRICATION : 85% FOR INSTALLATION: 15% ‘STAINLESS STEEL 3 SSA] Se [SH] SHO Gi 8 3 3 3 Sch 170 Saw Sch 405] els|els|e|x|s|2) UOnEaUUE 3 % a killed CSer 4. PIPES (DIN 2448)/2458) FOR PREFABRICATION : 8% FORINSTALLATION : 92% {1-1 INSTALLATION IN PROCESS PLANT. (M/m) Diem [oom = SwIoy 2 23 36 [| 38] a] 8 | s8] ©] 8 | 25 [oom 364 31410 = Materials: Man hour include next activities: = Stainless steel handling + erection High temp. alloy stee! on-site transport = welding + Prewrapped + prefabrication + pressure testing + Galvanized Aluminium alloy41. PIPES (DIN 2448/2458) FOR PREFABRICATION : 8% {LL INSTALLATION IN PROCESS PLANT [?hr/m) FOR INSTALLATION: 92% (CARBON STEEL - NONWRAPPED = IND = WALL THICKNESS 14,2 - 60 rom bmm [opm] t= sui 12 T a6 T zs | 20 Tm [2s | os [30 [x a | «0 | = | 9 | 5 | @ |e | a5 [213 20_| 269) 25 | 337 a | ana oz = = 508 SS 559 SS SS 610 Se SS 660 7 782 a3 364 ‘900 [914 ‘Man hour include next activities: handing erection + onsite transport welding + prefabrication = pressure testing ~ Aluminiue alloy@ 1. PIPES (DIN 2448/2458) 1.2 INSTALLATION ON PIPE RACK OR SLEEPER WAY [Mv/mi] FORINSTALLATION : 92% (CARBON STEEL - NONINSULATED - WALL THICKNESS - 2 mm - 12,5 mm. [Drm [O0-mm[t- Swiea] 2 23 26 [29 3, 610 660 7a 762 | 8 ai | 8 os | 88 ‘14 [10 Man hour include next activities: handling + erection on-site transport welding + prefabrication + pressure testing1. PIES (DIN 2448/2458) FOR PREFABRICATION : 8% LZ INSTALLATION ON PIPE RACK OR SLEEPER WAY [hm] FORINSTALLATION: 92% CARBON STEEL - NONINSULATED - WALL THICKNESS 14,2 - 60 mm. wz Dae om Ce ee | 259 | 23 269 [a7 37 sas a eon ne sre Te [as ms ie] 7 7 iso ie ies oor} 283 28 2a | 77 a ar | aan ane ara mE [#7 7 sm | a Ste sa [a = a ‘ar er a rar 7 7 | ren Ter sor [a air [ae a so} sa] “10 sit an hour include ext atts vate -rtan - San sed “dra “Hh ton. aly seat Cinna aD + pressure testing + Galvanized = Aluminium alloy4, PIPES (ANST and DIK) &@ 1.3 STEAM TRACING (Values in ths table apply only to piping in plants. For steam tracing of pipe lines on piperacks or (mb sleepeways other table for the installation of pipes on piperacks are applied.) ‘CARBON STEEL, ‘STAINLESS STEEL ‘STEAM TRACING ON PROCESS LINES [on-mm| [oo-mm| seh to] sed sch 40] xs [sch 80| sch 160 [xs | sch 55] sch 10s [sch 405 [Sch a05| (oranhour per meter of process line incl. 15 243 steam supply end condensate return 20 | 3/4" [25,7 © [number | (Mpr/m) 2s [1 [334 tracer_| of tubes | (oroc.) 32_ [awa] 42,2 we" [a 40 [iin] 48,3 yar | so | 2" [60,3 3/4" 65 [aur] 76,1 3/4" so | 3" [939 3A CARBON STEEL - WALL THICKNESS 2 -7,1 mm PrmmlOommbSae| 2 [33 [36 3a _| 32 [36 | 4] 45 [5 [56 [63 ‘COPPER TUBES - DUCTILE 1 [213 [22 ‘ob-mm [whem | _OD-mm 20] 269 [ 223 | m0 02 | 2 25 | 337 | 226, a KC 32 aaa | 22, 14 [018 [28 20 [483 [23026 15 0,20] 30 50] 093 | 2329 16 [921 [35 6 | 7 [2629 18 | 024 | 38 65_| 761 | 26129 20 | oa |e s0_| 89 | 2.932 (COPPER TURES - STRONG : x 1.4 INSTRUMENT AND CONTROL PIPING All acthvtyes on instalation and supporting these fnes, aso sizes t included. Lines to 3m ( 10 fe) totally Lines above 3 m (10 ft) rien) 1.6 STEAM DISTRIBUTORS AND CONDENSATE ‘COLLECTORS FABRICATED FROM READY-MADE DISTRIBUTORS FOR # CONNECTIONS 15 STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS (ready-made distributors for 4, 8 oF 12 connections) FABRICATED FROM PIPES AND FITTINGS. 15.1 STEAM DISTRIBUTORS, 1.6.1 STEAM DISTRIBUTORS Fabrication fea] + Ml PHnefconnect.] abr [he] x number of connections Erection [Mea] (supporting included) Erection: | fMhr/ea) (Supporting included) 15.2 CONDENSATE COLLECTORS. Fabrication rea} + [ [oh/ connect] Erection [/J/(Mhrfea] (supporting included) 1.6.2 CONDENSATE COLLECTORS Fabrication: [ll] (Mhr] x number of connections Erection] (Mea) (supporting included) Fihr/m x 03048 = Mhrd 2, FITTING (OIN ) FOR PREFABRICATION: 85% 2.1 ELBOWS [Mhr/ea) oo z x B oo-mm 213 | 8 ase [38 ae [10 2.2 CAPS (wnrjea) x Materials: = C-Mo alloy stel 1,00 + 1,80) Copper alloy 1,60 killed CS 41504 2. FITTINGS (OIN) FOR PREFABRICATION : 85% 2.1 ELBOWS [Mrv/ea) FOR INSTALLATION : 15% ‘CARBON STEEL - WALL THICKNESS 14,2 - 60 mm Eswiee] 142 [ 6 [ ms [2 | met a | 2 [0 [3 Zz 2s 2126 226 a AT 5 oo = {es a = SSS = = SS aes = = = Materials: f Stainless steet = Cr-Mo alloy stee! 1405 1,60 High temp. alloy steel Copper alloy 1,20 Nt killed CS 100 + 4,259 2. FITTINGS (DIN) 23TEES [Mies] 2.3.1 STRAIGHT TEE pamm | Obs Sat z [CARBON STEEL - WALL THICKNESS 2 mm ~ FOR PREFABRICATION : FOR INSTALLATION: a3 8 864, 88 S| lS |S 34 [10 Se 2.3.2 REDUCED TEE (shrjea) x + Stainless steel 1,25 High temp, aly steel 1,00 + 1,80 Alloy steel Ni 1,60 ‘Aluminium aloyaz 2.3 TEES FOR PREFABRICATION : 85% 2.3.4 STRAIGHT TEE [Mbrjea) FORINSTALLATION : 15% [CARBON STEEL - WALL THICKNESS 14,2 - 60 mm Drm [OD-mm| t-stélexf 142 [16 [ 7s | 20 [ m2] 2 [ 2 [ 0 [| 2 [| 3% [ wo [ 30 5 o 15 = [== = = [Es] = = 3) 8] 8] 3 ]2|8 S|] 8/8 |8/S]8/3/8]5|8 | |a]als|s/slals 2.3.2 REDUCED TEE (Mbrjea) x Materials: t = G-Mo alloy ste! 140 = 1,60 = Copper alloy 4420 - Killed CS 4,00 + 1,25,2. FITTINGS (DIN) FOR PREFABRICATION : 8596 24 REDUCERS - CONCENTRIC AND ECCENTRIC [Mh/ca] FORINSTALLATION: 15% 3a_[ 10 welding + pressure testingDremm| OD-mm| t= Stal 62 2. FITTINGS (DIN) FOR PREFABRICATION : 85% 2.4 REDUCERS - CONCENTRIC AND ECCENTRIC. [Mhr/ea} FOR INSTALLATION : 15% (CARBON STEEL = WALL THICKNESS 14,2 -60 mm 2 [22 [2s Ts | 30 | 2 = |» [| s | = a2 | 16 [7 Materials: = Cr Molloy tee! Copper alloy killed CS.3. FLANGES: FOR PREFABRICATION : 80% 3.1 WELDING NECK [Mhr/e] FORINSTALLATION: 20% = a Man hour include next activities: Materials: t ~ handling erection =Cr Molloy steel 1,40 + 1,60 onsite transport + welsing = Copper alloy 120 + prefabrication = pressure testing killed C5, 4,00 + 1,25Te 3. FLANGES 3.2SLIP~ON [Mhr/ea) FOR PREFABRICATION: 80% FORINSTALLATION : 20% 00F PN320 niauiaalafectelea ag Notice: Unit weights inthis table refer tostip on flanges ‘acc. to 480, 28 307 a 38 36° 5400 7260. os | ee 3.3. SOCKET WELDING 3.4, LAP JOINT + STUB END 3.5, BLIND 3.6, ORIFICE COMPLETE oF include next activities: = Stainless ste! + erection 160 -High temp. alloy steel 1,00 = welding Alloy steel Ni Aluminium alloyze 4, SMALL FITTINGS. (he/ea} 4.1 WELDOLETS, SOCKOLETS, NIPOLETS, etc 4.2 HALF COUPLINGS FOR WELDING CARBON STEEL “CARBON STEEL soo | 3000 | 6o0oF 30008 | 60008] Demm| enh [Oomm| sd | xs | 0S Damml etneh | Obmm| XS | 0S [apr [a3 is_ |p" | 213 zo [3a [267 20) 257. 25 7 334 25, 334 3p awa [a2 3o_[ ae [232 40 | aie" [483 40] ua | 83 30 2 | 603 so] 2 | 603 [aye [73 5s [au [73 30 3 389 30] 3" | 889 too [4 | 4s 100 | 4 [43 ws | s*| aaa 1s0_| 6 | 1683, 4.3 FITTINGS WITH SOCKET ENDS 200 | 8" | 21941 ‘CARBON STEEL 250 | 10" | 273 WITH ONE END. 300 | 12" | 3339) Daomm [o-inch | OD-mmn| [Mhzea] 350 | | 355.6 is | a | a3 ware 2 ENDS x2 400 [367 | 406.4 20_[ 3/4" [267 WITH 3 ENDS x3 450 | 18" | 457 25 i | 334 00 | 207 | 508 32 | auar| 42.2 sso | 22” | _ss9 40] aye"| 03 600 | 2a" | ato 30 2 | 603 650 | 26" | 660 s | 2url 73 700 | 287 | in 80. 3° | 889) 750 | 30° | 762 100 | 4" | 1143 Materials: Man hour include next activities: (FOR WELDED FITTINGS ONLY) fF ~ erection ess steel 125 = welding F Mo alloy steel 1140 + 1,60 + pressure testing High temp. alloy steel 4,00 + 1,80 120 1,60 100 + 1,25 ~ Aluminium alloy 1,50 FORPREFABRICATION : 85% FORINSTALLATION: 15% 4.4 THREADED FITTINGS 4.4.1 CARBON STEEL \WITH ONE END On-mm | e-Ineh_| oD-mm [[Mhrjeal as [ap | 23 20 | aia" [26,7 25 vo Ba 32 | aye | 22,2 ao | 1" [48,3 so] 2 | 69,3 | 2 | 73 so | 3 | 858 too [a [ata 44.2. NON-FERROUS METALS. ‘VALUES FOR, ‘CARBON STEEL x 4.43 "HERMETO" COUPLINGS VALUES IN| TABLE 4.4.1 x5. VALVES 5-1 VALVES WITH FLANGED ENDS 5.1.1 GATE, GLOBE, CHECK, SWING CHECK, BONNET, LF - Factor for installation of flanged valves BALL, BUTTERFLY, FILTER, ete [Mea] Tor flanged valves ‘Da 125 +200] Drabove 250 ‘above 10" PN_6= 16] 150m PN 2540 3008 PN 68 008 PN 100 6008 = = = PN 160 9008 = = = PN 250 sso0¢ [eT = = PN 320 25008 [ee = = included in table) 54.2 CONTROL VALVES 5.13 SAFETY VALVES Sa. HYDRANTS 5.5 FLOW RATE METER 54,6 LEVEL GAUGES 5.1.7 CONDENSATE SEPARATORS 5.1.8 SIGHT GLASS 5.19 VENTURI TUBE 54.10 VALVES WITH EM, DRIVE5. VALVES ‘5.2 VALVES WITH WELDING ENDS. (Mir/ea] 5.2.1 BUTT WELD 5.2.2 VALVES WITH SOCKET ENDS 5.3 VALVES WITH THREADED ENDS. & £ bd safe 8 fs she 5. PRESSURE GAUGES [ll (Nhv/ea) SSTHERMOMETERS [oo (Miriea] + prefriction| = pressure testingse RATES FOR TENDER CALCULATIONS 11. MANHOUR ESTIMATE FOR INSTALLATION OF PIPING BASED ON DIAMETERS AND WEIGHTS (FOR CARBON STEEL ONLY) (Grigin: Technical Journal "3R International" of Apri 4, 1985) roductivity Efficiency Percentage (Pt Typear Type 8S. TyoetF [Hieton] pein] |FHreton][ha/ehe] | TMhftor] eayMe]| Type AS Piping inthe plan with prefabricated weld joints Domm 25 2 40 50 65 20 300 125: 150 200 250 300 350 400 500 600 1000 “Type AP_Plping in the plant with prefabricated flanged joints “Type 3S. Piping outside the plant (pipe racks, sleeper ways, ec) with prefabricated wele joints “Type 3F Piping autside the plant (pipe racks, sleeper ways etc.) with prefabricated langed joints kg/Mhr x 2,2046 = Ibs/Mhr ‘Above standards do not include: Time allowance for ~ storing and store handling (calculate separa site grading and facilties (ada [4 ~ decrease effect of due to bad weather (add [+11 %) + scaffolding (calculate separa + radiographic inspection (calculate separa ~ performance tests (oleulate separ2. EFFECT ASSESSMENT FOR QUICK CALCULATION (Use only f not possible ace. to man hours derived from basi estimate pots) 2.1 PIPING IN PROCESS PLANT Prefabrcaton ane erection (kg/m) Procuctivty ciency percentage (PEP) = 75% Shoo [Sho Sao] Sao ‘Se a0 [Sch 100 [ Sch 120 | Sch 140] Seh 160 | WS _[o-Ineh UO) epapaalape a7 508 559 10 660 7 762 3a | EOE AS HeLa a epee as“ 2, RATES FOR QUICK CALCULATION (Used only when such data provided in tendering documents ) 2.2 PIES (CARBON STEEL - NOT INSULATED) {Mbedon)_f kote} ‘MEAN VALUE Productivity Efficiency Percentage (PEP) = 75% Sch 1202. EFFECT ASSESSMENT FOR QUICK CALCULATION (Used only if such data provided in tendering documents) Productivity efficiency percentage (PEP) 75% 2.SFITTINGS (CARBON STEEL) - MEAN VALUE. [ka/Mhr] Al types of fitings included. FOR “TECHNIP" COMP. Average iametes [inch] Damm] einen | OO-mm | Schi0 | seh20 saad_[¥S_[ Sch 60 | Sch 120 | Soh 0S, as [4/2 E = = = zo 3/4" = = = 25 a = = = = = = = = ey) Re] %e|e2] & eye Materiats: Stainless steel High temp. ally steel kills cs 43,01-45,0 4501-470 2470 alse ee fc ene sce ngs 08 1 ‘are used in petrochemical “Iperf ane mite of overage wal thickness kg/Mhr x 2,2046 =Ibs/Mhr6€ 2A VALVES MEAN ALUE (ALL KINDS OF VALVES INCLUDED) Productivity Eficiency Percent (PEP) = 75% 2.5 PIPE SUPPORTS. Procuctivty Efficiency Percentage (PEP) = 80% 2.4.1. WITH FLANGED ENDS [Mh/kg] 25.1. PARTICIPATION IN THE PIPING QUANTITY tm be estimated % i 00% a 00. 15008 2.5.2. FABRICATION AND INSTALLATION Dam NP5-16 NP NPD N64. 25.2.1 __ DIVISION BASED ON THE UNIT WEIGHT OF SUPPORT 5 Unit Fearication Tnstallaton 20 weight 25 Tka/oe] Teavhe] [keine] [ka/Mhr] 32 wos 0. 5220 30 20 50 65 50375 80, 75-2100 100) 100150) 150, above 150 200 8 [Spring suppor 250 | _i0" 300 | 2 25.2.2 DMSION BASED ON IME PPING DIAMEIER 350 |i Fabrication Installation 400 [167 450 | 187 Tesi] gine] 500 | 20" = 350 | 653100 | 27° 600 [2 25150 | 576" 2002350 | _ets14" 24.2. WITH WELDING ENDS above 350_[above 14" 25.2.3 EFFECT OF SUPPORT FABRICATION AND INSTALLATION WITH ALREADY 2.4241. BUTT WELDING: [heres x KNOWN AVERAGE DIAMETER OF PIPING 2.4.22. SOCKET WELDING: [Mike] x ‘Mr /kg x 0,4536 = Mhrjlbs kg/hr x 2,2046 = Ibs/Mbr The effect ofthe fabrication and instalation [kg/hr] isl to the average clamet inches, 26 AVERAGE DIAMETER - Manner of Calculation Average clam caleuated in the fllowing way: (ation product ofthe élameter and length of each pipe ‘sum of the m shall be divided by the sum of all pipe lngths. (One t+ (On x Weld Tm (onx nyt ofall ppings in the plant or onthe project shall be13. RATES FOR INSTALLATION OF POLYETHYLENE PIPING. Productivity Efficiency Percentage (PEP) = 80% 3.1 PE Pipes DIN 8074 PES FITTINGS AND VALVES Pa Seaight pipes | Cole Tees [Reducers | Caps Dremm | tram) (heim) [Thc Teal | (oiwfeal | Ttieal 16, = = 20 = SSS = 25 = = = = = = 32, = = = = = = = “0 = eee a 50 = ee a 8 = SSS ss _ a 75: = = = = = = = 90 = = = = = = = = = = = = = = = _ fee = _ fee = _ fee = = SWS ss = =| STS Ts = =| STS E = = = = = = 25,70 = _ a 32,60 = = ee ([Mhr/ea} 3BTe 4. RATES FOR ERECTION OF PVC & FRP PIPING Productivity ficiency Percentage (PEP) 80% Valves eve Nozle at 90° and reinforce | housing ment _|(hane Dn [Whe7eal | (Mivfeal | 0 Fs 20 25 30 20) 30 5 30 100) 150) 200) 250 300 350 200 250 500) 550) 00 50] 267 700] 28" 750_| 30" ‘300_| 32" 50 | ‘900 36" 950_| 38" 1000 [40 ‘SYNTHETIC MATERIALS [ABBREVIATIONS & INTERPRETATION FRP- FIBREGLASS RESIN POLYESTER PE- POLYETHYLENE: PVDF-POL. YVINYLDENFLUORIDE PVC POLYVINYLCHLORIDE, HARD PP- _ POLYPROPYLENE FPM- (VION A ®) FLUOR INDIAN RUBBER (KAUTSCHUK) EPDM -(APTA) ETHYLENE PROPYLENE INDIAN RUBBER, CR- (NEOPRENE ®) CCHLOROPRENE INDIAN RUBBER PTFE (TEFLON @) POLYTETRAFLUORETHYLENE POL YINYLCHLORIDE, [ADDITIONALLY CHLORINATED PB- POLYBUTENE Pvc 4 POM- POLYXYMETHYLENE NBR NITRIL INDIAN RUBBER IR BUTYL INDIAN RUBBER CSM- (HYPALON @®) CCHLORSULFONYLPOLYETHYLENE EHD -POL YETHYLENE HIGH DENSITY PREV -POL_YESTER RESIN FIBREGLASS REINFORCED, INTERNAL CORE OF PVC ‘5. CARBON STEEL PIPING (SCH 40) (CEMENT LINED INSIDE Productity ficiency Percentage (PEP) 80% Sleeve joint] Nozzle | Repair of Pipes with two} at go | concrete handling | Pipe cutting] Butt weld welds Damm jen) | [hefeut.) | [teyea) | [er/jint | [ 150, 200. 250 300 1 350 1a 400 16 500 20" 600 2 700) 28" B00 a 900 36" 1000) 40 1100) aa 1200) ae Note: 1. Piping of synthetic materials te be calculated acc. to the tables for PE or PVC piping 2. For diameter larger than 40” (1000 to be calculated proportionally to4o” Mhr/m x 0,3048 = Mhr/fta 6. PIPING MADE OF STEEL AND GREY CAST-IRON made an exception and included steel and grey cast piping in the Chapter Piping Above Ground although they are in most cases laid undergroune ‘According to these man hour rates ony the pipes are determined according to the unit of length whereas the man hour rates forall ather fittings should be calculated acc. to the type and number of joints. For examph Tpiece with a flange at one en and a socket at two ends should be calculated as 1 x flanged end and 2x socket end Productivity efficiency percentage (PEP) = 80% 6.1 CAST IRON PIPES Torin diameter Pie leh om Taal + Note: so 5 coring to Jon 5. Pog’ mana 10) 5 each ont between the pipes also 255) A ded man hour forthe socket or 50) A To not agree wth hat. Ts could 70-1 Beni any the Mtns are B01) notated separately, st to 200 G2) Inston that his man hour for a socket 350 067) Jon les than tre man how #00 069 inthis tab, 50 16") 00 G8) coe) Es 700 25) 50032) 6 vin 03088 = Mt 6.2 FITTINGS (DIN: A, €, FFF, K,FFK, Q MQ, MMQ, MMK, FFR, 7, TT, U, MMA, MMB, MMR, Xx, N) \When calculating man hours for each fing each ced is calculated according to Its type, except forthe straight end Nominal Soke Flanged iameter ene end DN [wheieal TwheFea] Ee 700) 3256) 350 (67) 20069) 250 (10°) 300,112") 350.14") 400.16") 450,(18") 500 (20°) 600 (24°) 700-28") 00 (32 6.3. VALVES Vales to be estimated by considering the handling as forthe piping above groune and by adding 2.x Mhr/ea fora flangee end,ep 7. RATES FOR PIPING BASED ON INCH-DIAMETER (ID) Productivity efficiency percentage (PE) 80% ‘Some world companies ask in te! inchdiameter (1D) and ind for tender fora price review according the operations and works involved in in Rem 3.1.x F = Mhe > 1D 3.4. ~ Estimate points for butt joint ofa relative lameter and wall thckness( Chapter |X. Pages 147 = 201) F sum of factors forthe activities required (see below) D_-diameter (or average diameter) of piping in Inches ACTIVITY FACTORS + PIPES + prefabrication PIPES ation ~ FITTINGS. + prefabrication - FITTINGS. lation ~ FLANGES, + prefabrication ~ FLANGES: installation - VALVES ation = PRESSURE TEST _- hydrostatic PRESSURE TEST pneumatic ~ ELEVATION TMPACT. - IMPACT OF SPACE OBSTRUCTION Sim Every company has its own way of sting the prices foreach activity Is call for tenders. Therefore, only the factors for the activites that are required by tenderin documents are summed up. Fabrication and installation of pipe supports is considered separately acording to the tables on page 39.. ‘CORRECTION FACTORS: - Different materials cs ow alloy (0,5 Mo) 1,25 cr 5a 9G composite pipe Non-ferous material Plastic resin cement (Lining ¢5):~ ils - Place of instalation: ‘Above Ground Under Ground Pipe rack Bridge ‘Around equipment Line pipe - Sleeper way - Prefabrication ‘ype of joint: butt weld ‘90° Nozzle weld ‘90° Reinforced nozzle weld Socket weld ‘Seal weld Threaded joint Root pass: Filet wela ite weld ockolet, weldole, coupling, etc) to wasting piping 35 55.308 $5 316 ss321 $8347‘8, RATES FOR UNITS OF OPERATION (BASED ON INCH-DIAMETER) Produ ficiency percentage (PEP) = 80% 1. Cuts, bevels and welds 1.1 Cuts and bevels ~ all materials 1.22 Stainless steo! “Schedule 19 “Schedule 55 (he /10] -Schedule 20 =Schedule 105 [he /10) -Schedule 40 ~Schedule 20 [the /1D) Std -Schedule 40 [he/10] =Schedule 60 “Schedule 60) ~Schedule 80 -Schedule 80S. -xs “Schedule 80) =Schedule 100 -Schedule 120 “Schedule 100 -Schedule 120, =Schedule 160 =Schedule 160, [he710) =xXs + Shop fabrication Shop febrication - Field fabrication Feld fabrication 1.2 Welding 1.21 Carbon Steel 1.2.3 Alloy Steel ~Schedule 10 ~Schedule 10 [he 710) =Schedule 20 -Schedule 20 [he/10} -Schedule 40, “Schedule 40, - Sid “86 ~Schedule 60 “Schedule 60) ~Schedule 80 -Schedule 80 23s: xs ~Schedule 100 -Schedule 100, =Schedule 120, =Schedule 120, [he10] Schedule 160 =Schedule 160, [ihe /10] = 3xS 0S [oehe/10] Shop fabrication Shop febrication - Field fabrication Feld fabricationSb ‘8. RATES FOR UNITS OF OPERATION (BASED ON INCH-DIAMETER) 2. Pipe - Handing Based on MID (meter-inct-diameter) Schedule 10 Schedule 20 Schedule 40 -std Schedule 60 Schedule 60 “xs Schedule 100 Schedule 120 Schedule 160 0S + Shop fabrication ~ Flle fabrication Meike x 0.4536 [Mhe/0) [Mne/10} {Mhr/0) {Mhr/0) (ond) (nr/MI0) (10) (ohe/10} [Mne/M0} 3, Miscellaneous 3.1 Temporary Items Temporary Supports [hee] ~ Temporary Spacers [Mtyko} 3.2 Tapering Wall Thickness fo Ftings and Flanges = t05 mm (he /10) = 510mm [ihe j10] = 10 + 15mm [he f10] -15 20mm [he f10] = 2025 mm [she + Shop fabrication % - Field fabrication % 3.3 Bending of pipe Bending of pipe to 1 1/2" [Mhejbena‘9. RATES FOR PIPING WELDING- (Fitts work not included) BUTT WELD (C. S.) - COMPLETE [Mh eld) Productivity efficiency percentage (PEP) = 90% 10 [20 | 30 60 [xs [a0 | i00 ie ee Factors for ‘ealeulating the rates ace to type of weld Weldoet,sockoet,nipoet, ee weld "dummy" on elbow 9, Filet weld closing dummy 10. Mitre weld Fectors for diferent kinds of materials 1. Carbon stee! 2. Stainless steel 3. Gromium-Molidéen steel10, MAN HOURS FOR WELDING OF PIPING BUTT WELD = ROOT PASS AND FILLER PASSE Root pass =crAW FILLER AND COVER PASSES ia i sa [0 | abay M. BULIC 2003. dD oo napa fas p00 GENERAL FACTORS ‘WELDING FACTORS: WORK CALCULATION - MAN HOURS FOR PIPING MODIFICATION AT SITE 1. DISMANTLING IS 50% OF THE SPECIFIED MANHOUR RATE FOR INSTALLATION (WITHOUT ITEM 13 and 14) 2: PRODUCTIVITY “EFFICIENCY PERCENTAGE: 85% = VERY GOOD.1. Pipes Prefabrication 1.1. Pipes in the plant to11/ % 2" 48 % above 48" % 1.2. Pipes on pipe rack % 2, Fittings 2, L.Elbows 2.1.1.Elbows and mitre bends prefabricated to to1 1/2" % 2" =48" % 2.2.2.Mitre bends to be manufactured to 48" % abovets" % 22. Tee pieces to to11/ % 2"- 48" % 2,3. Reducing pieces completed tol 1/2" % 36" % 2.4. Caps - all bores % 25. 0’ lets, half - couplings and the like % 3. Flanges 3.1, Flanges - for welding all types and bores, % 3.2. Blind flanges, orifice plates, spectacle % blind and the like 4, Valves -all kinds, types pad bores, % 5. Pipe supports to 2 % 6 % -14" % 16" and above % 6. Miscellaneous 6. L.All branch welds % 6. L.Stiff_ ener rings and reinforcing pads % 7 12. INSTALLATION OF PIPING ABOVE - GROUND Unit standards as per integral elements Prefabrication and installation breakdown (Technical calculation manual, year 2003.) Bolts and gaskets - not to be taken into account 49 Installation od FFE KKKK KKKFIL. PIPELINES - Basis for calculation of man hours Productivity efficiency percentage (PEP) = 75% Contents: 1 PIPE TRANSPORT 8.1 BORING UNDER ROADS OR RAILROADS 2. STRINGING 8.2 BREAKOUT OF ROADS 3, BENDING 8.3 CONNECTING PIPELINE SECTIONS 4, JOINTING 84 CROSSING WATERCOURSES 5. WELDING 8.5 INSTALLATION OF CLEANING STATIONS 6. WRAPPING 8.6 PUTTING UP PIPELINE MARKERS 6.1 MACHINEWRAPPING 9. PRESSURE TESTS 6.2 HAND WRAPPING 10. PRELIMINARY & FINISHING WORKS. 7, LAYING IN TRENCHES 10.1 PRELIMINARY WORKS 8. SPECIAL POINTS 10.2 _ FINISHING WORKS ‘To make an estimate for laying a pipeline is a very “sensitive” operation, particularly for estimators, lacking experience in the laying and installation of such pipelines. World recognized companies specializing in this kind of work have empirical rates based on diameter and length, and on “inch-meter” respectively. A widely recognized manual for that purpose is John S. Page's Cost Estimating Manual for Pipelines and Marine Structures, ‘The impact of climate, ground and the state is quantified empirically, Since our company does not specialize only in pipelines, we developed rates and elements for calculation of the time needed. However, these rates cannot substitute an estimator, They can assist estimators in making their estimates. In principle, call for tenders do not provide all the elements needed to determine precisely the time needed for erection/installation/laying, Therefore, there are many variables to be taken into account and evaluated by the estimator in order to foresee in detail the conditions under which the works may be executed. The estimator has to make an accurate estimate of the rates, and when and which rates to apply. Similarly, he can change them depending on the case. 1, PIPETRANSPORT Basicrate for pipe transport is, [Mhr/ton) ‘The basicrate changes with the conditions by adding or deducting the following rat Distance: _for each kilometre more than 5 km.. plus [Mhr/ton] Roads: =city roads+ plus [Mhr/ton] = asphaltroads 050% not considered sasphaltroads above 50% plus [Mhr/ton] Meansof trailer truck long vehicle. not considered transport: trailer with HIAB minus [Mhr/ton] « tracktor with a trailer plus [Mhr/ton] Loading = special crane for loading, not considered loading by HIAB. plus [Mhr/ton] += crane used also for loading. plus [Mhr/ton] Unloading: unloading bya special crane to ~atemporary pipe storage. minus! [Mhr/ton] - unloading with pipe stringing along the right of-way byaspecial crane. not considered = unloading and pipe stringing by HIAB.......plus [Mhr/ton] 50Pipe Diameter: toa” plus [Mhr/ton] ors 8" not considered 10" = 12" minus [Mhr/ton] 14" = 16" minus [Mhr/ton] 18" + 24" minus [Mhr/ton] 26" and above. minus [Mhr/ton] Pipe Type: ~ not wrapped. not considered - wrapped. plus [Mhr/ton] Continuity of continuous transport: minus [Mhr/ton] = with occasional stoppagesnat considered ~ acc, to circumstances. plus [Mhr/ton] * Crane operators and drivers included in the price of machinery 2, PIPE STRINGING If pipe stringing is done as a separate operation by stringing pipes along the right-of-way from the reference storage, the following rates apply: to 3” plus [Mhr/pe] to 4" plus [Mhr/ pc] 6" = to BY plus [Mhr/ pe} 10"+ to 14” plus [Mhr/ pe] 16" + to 20" plus [Mhr/ pe} 22" and above, plus [Mhr/ pe] If no data is available on the number of pipes, it should be estimated. The manhour does not include transport of temporary timber supports. Drivers and crane operators are not included. 3. BENDING OF PIPES ~ Pipe bending on the right-of-way to 3" [Mhr/bending] 4" [Mhr/bending] ors 8" [Mhr/bending] 10" + 14" [Mhr/bending] 16" = 20" [Mhr/bending] 22" and above. [Mhr/bending] ~ Shop bending: contractors - Bending for special points is not calculated according to this rate but is included under special points. 514. PIPEJOINTING Itincludes pipefitter works for joining of pipes. Welding is not included. ~ Basicrates: 3" [Mhr/joint] 14” [Mhrfjoint] a [Mhr/joint] 16" [Mhr/joint] 6” [Mhr/joint] 18" [Mhr/joint] 8" [Mhr/joint] 20” [Mhr/joint] 10" [Mhr/joint] 22 [Mhr/foint] 12" [Mhr/joint] 24” [Mhr/joint] ‘The rate for pipe joining is calculated by increasing or decreasing the basic rate by the following percentages: a, Place of jointing: ~ neartrench on temp.timber supports % = above trench + 1% intrench +7% b. Type of pipe: = ironpipes % ~ prewrapped pipes +/% . Right-of- way quality ~ city street +/n% - alonga road - E% = dry rocky right-of-way % = possiblemud +/% d, Means of production: ~ crane +[% ~ pipelaying machine % e. Average pipe length: ~ shorterthan 8 m % = longerthan 8 m + [% Example: pipe 06" basicrateis 1,75 [Mhr/joint] -a + E% | a MT r= 088 mm] 13.5 aren [Mar ee ime |? [Men t=iomm | 153 prion [ln Mare Mime ‘Mw/m@ [Mine mM 1.6.2 Type "KRUPP_ HOSCH'" (length 3,6 + 5,8 m, width 700 + 800 mm) Tivo m® ] ton 500 | 500 = 1000 ]1000 10000 Jl0000 = 5000q] above weight m m m m 50000 m2 [kg/m] [%6 1000 sq | 1000 = 000 [5000 + 10 000) 10000 | 100.000 > above 500 009 saft sqft | 109 000 sqft | 00 000 sat | soft Re MARTE i? | MT Miim_[ MT MT] 750 Marine Marine | __—MT= Perm [__eim Mini] 192 Marien acim [Mele erie [Mem Mhe/ Note: 1. Steel brackets for trapezoidal plates (Stahlknagge) are generally shop welded. Ifsite welded, the rate of lilll% is added. 2. Above rates include also placement of Z sections and seal caps. 1.7 _ INSTALLATION OF WIRE ROPE CLAMPS 2 i a wie] Mivjea] —_o 7 iejea we20mm 26 = 30mm 36: mm 46 = 50 mm 36 = Hmm 21=25mm. 31235 mm 412 45mm 51=55 mm > 60mm 1.8 REAMING OF HOLES ™20 [M22 [M 24] 27] M 30]M 36 [M42[M 48] M56] M64 ) by pn. oF el. drilling machine from scaffold - manhour/hole b) by a reamer - man hour/hole ‘mm x 0,03937 mx 3,28 = ft Mho/m?x0,0929 = Mhe/sqft ka/mex 0,2048 = Ibs/sqft inch 1.9 BOLTING FROM SCAFFOLDING - MANHOUR PER 100 PIECES M20 | M 22] M 24[M 27[M 30]M 36M 42[M 48|M 56|M 64 When tightening the bolts by a torque wrench, manhours are multiplied by jill factor, Note: The above manhours do not include scaffolding, 582, ERECTION OF MISCELLANEOUS STEEL STRUCTURES (PEP = 75%) 2.1 BASICMANHOUR RATES - TOTAL 2.1.1 BUILDINGS AND CANOPY FRAMING Cubic Cubic Cubic Cubic weight | Rate weight | Rate | weight Rate | weight | Rate Ikgim3]_| [Mihriton] | fkgims | (Mhriton] | fka/mg__| [Mhr/ton) | fkg/ms__|[Mhriton] 2 12 22. 35 4 14 24 40 6 16 26 45 8 18 28 50 40 20 30 55 Cubic weight [ka/m3] = Structure weight [ka] ‘Wit x Length [en] x Helght [ma Mnrfton 76 of structure Tight | Medium | Heavy 2 Equipment & bridging supports 3 Towers for transmission lines 4 Stairs structure 5 Tower structure for chimney or similar 6 Antennas and torches 7 Single member support .8 Bridging between the buildings “9 Conveyor bridges 10 Crane tracks outside buildings ob Be it ot I BI 1 Bridge crane .2 Portal crane 3 Port crane '4 Construction crane 5 Stationary crane 6 Piping bridges (outside oll refinieres)| ight to 30 kg/m; medium-weight 30 + 60 kg/m; heavy above 60 kg/m 3, CORRECTION FACTORS ‘The rate for calculation is computed by multiplying the basicrate by a medium correction factor. ‘The medium correction factor is computed by adding up all selected factors and dividing them by 10. K1 Weather impact Month: | 1 | [im [Tw Tv [wl wi{wnl im [x 7x [a Ki K2 Abnormal impact of temperature ‘Average temp. ‘| below - 10°C [_(io°C = 5)°C = 5) C= 30° C | above 30° C Kz kg/m x 0,672 kg/m 2,204 = Ibsjfe lbs/m3 59K3 Impact of elevation at which the works are executed, Heghtin{mJtof 15 [25 [ 35 [ 45 [ 60 | 75 [ 80 | 100 K3 K4_ Impact of the job site ground ~ hard and flat ground = fill ground consolidated by a roller and provided with drainage loose ground with drainage = fill ground without drainage = levelled out ground without drainage ~ muddy ground K5_Impactof the structure engineering level = documentation fully developed - only erection process with written instruction - documentation not developed K6_ Impact of installation joint type = min. 90 % bolted joints ~ min, 90 % welded joints - min, 90 % riveted joints K7 Impact of pre-assembling practicability - pre-erection possible - smooth ~ pre-erection possible - restricted - pre-erection not possible KB Impact of the structure design ~ very simple ~ simple = normal ~complex ~very complex K9_Impact of the structure complexity ~ welded plate structure ~ rolled sections structure - pipe structure K10 Impact of the component bulking ~ delivery in bulk - basic assembling ~ assembled for normal transport ~ assembled for special transport 604, STEEL STRUCTURES IN OIL REFINERIES AND PETROCHEMICAL PLANTS — (PEP = 75%) 4.1 LIGHT STRUCTURE (to 30 kg/m) 4.1.1 Ladders and step irons [Mhr/ton] 4.1.2 Floors - treads [Mhr/ton] or lm [Mhr/ea] 4.1.3 Light platforms and landings [Mhr/ton] 4.1.4 Railing - straight [Mhrfton] or [Mhr/m] Railing - round [Mhr/ton] or [Mhr/m} 4.2 MEDIUM-WEIGHT STRUCTURE (31 + 60 kg/m) 4.2.1 Air coolers [Mhr/ton] 4.2.2. Medium platforms and landings [Mhr/ton} 4.2.3 Structure on towers [Mhr/ton] 4.2.4 Staircases [Mhr/ton] 425 Torch structure [Mhe/ton] 4.2.6 Pipe supports, trestles, supports on prepared foundations ([Mhr/ton] 4.3 HEAVY STRUCTURE (above 60kg/m) 4.3.1 Pipe racks [Mhr/ton] 43.2 Kiln structure [Mhr/ton} 43.3. Reactor and regenerator structure [Mhr/ton] 43.4 Large workshops = span to 10m [Mhr/ton] +10 + 20m [Mhr/ton} + above 20 m [Mhr/ton} 4.4 MISCELLANEOUS STRUCTURES 4.4.1 Floor grids [Mhr/m2] 4.4.2 Chequered plate flooring - fabrication [Mhr/m?] - installation [Mhr/m2] 4.4.3 Lining of large workshops and hangars + corrugated sheets [Mhr/m2] ~ sandwich elements - roof [Mhr/m2] ~ sandwich elements - fasade [Mhr/m?] 4,5 PIPE HANGERS AND SUPPORTS 455.1 Fabrication [kg/Mhr] 45.2 Erection [kg/hr] 45.3 Spring supports erection [kg/Mhr] (Classification of steel structures acc. to UHDE Dortmund) 615, ERECTION AND DISMANTLING OF MISCELLANEOUS STEEL STRUCTURES (PEP = 75%) 5.1 ERECTION OF STEEL STRUCTURES - ACC. TO THE WEIGHT Bulking, raising, Unloading | positioning Structure weight and on-site | and Structure fastening TOTAL hauling | temporary bolting [Mhejton|_| [Mhr/ton) [Mhr/ton] [Mhr/ton) to 20 tons [welding of bolted joint. 20 + 50 tons, ‘welding of bolted joint 50 + 100 tons welding of bolted joint 100 + 250 tons ‘welding of bolted joint 250 + 500 tons: welding of bolted joint 500 + 750 tons ‘welding of bolted joint 750 * 7000 tons welding of bolted joint 7000 * 7500 tons ‘welding of bolted joint 1500 + 3000 tons welding of bolted joint 3000 + 5000 tons ‘welding of bolted joint ‘above 5000 tons welding of bolted joint ‘Above man hours do not include painting and scaffolding, 5.2. MISCELLANEOUS STRUCTURES 5.2.1 STRAN STEEL FRAMING ~ stud system (Mhr/m?] ~ rafter system [Mhr/m?] = joist system (Mhr/m?] Man hours do not include covering, painting and scaffolding, 5.2.2 STEEL OVERHEAD PIPE, BRIDGES, ETC. - unloading [Mhr/ton} - bulking, hoisting, positioning and temporary bolting [Mhr/ton] fastening: - welded design [Mhr/ton] ~ bolted design [Mhr/ton] Total:-welded design [Mhr/ton] - bolted design [Mhr/ton} Man hours do not include covering, painting and scaffolding, 625.2.3 DOCK AND CANOPY FRAMING unloading [Mhr/ton] - raising, positioning and temporary bolting [Mhr/ton} + fastening = welded design [Mhr/ton] - bolted design [Mhr/ton] Total: - welded design [Mhr/ton] ~ bolted design [Mhi/ton] Man hours do not include covering, painting and scaffolding, 5.2.4 PLATFORMS AND FLOORS ~ unloading [Mhr/ton] - erectior = platform framing [Mhr/ton] + catwalk framing [Mhr/ton] ~ chequered floor plate {kg/Mhr] or [Mhr/ton] Man hours do not include painting and scaffolding, 5.2.5 BAR JOISTS, PARTITION FRAMING, MONORAILS AND EQUIPMENT SUPPOR a) bar joists + unloading [Mhr/ton] - erection and fastening L[Mhr/ton} Total: [Mhr/ton] b) pattition framing = unloading [Mhr/ton] = fabrication cutting out [Mhr/ton] - erection and fastening [Mhr/ton] Total: [Mhr/ton] ©) monorails + unloading [Mhr/ton] ~ erection and fastening [Mhr/ton] Total: [Mhr/ton] 4) equipment supports = unloading [Mhr/ton] + fabrication cutting out [Mhr/ton] ~ erection and fastening [Mhr/ton] Total: [Mhr/ton] Man hours do not include erection of equipment, painting and scaéfding, 5.2.6 STAIRS & LADDERS + unloading miscellaneous steel items [Mhr/ton] a) stairs: + fabrication of all sizes [Mhr/ton] + field erection 915 mm (3! 0") wide [Mhr/ton] = field erection 1067 mm (3' 6”) wide [Mhr/ton] + field erection 1220 mm (4' 0") wide [Mhr/ton] - landing fabrication [Mhr/ton] 63b) ladders - fabrication of straight ladders [Mhr/ton} = fabrication of ships ladders [Mhr/ton] - fabrication of safety cages [Mhr/ton] = erection of straight ladders. ([Mhr/ton] = erection of ships ladders [Mhe/ton] - erection of safety cages (Mhr/ton} = rung erection 019 mm (3/4”) [Mhr/ton} Man hours do not include painting and scaffolding. 5.2.7 HANDRAILS a) Standard Pipe Handrails - 1067 mm (3' 6") High - fabrication 1 1/4” & 1 1/2" - straight runs [kg/Mhr] or [Mhr/ton] + fabrication 11/4" & 1 1/2" - angled runs [ka/Mhr] or [Mhr/ton] - erection 11/4” pipe - straight free standing [Mhr/m}* + erection 1 1/4" pipe - angled free standing [Mbr/my* - erection 1 1/2" pipe - straight free standing [Me /m}* ~ erection 1 1/2” pipe - angled free standing [Mbr/my* b) Single Pipe Handrail - Wall Attached: = fabrication 1 1/4" & 1.1/2" pipe [ka/Mhr} or (Mhr/ton} serection 1.1/4” pipe [Mhr/my* serection 1.1/2" pipe [Mhr/m}* - erection of wall brackets [Mhr/ea] ©) Standard Angled Iron Handrail - 1067 mm (3' 6") High + fabrication - straight runs [kg/Mhr] or [Mhr/ton] - fabrication angled runs [ko/Mhr} or (Mhr/ton} + erection 50x50x6 mm - straight free standing [Mhr/mp* - erection 50x50x6 mm - angled free standing [Mhr/m}* ~ erection 50x50x6 mm - straight free standing [Mhr/my* + erection 50x50x6 mm - angled free standing [Mhr/mp* ) STANDARD TOE OR KICK PLATES 3,5. mmx 150 (6") [Mhr/m] 4,76 mm x 150 (6") [Mhr/m] 6,35 mm x 150 (6") [Mbc/m] [Mhr/m]* refers to the length of handrail and not the length of a pipe or a section. = Straight runs are those with all connecting members at 90° angles. ~ Angles runs are those with all connecting members at an angle larger or smaller than 90°. - For erection of handrails made of light tubes and solid round and flat sections, use the man hours for angled handrails. - For handrails with expanded metal panels, increase angle iron man hours thirty (30) percent. = Man hours do not include painting, 5.2.8 DOOR, LOUVER AND DUCT FRAMES a) Door Frames - unloading [kg/hr] or [Mhr/ton] = fabrication [kg/Mbr] or [Mhr/ton] = installation [ko/Mhr] or [Mhr/ton] 64b) Louver Frames - unloading [kg/Mbhr] or [Mhr/ton} = fabrication [kg/Minr} or {Mhrton} - erection [kg/Mbr] or [Mhr/ton] ©) Duct Frames - unloading [kg/Mhr] or [Mhr/ton] = fabrication [kg/Minr} or [Mhrjton} - erection [kg/Mhr] or [Mhr/ton} Man hours do not include painting and scaffolding. kg/hr x 2,2046 = Ibs/Mr 5.2.9 MISCALLANEOUS IRON & STEEL a) Bins & Hoppers - unloading [ko/Mhr] or ([Mhr/ton] ~ fabrication kg/Mar} or [Mhr/ton} - erection [ko/Mnr} or ([Mhr/ton} b) Miscallaneous Hangers - fabrications [ko/Mhr] or ([Mhr/ton] ~ erection [kg/Mhr] or [Mhr/ton} ©) Metal Thresholds + Installation [Mhr/ea} 4) Wheel Guards + installation [Mhr/ea] €) Trench Framing ~ Unloading [ko/Mhr] or ([Mhr/ton] - Fabrication [kg/Mnr] or [Mhr/ton} + Installation Tkg/Mhr} or [Mhr/ton} ) Trench Covers ~ Plates installation (Mhr/m?] ~ Grating installation [Mhr/m?] 9) Curb Angles = unloading [kg/Mhr] or [Mhr/ton] ~ fabrication {kg/Mbr] or [Mhr/ton} ~ installation [ko/Mhr] or [Mhr/ton] h) Steel Curbing - unloading {kg/Mhr] or [Mhr/ton] ~ fabrication {kg/Mbr] or {[Mhr/ton} - Installation [kg/Mbr] or [Mhr/ton] i) Pipe Sleeves = fabrication [kg/Mhr] or [Mhr/ton] + installation [ko/Mhr} or [Mhr/ton] 3) Anchor Bolts = fabrication [kg/Mhr] or [Mhr/ton] ~ installation [ko/Mhr] or [Mhi/ton] k) Ledger Angles ~ unloading [kg/Mhr] or [Mhr/ton] + fabrication [ko/Mhr} or [Mhr/ton] ~ installation [ko/Mnr] or [Mhr/ton] Man hours do not include painting and scaffolding. 655.2.10 STEEL GRATING ~ Installation of floor grids Grating Bar Size Weight (ka/m?] [Mhe/m?] 19,05 x 4,76 mm 28,80 25,04 x 3,18 mm 25,39 25,04 x 4,76 mm 371L 31,3. x3,18 mm 30,76 31,3. x4,76 mm 44,92 38,1 x3,18mm 36,13 38,1 x 4,76 mm 53,22 44,45 x 4,76 mm 61,52 50,8 x 4,76 mm 69,82 57,15 x 4,76 mm 77,64 63,5. x 4,76 mm 85,94 - Fabrication and modification of floor grids: + straight and diagonal cutting = circular cutting - straight and diagonal banding = circular banding ~ welding of curb angles + rounding of curbs by grinding Man hours do not include painting and scaffolding. 5.2.11 SIDING OF LARGE WORKSHOPS AND HANGARS + section sheets - section aluminium plates - stainless steel sheets + insulation boards (sandwich) Man hours do not include sealing and scaffolding. 5.3 REMOVAL OF STEEL STRUCTURE AND MISCELLANEOUS ITEMS - Steel structure - Miscellaneous steel items ~ Machinery: light heavy - Pipes (CS) to2" rg" 8" 212" 14” 5 16" 18” +24" 26" + 36" - Rallroads: Ties and tracks Tumouts ~ Miscellaneous Fence of three strand barbed wire Fence of five strand barbed wire Chain fink fence Guerd rail (Mhr/m)] (Mhr/m] [Mhr/m] (Mhr/m] [Mhr/m] [Mhr/m] [Mhr/m2] (Mhe/m2] [Mhr/m?] [Mbr/m?] [Mhr/ton] [Mhr/ton] [Mhr/ton] {(Mhe/ton) [Mhr/m] (Mhr/m) [Mhr/m] [Mhr/m] (Mhr/m) [Mhr/m] [Mhr/m] [Mhr/ea] [Mhr/m] (Mhr/m] [Mhr/m] [Mhr/m] Man hours do not include loading, transport and unloading and scaffolding, 66 aj 0.2048 = tse vf 0,0929 = Meso Wf x 03088 = Mee yh 2.2086 = itIV. ERECTION OF EQUIPMENT IN PETROCHEMICAL INDUSTRY Productivity Efficiency Percentage (PEP) = 75% 1. STATIONARY EQUIPMENT (towers, heat exchangers, reactors, regenerators, small storage tanks, air coolers, etc.) ‘These man hours include the erection of equipment delivered as a whole or in sections that are completed but not fully assembled because of their overall dimensions (transport). Man hours include: Unloading = Hauling from storage to the place of erection - Hoisting by usual hoisting means - Putting upto the design elevation - Positioning of connection points - Position inspection TIME ALLOWANCE FOR ERECTION OF EQUIPMENT AT ELEVATION All stated below, man hours for erection of equipment are applicable when the equipment base is atan elevation of up to 2m above the site zero level. Apply the following factors for higher elevations: Elevation Factor 1.1 All Equipment to 0,5 ton [Mhr/ea] or fitka/Mhe] 1.2 Towers above 0,5 ton ([Mhr/ea] + lmi[Mhr/ton] 1.3 Towers consisting of more pieces: [Mhr/ea] + lmmi[Mhr/ton] + joint Joint: [Mhr/m] of jointcircumference 1.4 Package Unit to10tons : [Mhr/ea] + [ili[Mhr/ton] above 10 tons [Mhr/ea] + S[Mhr/ton] 1.5 Other Equipment 0,5 + 2tons [Mhr/ea] + lmmmi[Mhr/ton] 2,1 10tons: [Mhr/ea] + [Mhr/ton] 10,1 + 20tons [Mhr/ea] + SfMhr/ton] above 20tons : [Mhr/ea] + [Mhr/ton] 1.6 Bridge Cranes ~ Erection of crane track (rails) [Mhr/m] ~ Erection of crane with a trolley and a drive [Mbr/m] span Lifts [Mhr/m?] shaft + [lll Mhr per meter of elevation 671.8 Electrostatic Precipitators Weight[ton] _Effect{ka/Mhr} to 100 ton/unit 4100 = 250 ton/unit above 250ton/unit 1.9 Marine loading arms (acc, to John S, Page) assembling and erection (Mhr/ea] Toad. arm diam. TTotal length of loading arm (meters inch__ [to 629 | 9212 | 12+ 15 | 15+ 18 | 18221 | +24 | M227 | 7-30 * e a NOTE: I find above man hours for loading arms too stringent, so I suggest they are increased by [ll + [ll %. 2. ROTARY EQUIPMENT (pumps, compressors, fans, blowers, mixers, etc.) ‘These man hours include the following: Hauling from storage to the place of erection - Placing onto previously built foundations - Vertical positioning = Machine positioning and inspection = Installation of guards and covers ~ Completion with pertaining parts mx 3,281 = ft ka/Mhr x 2,2046 = Ibs/Mr Mhe/m x 0,3048 = Mhr/ft 2.1 CENTRIFUGAL PUMPS 2.1.1 MAN HOURS BASED ON POWER [kW] Power [kW] [Mhr/kW] — [Mhr/ea] Minimum hours to10kW + 10+ SOkW + 50+ 100kW + 100+ 150kW 150+ 200kW 200+ 250kW above 250kW 68~ Pumps supplied with a coupling on one pedestal - Pumpsand drive motors supplied separately - Pumps, drive motors and reduction gears supplied separately ~ Vertical pumps - Fans = Blowers - Gear pumps ~ Mixers - Compressors to 200 kW 2.1.2 MAN HOURS BASED ON WEIGHT [kg] Weight[ka] Effect [kg/Mhr] Min.{Mhr/ea] to 100 101 = 200 201 + 300 301 + 400 401 + 500 501 + 600 601 + 700 701 + 800 801 + 900 901 = 1000 1001+ 1250 1251 + 1500 1501+ 2000 2001 + 2500 above 2500 = vertical pumps [ko/Mhr] x = fans [ko/Mhr] x = blowers (ka/Mhr] x ~ gear pumps tkg/Mhr] x kg x 0,4536 = Ibs » mbers [kg/Mhr] x kg/Mhr x 2,2046 = Ibs/Mhr = compressors tkg/Mhr] x NOTE: If the data on power and weight are available, perform the calculation on both bases and take the mean value, 2.1.3 MAN HOURS BASED ON THE CAPACITY [mjhr] (FOR LIQUID MEDIA ONLY) {miPhe] Mhex [rifhr] [rifhr] Mhex [oifhr] to10 160,15 170 10,1 +20 170,12 180 20,1 +30 180,1+ 190 30,1+40 190,1+ 200 40,1 +50 200,1+ 210 50,1 +60 210,1+ 220 60,170 220,12 230 70,1 +80 230,1+ 240 80,190 240,1+250 90,1 = 100 250,1260 100,1 +110 260,1+270 110,12 120 270,1+280 120,1+ 130 280,1+290 130,12 140 290,1+300 140,1+ 150 300,1+750 150,1+ 160 above 750 69Conversion of Units Vsx3,6 = mfr min x 0,06 = mae US gallons per minute: US gpm x 0,227 = mi/hr Cubic feet per minute: cfpm x 1,7 = m'/hr Cubic feet per hour: cfphr x 0,283 = m'/hr 2.2 COMPRESSORS 2.2.1 COMPRESSORS DRIVEN BY ELECTRIC MOTOR, to200 kW Acc. toTable2.1.1 300 kW [Mhr/kW] (min Mhr) 500 kW [Mhr/kW] (min Mhr) 750 kW [Mhr/kW] (min, Mhr) 751+ 1000 kW [Mhr/kW] (min Mhr) 1001 + 1500 kW [Mhr/kW] (min Mhr) 1501 +2250 kW [Mhr/kW] (min Mhr) 2251 + 3000 kW [Mhr/kW] (min Mhr) 3001 +4000 kW [Mhr/kW] (min Mhr) 4001 = 5000 kW [Mhr/kW] (min Mhr) above 5000 kW [Mbr/kW] (min. Mor) 2.2.2. COMPRESSORS DRIVEN BY GAS TURBINE t0250 kW [Mhr/kW] (min Mr) 251+ 350 kW [Mhr/kW] (min Mor) 351+ 450 kW [Mhr/kW] (min Mhr) 451+ 600 kW [Mhr/kW] (min Mhr) 601 = 750 kW [Mhr/kW] (min. Mhr) 751+ 900 kW [Mhr/KW] (min Mhr) 901 +1100 kW [Mhr/kW] (min Mhr) 1101 + 1300 KW [Mhr/kW] (min Mhr) 1301 + 1500 kW [Mhr/KW] (min Mhr) 1501 +1750 kW [Mhr/kW] (min Mbr) 1751 +2000 kW [Mhr/kW] (min Mhr) 2001 + 2500 kW [Mhr/kW] (min Mhr) 2501 + 3000 kW [Mhr/kW] (min Mhr) 3001 + 4000 kW [Mhr/kW] (min Mhr) above 4000 kW [Mhr/kW] (min Mbr) 703. TOWERS & VESSELS - INSTALLATION OF INTERIOR COMPONENTS & EQUIPMENT 3.1 INSTALLATION OF TRAYS AND DEMISTERING PADS [Tower Diameter [ane Tkgitinr] [mm] z 3 z 6 ‘to 1000 1001 = 1200, 1201 = 1400, 3401 = 1600 1601 = 1800 1801 = 2000 2001 + 2250 2251 = 2500. 2501 = 2750 2751 + 3000 ‘3001 = 3250 3251 = 3500 above 3500 1. Single downflow valve type trays 2. Double downflow valve type trays 3. Single downflow bubble cap type trays 4, Double downflow bubble cap type trays 5. Sieve or perforated type trays 6. Demisting pads* “If the bottom and roof of a demisting pads are already installed, the man hours should be decreased by [NNT %. 3.2 VESSELS & TOWER PACKING Packing the vessels and towers with different solid packings in bulk condition: towers: [Mhrfea] +l [Mhr/m'] or [Mnr/ton] vessels: [Mhr/ea] +l [Mhr/m'] or [Mhr/ton] 3.3 OPENING AND CLOSING OF MANHOLES ON VESSELS AND TOWERS ManholeSize _[Mhr/ea] to14" 16" 18" Class 20" 24" 150#x 1,0 28" 300% 1,15 30" 600#x 1,30 32" 36" 40" 42" Tar/mak 0,0929 = Mnr/safe Mhr/m3 0,02831 = Mhr/cuft kg/Mhr x 2,2046 = Ibs/Mhr nm3.4 ERECTION OF PLATFORMS, LADDERS AND FLOOR GRIDS ON VESSELS AND TOWERS (PREDRESSING) 3.4.1 Erection average effect : [kg/Mbr] 3.4.2Estimate of quantity of platforms, ladders and floor grids Itis calculated per [m] of the shell surface area (without bottom and roof). Elevation [kg/m] [Mbe/m?]* to10m 10,1+15m 15,1+20m 20,1+25m 25,1+30m 30,135m 35,1440m 40,145m 45,14 50m 50,1 55m 55,1+60m above 60m * These data should be regularly monitored and occasionally revised, 4, EQUIPMENT SCAFFOLDING 4.1 Tubular scaffold (for each piece of equipment separately) to10m] 10+50m'| 502100m' | 100+500m' | —_500+1000m’ | above 1000 m" Scaffold erection [Mhr/m"Jor [Mhr/m’] Scaffold dismantling [Mhr/m*Jor [Mhr/m’] Total Elevation factor at which the scaffold is erected or dismantled: 0+ 5m 5 +10m 10 +15m s Ka/tihr x 2,2046 = Ibs/Minr 35 220m kg/m’ 0,2048 = Ibs/saft 20 +25m Mr/mi0,0929 = Mhr/safe 25 +30m Mar/mx 0,02831 = Mhr/euft ‘above 30m mm 35,32 = cuft 24,2 Patent Scaffolding Sections: Length : 7 feet;2,1m Width : 5 feet;1,5m Height : Sfeet;1,5m Manhoursper section Length Oneor TwoSections MoreThan Two High Sections High Erection | _Dismantiing Total_| Erection [Dismantling [Total (One to Two Sections Long Three to Five Sections Long ‘Six and More Sections Long 2BV. STORAGE TANKS - CYLINDRICAL AND SPHEROIDAL Productivity Efficiency Percentage (PPE) = 85% 1, APPROXIMATE WEIGHTS AND ERECTION EFFECTS OF CYLINDRICAL STORAGE TANKS (The weights are based on already designed storage tanks, mostly pursuant to API-650. Nowadays, storage tanks are also designed according to other standards so some 75% storage tanks have smaller weight) RATED vowume | Weight Conventional] Bygging*| Weight | Erection | Weight | Erection mn © ka/Mhe] | [ko/Mhr] | c. [kt ka/Mhe] | c[k ka/Mhe] 50 4715 8.100 9.740 11,440 12.400 14.000 u 19.950 23.800 74RATED Fixed Roof Floating Roof Fixed + Floating Roof votuMe Weight] Conventional] Bygging™| Weight | Erection | Weight | Erection | tot etka) | tkaythey | thay | etka) | tkayttney | c.tkal |e. those] 207000 566,000 449,000 60,000 22,500 594,000 500,700 540,000 25,000 622,500 552,500 30,000 684,000 660.000 35.000 742,000 766.500 40.000 04.000 872.000 50,000 976,000 1.002.100] 60,000 1.148.300, 1.151,500| 79,000 1.360.500] 0,000 1.520.600] 90,000 1,710,000] 700.000 1.890.000] ygging a method of erection by hycraute jacks -a series of identical storage tanks: each next storage tank x illlup to the maximum lll % effect increase Effect of storage tank erection with a steel berm (double shell and bottom) + Inside tank is calculated acc. to man hours in the table - Effect for the berm acc. to man hours in the table + Ifthe total weight is known, then acc. to man hoursin the table mx35,32 = cu ft kg x 0,4536 = Ibs kg/thr x 2,2046 = Ibs/Mhr 1.1 STATISTICAL PARTICIPATION OF STORAGE TANK COMPONENTS IN TOTAL WEIGHT Based on the analysis of 33 cylindrical storage tank projects of total 16,500 tons, 300 mito ‘80.000 m’, an average participation of the components in the storage tank total weight is as follows: Bottom c.[% - Shell c.lm% = Roof .[limm% (of which: steel sections NNNN%, roofing plates lll %) ~ Supporting structures <.lm% = Nozzlesand manholes z Storage tanks witha berm: ‘The berm weightis c, [lll % of the inside storage tank weight of which fllll% accounts for the shell and .[lllll% for the bottom, 52, ERECTION OF CYLINDRICAL STORAGE TANKS - DETAILS ‘The above table defines approximate effects of complete erection of cylindrical storage tanks according to the volume, type and method of erection, It is often the case that a very detailed erection estimate is required for already completed projects. This could be done if you follow this chapter. For some storage tank components, man hours are given only for erection without welding. In that case the welding should be computed and estimated according to the man hours for welding under the Chapter WELDING ‘AND FLAME CUTTING. Similarly the following correction factors should be considered ‘L.Impact of average outside temperature ~5°C to +10°C factor 10°C to 30°C factor 30°C to 40°C factor above 40°C factor 2. Impact of the job site ground Hard and flat ground factor - Fill ground consolidated by a roller provided with drainage factor -Fill ground, not consolidated provided with drainage factor - Fill ground consolidated by a roller mmm 0,03897 fen without drainage factor ( s¢nrjat 0,0929 = Mh/sa ft Ground levelled out kg/Mhr x 2,2046 = Ibs/thr without drainage factor Mhr/m x 0,3048 = Mhr/ft 2.4 PRELIMINARY WORKS Unloading plates [Mhr/ton] Material disposal [Mhr/ton] - Inspection and take over Tank diameter [Mhr/m2] of foundation, measurement, to15m and other: 16 = 25m 26 +40m 40 + 50m above 50m 2.2 STORAGE TANK BOTTOM 2.2.1. Installation of tank bottom Installationw/o Installationand welding welding* plate thicknness [ko/Mhr] {ka/Mhr] 6mm 6.5mm 7mm 8mm Annular ring to be computed with the effect for the central part decreased by 25 % * welding: 10 % SMAV 10 % automated machine 2.2.2 Corrosion protection of plates (underside) Tank diameter ([Mbr/m'] to 15m 16+ 30m 31+ 50m above 50m 2.2.3. Weld vacuuming on the tank bottom [Mpr/m] 762.3 STORAGE TANK SHELL 2.3.1Shell Erection - Con ventional (from bottom to top) [Mhr/plate] Prate thickness [mm (Course 36 [32 [ 28] 247 my te] | if 3 | mya + Correction factors according to the plate length Length [m] to 5 6 7 8 9 10 12 Factor -Welding not included 2.3.2Erection of shell plates (by hydraulic jacks) (*Bygging" hydraulic jacks, from top to bottom) Plate Thickness [mm Fa (mee + Correction factor according to the plate length as under item 2.3.1 -Welding notincluded + Installation of hydraulic jacks [Mhr/ea] Removal of hydraulic jacks [Mhr/ea] 2.3.3Weld grinding on the inner side of shell mm x 0,03937 = ine (storage tank with a floating roof) mx 3,281 = ft Mhr/m'x 90,0929 = Mhe/sq ft kg/Minr x 2,2046 = lbs/Mar Mhr/m x 0,3048 = Mhr/ft [Mhr/m] or [myMhr] 2.4 WIND BINDINGS - RINGS FOR SHELL STIFFENING 2.4.1 Top angle piece Erection w/o Erection and welding welding (SMAW) = Placing angle piece with conventionally installed shell and no walkway [Mhr/m] [Mhr/m] Placing angle piece with conventionally installed shell anda walkway [Mhr/m] ([Mhr/m] Placing angle piece with a shall installed by hydraulic jacks (Mhe/m] [Mhr/m] 72.4.2 Primary windscreen with a walkway Erection w/o Erection and welding welding [kg/Mhr] [ka/Mhr] 2.4.3. Secondary and additional windscreens 2.4.3.1Placing windscreens with conventionally erected shell Erection w/o Erection and Welding Welding (SMAW) woreinforec. | withreinfore. | w/oreinfore. | with reinfore T* windscreen, from the bottom up [Mhe/m] [Mhr/m] [Mhr/m] [Mhe/n 2" windscreen, from the bottom up [Mhe/m] [Mhr/m] [Mhr/m] [Mbe/m] 3” windscreen, from the bottom up [Mhr/m] [Mhr/m] [Mhr/m) [Mhe/m] 2.4,3.2Placing windscreens when ashellis er ected by hydraulic jacks Erection w/o Erection and Weldin Welding (SMAW) wforeinfore, | withreinfore. | w/oreinfore, | with reinfore ‘allwindscreens not used as walkways [Mhr/m] [Mhr/m] [Mhr/m] [Mbe/m] 2.5 FIXED ROOF 2.5.1 Erection of roof and support structure 2.5.1.1 Erection of the structure with a con ventionally installed shell Erection w/o Erection and welding welding * {kg/Mhr} {kg/Mbr} ‘mm x 0,03937 = inc 2.5.1.2Structure er ection with a shell installed by hydraulic jacks mx 3281 =f Erection w/o Erection and Mhr/m'x 0,0929 = Mhrisq ft welding welding* ka/Mhr x 2,2046 = Ibs/Mhr [ko/Mhr] ko/Mhr] Mhr/m x 0,3048 = Mt 2.5.2 Installation of roofing plates Erection w/o Erection and welding ‘welding * plate thickness mm] effect [kg/Mhr] [kg/Mhr] 5,00 5,50 6,00 6,50 * welding: 50 % SMAW; 50 % semiautomatic (MAG) 782.6 FLOATING ROOF 2.6.1 Erection of plates for the floating roof lower slab 2.6.1.1 For raising to the surface (water/air) Erection w/o Erection and welding welding* plate thickness [mm] effect [kg/Mhr] [kg/Mnr] 5,0 5,50 60 6,50 70 * welding: 10 % SMAW; 50 % MAG; 40 % automated machine 2.6.1.20na "spider net” steel structure ‘Above effects to be increased by lll % ~ "spider net” installation not included (Item 2.6.10) 2.6.2 Erection of concentric rings, radial partitions and supporting channels Erection w/o Erection and welding welding * Storagetankdiameter effect ka/Mhr] [kg/Mnr] to 20m 20% 30m 30 40m fmm x 003937 = inch above 40m mx3.261 =f * welding: 50 % SMAW; 50 % MAG Mi/n'x0,0829 = mesa fe g/Min x 2,2046 = Ibs/Mhr rj x 0,3048 = Marj 2.6.3 _ Erection of roofing plates (upper slab) Erection w/o Erection and welding welding* plate thickness [mm] fect [kg/Mhr] [kg/Mnr] 5,0 5,50 60 6,50 7,0 * welding: 20 % SMAW; 40 % MAG; 40 % automated machine 2.6.4 Installation of sleeves and reinforcements for the floating roof supports (legs) Erection w/o Erection and welding welding (SMAW) [Mnr/ea] [Mhrfea] 2.6.5 _ Installation of manholes on the floating roof Erection w/o Erection and welding welding (SMAW) ~ manhole to the storage tank through the floating roof [Mhr/ea] [Mhr/eal] - manhole to the floating roof chambers [Mnr/ea] [Mnr/ea] = welding not included 7927 2.6.6 Foam wall installation Erection and welding {kg/Mhr} 2.6.7 Preparation and raising the floating roof to the surface rm x 0303987 = inch x 3281 =f yn 0,0825 = Msg fe kg/hr x 22046 = Bsr rm 0,308 = Novi Storage tank capacity to 10.000’ (Mhr/ea] + Mhr/1000m > 10,000 + 20.000m [Mhrjea] + Mhr/L000m* 20.000 + 30.000 m* (Mhrjea} + Mhr/1000m” 30.000 +50.000m? = Mhr/1000m? above 50,000m * Mbr/1000m? 2.6.8 Installation of floating roof supports (legs) Erection and welding (SMAW) (Mhr/ea} 2.6.9 Placing the packers under the legs Erection and welding (SMAW) (Mhr/ea] 2.6.10Erection of supporting structure ("spider net”) ‘The supporting structure ("spider net”) is generally made of the remaining pipes or sections, It is made to the elevation at which the floating roof is supported on its supports or min. 1500 mm. To estimate the quantity of the supporting structure, the roof load of 110 + 130 kg/m’ should be considered (total roof weight to be divided by the lower slab surface area). - Steel structure quantity: «. ~ Erectionand dismantling effect: AUXILIARY STRUCTURE 27.1 _ Erection and welding of spiral stairs and landings 2.7.2 Erection and welding of inclined stairs and landings 2.7.3 Erection and welding of vertical stairs and ladder cages 2.7.4 Erection and welding of sliding stairs with a bearing anda guide 2.7.5 _ Erection and welding of a foam ejector holder 27.6 _ Erection and welding of prefabricated railings 80 [ka/m?} [ko/Mbr] m3 x 35,32 kg/m? 0,2048, [kg/Mbr] {kg/Mbr] {kg/Mbr] [ko/Mbr] [ko/Mbr] [kg/Mbr]2.8 CONNECTIONS AND OPENINGS 28.1 2.8.2 2.83 2.8.4 285 Manholes on the shell (generally welded during prefabrication) Installation and Installation welding (SMAW) Manhole & [Mhr/ea] ([Mhr/ea] 20" 24” 30” 36" Cleaning door (generally welded during prefabrication) Installation and Installation welding (SMAW) Dimensions [Mhr/ea] [Mhr/ea] 87x16" (203,2 x 406,4) 24"x 24" (609,6 x 609,6) 36x48" (914,4 x 1219,2) 48"x 48" — (1219,2 x 1219,2) Connection points with a flange on the shell @ [Mhr/ea] o [Mhr/ea] 14/2" 24" 2 26" x" 28" a" 30" 6" 32" 8" 34" 10" 36" 12" 38" 14" 40” 16" 42" 18” 44" 20" 46" 22" 48" - Welding included Connection points with a thread on the shell ° (Mhr/ea) 3/4" " 11/2" te or ~ Welding included Manholes on the roof Installation and Installation welding (SMAW) a [Mhr/ea} ([Mhr/ea] 20" (508,0) 24” (609,6) 812.8.6 Connection points with a flange on the roof o [Mhr/ea] 142" » 7 a 6 s 10" 12" 2.8.7 Connection points with a thread on the roof ° (Mhr/ea} 3/4" 142" o 3 ? Welding included 2.9 STORAGE TANK EQUIPMENT 2.9.1 Floating roof guide railing Installationand welding [kg/Mbr] 2.9.2 Installation of floating roof drainage = Installation of precipitation drain valve with a lever [Mnr/ea] = Installation ofa flexible steel pipe assembly {ka/Mhr] = Installation ofa flexible drain hose of syntheticmaterial [Mhr/ea] 2.9.3 Installation of air vent valves - on fixed roof (Mhr/ea] on floating roof [Mnr/ea] 2.9.4 Installation of sampling and inspection holes [Mnr/ea] 2.9.5 Placing davits and welding (kg/Mhr] 2.9.6 Installation of level indicators -for fixed roof [Mhr/package] = for floating roof [Mnr/ package] = connections not included 822.9.7 _ Erection and welding of a floating roof seal 1. General American Transportation Corporation / Wiggins = "Safety seal” (Mhr/m] 2, Pittsburgh Des Moines Steel Comp. = "Hydroseal” [Mhr/m] = "Hammond Tubeseal" [Mhe/m] ~"Hammond Spring -Tite seal” [Mhrfm} 3, Chicago Bridge & Iron Company ~Seal"SR-1" [Mhe/m] *Seal"SR-3" [Mhr/m] -Seal"SR-5" [Mhr/m} ~Seal"SR-7" [Mhr/m} -Seal"SR-8" [Mhr/m} -Seal"SR-9" [Mhr/m] 2.9.8 Installation of the storage tank bottom heating PipeDiam. [Mhr/m] 11/2" = oa Bending, welding, supporting and tests included. 2.9.9 _ Installation of an energy-saving heater [ka/Mhr) - Welding also included 2.10 FINISHING WORKS 2.10,1Stor age Tank Hydrostatic Testing Volume Hours to 5.000 m' [Mhr/ea] + Mbr/t000m. 5,000 + 10.000 m’ [Mhr/ea] + Mhr/tooom, 10,000 + 20,000 mi [Mhr/ea] + Mhr/t000m. 20.000 + 30.000 m’ Mhr/t000m. 30.000 + 40.000 m’ Mhr/to00m. 40.000 + 50.000 m° Mbr/t000m, ‘above 50.000m’ Mhr/tooom. 2.10.2Stor age Tank Final Cleaning - Hydrostatic testing performed with water from the hydrant network [Mhr/m’] tank bottom surface area - Hydrostatic testing performed with silt water [Mhr/m’] tank bottom surface area 1000 m= 35320 cu ft Mhr/m x 0,3048 = Marit kg/Mhr x 2,2046 = Ibs/Mhr Mhr/mk 0,0929 = Mhr/sq fe 833, ERECTION OF SPHERICAL AND SPHEROIDAL STORAGE TANKS For this kind of works I neither had available nor was familiar with any bibliography that would provide me with practical parameters and man hours for a technical calculation, Only John S. Page (USA) provided some tables for spheroidal storage tanks to 800.000 gallons (3.028 m’) and spherical storage tanks to 200.000 gallons (757 m’). I found his manhour calculation too stringent. They allow for too few hours for erection. During my practice I had to make the calculations for such storage tanks many times. I did itn the following way: 1. Unloading & storing material f= fim [Mhr/ton] 2. Shell welding Calculate the weld runs and determine the hours according to the tables under the Chapter VI/4 Welding of Spherical Storage Tanks 3. Assembling prefabricated plates and supports of tank. Shell welding manhours x 4, Placing and welding the connections and equipment Use man hours for cylindrical storage tanks and other respective items 5. Hydrostatic Testing [Mhr/m’] [Nil hours at least 84VI. WELDING AND FLAME CUTTING Productivity efficiency percentage (PEP) = 70% 1. MANUAL ARC WELDING OF CYLINDRICAL TANKS - SMAW (Man hours for calculation) » 1.1 Fillet joint Overtap joint Plate Weld Deposit FILLET VERTICAL ‘OVERHEAD thickn. "b" |reinforc. "a]|_weight 2F 3F 4F [mm] [mm] [tka] [fever] | Marin] | myer] (Miri) [Emer] | [Mhr/m] 3 2h 0,07 4 28 0,09 5 35 0,13 6 42 0,18 7 5,0 0,25 8 56 0,33 9 64 O41 10 7A 05 2 85 0,75 14 89 1,04 15 10,6 1,18 16 113 1,33, 18 12,7 1,62 20 14,1 214 2 15,6 2,52 24 W7 29 25 17,5 3A ‘mm x 0,03937 = inch kg/m x 0,672 = Ibs/ft rm/Mhr x 3,281 =ft/Mbr Mhr/m x 0,3048 = Marit 851.2 Single "V" butt joint Angle Deposit weight Skg/m HORIZONTAL 1G VERTICAL a i Be A (OVERHEAD imp hr) 3 E imp hr) [mM hr. iS oo 0,08) 0,12 60 0,2 60" 0,26. 60" 033 60" oat 60" 0,53 60° 0,67 60" 0,78 60 0,9 60" TIS 60" iat 60" 1,96 oO 214 60" 2,58 0 32, oO 387 ee ae a a a eae aya aa eee ee aaa a ae ayaa ee aye a aa a ave ayaa es eee ee kglm x 0,672 im/Mhr x 3,281 =ft/Mhr Mhr/m x 0,3048 theft1.3.Double "V" butt joint Plate Distance | Deposit VERTICAL HORIZ -VERTIC. thickn. "st" | "Br weight Et 26 (rm [mm (kof) [fever] | (ethrien) | (mv) | [Mei] 10 045 i O51 12 0,57 4 O77 15 0,86 16 0,94 18 1Az 20 134 2 156 24 176 a 2,13 26 2,26 28 2,53 30 2,85 32 3,13 34 3,45 36 3,79 40 457 NOTE : Double “V" butt joint can also appear under different angles, also under irregular. In that cases standard is calculated with value for single "V” butt joint, ‘mm x 0,03937 kg/m x 0,672 87Area = (0,25xs1x 2t9")+(sxb) 1.4 Double bevel butt. Plate | Angle MEASURES | Area Deposit | HORIZ.- VERTICAL s [mm] Weight 2G mm z b Te [st [fmm J[ tkaimy | [mime] [ [ne/m] 10 50° 3 [2 [a3] a 0,63 2 50° 3 [2 [is [104 0,82 4 50° 3 [2 [18 [139 1,09 15 50° 3 [2 [as [13 12 16 50° 3 [2 [20 [168 132 18 50° 3 [2 [22 | 199 1,56 20 50° 3 [2 [24 [333 1,83 22 50° 3 | 2 [26 | 269 211 25 50° 3 [2 [29 [327 2,57 30 50° 3 [2 [36 | 479 3,76 35 50° 3 [2 [a1 | 609 4,78 40 50° 3 [2 [a6 | 755 5,93 NOTE : When horizontal joints of the tank shell are welded by SMAW process, two different thickness mostly are used. In that case a mean value is used for operating time. kg/m x 0,672 m/Mhr x 3,281 Mhr/m x 0,3048 = Mart 88sl 1.5 Single bevel butt joint “ "" Weight HORIZ, - VERTICAL (2G) [mm] mm] [kg/m] [Mhr/m] [m/mhr] 5 [ 1s2 0.244 6 | 122 0,313 7 [122 oa 8 | 223 0,58 9 [253 0,686 wo | 233 08 a [233 0,922 wz _| 233 1,079 a2_[ 233 1,31 14 | 23 1,464 as | 223 1,624 16 | 223 1,793 18 | 253 2,154 20 | 223 2,547 22 | 233 2,971 2 | 233 3,426) 89 m/Mhe x 3,281 Mhi/m x 0,3048 mm x 0,03937 = inch kg/m x 0,672 = Ibs/ft Me2, SUBMERGED ARC WELDING (Data for calculation) 2.1 Welding machine "Lincoln Lt-3" ® o 2.1.1 Welding of overlap joint Wire EPP - 2.04 mm. Wire EPP - 2.03 mm s]e] » Number s]e v Nuraber ev | tm | towminj_| of Passes_| cmv | tmtney} [gmc] | temyminy_| of Passes _|rmnrim) |rmttne 3 [35 | 8 T 3 [35[ 80 T 554 | 75 T 35[ 4 | 70 T 6 [45] 65 1 6 [45] 6 1 65 [5 | 54 1 65| 5 | 50 T 7 [55 [42 1 7 13538 1 v= travel speed 2.1.2 Welding of filet joint (bottom shell, internal site ) Wire EPP- 204mm Wire EPP- 203mm ey] Tamer 2 v Namber few | fenvming_| of Passes | (mhw/m)_| trv) Lon] |femyming | oF Passes | iMivimy | _[mytthe) oe] 18 3 8 | 35 3 eo] 14 3 @ | 105 3 v= travel speed kg/m x 0,672 im/tthr x 3,281 =fY/Mhr Mhifm x 0,3048 = Mhryft 902.2 Machine welding, "ESAB A-2T" ® L 2.2.1 Welding of overlap joint Wire EPP - 2.04 mm. Wire EPP - 203 mm =a v Norber =]. v Naber evr | towed | fervent | of Passes | tmhetml| tmvothr}} [tment | trom) | fem/mind | of Passes | tMrm_|imy/hr] 5 [35] 85 1 5 [35] 80 1 55[ 4 | 75 1 354 | 70 1 6 [45] 65 1 6 [45] 60 1 65] 5 | 55 1 65] 5 50 1 7 [55] 50 1 7 [ss] 45 1 v= travel speed 2.2.2 Welding of fillet joint (bottom shell, inside of tank ) Wire EPP-204mm Wire EPP- 203mm ay Number 2 v Nomber town | ferviminy | of Passes | othr) | (myte town |femverint | of Passes | tvtefm) | Emer] S| 18 3 8 | 335 3 a, 3 9 [105 3 v= travel speed ‘mm x 0,03937 = inch kg/m x 0,672 m/Mhr x 3,28: Mhefm x 0,3048 912.3 Welding with Vertomatic "ARCOS” Gas shielded, flux cored welding rod -outershield. Mhr/Vertical Weld 3 a B v Height of One Vertical Weld [mm] mm|_TYPE OF JOINT mm mm___| em/min [to 1600 [ 1800 [2000]2200]> 2400 36 3 7 63 35 a 3 16.6 65 32 a 3 15.6 68 30 2 13.6 72 25 2 115 83 24 b 2 wa 87 2 2 10.3, 9.1 20 2 9.5 10 20 3 19 117) 16 b 2 15 14.9 15 2 124 158 4 Ta 2 1.6 7 3B \ 2 107 183 12 2 10 19.9 uw ae] &S | 2 3 17 6 9e12 ez| 2% 25 | 2 z za | 20 8 629 ug |B o3 2B 10 538 HES 26 26 12 436 30 8 2 34536 2 8 o — z 8 2 34236 * a | Ww z 2 2 Jo 4 17520 g B a 13 4 16+19 ase | ra Z 16 c 16 4 15+18 mr g 18 5 18. 6 orl 8 21 21 7 7210 a Root pass full penetration will be calculated according to SMAW or GMAW process. ‘When calculating the welding time for each horizontal oint, to be added Each shifting of welding machine Mhr (the number of shifting is defined by weld eng.) = Positioning and taking off Mhr = When two welding machines are used - (simuttaneos from both sides) - positioning and taking off Mhr 943. WELDING WITH SEMIAUTOMATIC (GMAW) (Data for calculation) 3.1 Semiautomatic - GMAW (CO) 3.1.1 Welding of fillet joints ms 2 2 o s a Deposit | HORIZONTAL (2F) VERTICAL (3F) mm mm | Weight [ka/m) | {ethefm) | [myMhr] | [hey] | [m/Mhr] 3 2a 0,07 4 28 0,09 5 35 0,13 6 42 0,18 2 5 0,25 8 56 0,33 9 64 Oat 10 74 Os 12 85 0,75 14 89 1,04 16 113 133 18 12,7 1,62 20 14,1 214 2 15,6 2,52 24. 17 29 95 Mni/m x 0,3048 m/Mhr x 3,281 =fyMhr Mhe/te3.1.2 Welding of single "V" butt joint 60° a b s Angle b Deposit | HORIZONTAL (1G) | VERTICAL (36) mm " mm Weight ko/m} [~[Mbr/mi] (mime) | (ahi) | [m/Mhr] 4 60° 15 0,12 5 60° 2 0,2 6 60° 2 0,26 7 60° 2 0,33 8 60° 2 oat 9 60° 3 0,53 10 60° 3 0,67 i 60° 3 0,78 2 60° 3 09 4 60° 3 115 16 60° 3 LAL 18 60" 3 1,76 20 60° 3 2,14 mim x 0,03937 = inch Mhr/m x 0,3048 = Mhr/ft 963.1.3 Welding of double "V" butt joint a= 60° = 45° S | b | Deposit] VERTICAL (36) S | b | Deposit] VERTICAL (36) mm mm] Weight mm] mm] Weight kg/m) | [Mhe/m]_[tm/Mhry (ka/m) | TMhe/m) | [m/Mhr] {3 | 057 [3 | 039 a4 [3 | 077 w4[3 | 052 15 [3 | 086 [3 | 059 16 | 3 | 094 1s [ 3 | 077 20 [3 | 134 20 [3 | 092, 2 {3 | 156 22 [3 _| 107 24 [3 | 176 2a[3 [12 25 [3 | 213 25 | 3 | 146 26 [3 | 2,25 26 | 3 | 155 ze | 3 | 253 ze [3 | 173 303 | 2,85 30 | 3 | 195 xis | 313 32[3 | 214 34 [3 [345 34[ 3 | 237 36 | 3 3,79 36 | 3 2,6 4o [3 | 457 4o [3 [313 7 mm x 0,03937 = inch kg/m x 0,672 = Ibs/ft3.1.4 Welding of double-bevel butt joint kg/m x 0,672 im/Mbr x 3,281 =ft/Mbr Mim x 0,3048 = Mhefft When horizontal joints of the tank shell are “welded two different thicknesses mostly occur ( S$ # SI) in which case a mean value is used for the man hour time s] > | Deposit | HORIZ-veRTIC.] [s | b Deposit. | HORIZ. - VERTIC. mm} mm | Weight (26) mm | mm Weight (26) {ka/m]_[[Mhr/mI] fm/Mhr] kg/m] _[(Mhr/my [_[m/Minr] oF 0,47 0 23 to [a=2 0,55 2s [az 2,49 233 0,63 2 2,69 o=1| 054 OF 2,59 u [a2 0,63 2% [a 2,81 233 0,72 2 3,03 Oz 0,62 0 2,75 a [4e2 O71 a 2,98 233 08 2 32 OF 0,74 0 2,92 13 [az2 | 084 2 [ae 3,14 233 [094 2 3,36 o=1| 0,82 OF 3,26 14 [42 0,93 30 [2 35 233 1,04 2 3,73 OF 0,96 0 3,62 as [432 1,08 32 [ae 3,88 233 12 2 4,13 OF 1,06 0 4,0 16 [422 118 34 [a 427 233 131 2 4,54 oF 27 0 42 1s [432 1,43 35 [a 4,48 233 16 23 475 Oz 15 0 44 20 [az2 1,68 36 [ae 4,69 233 1,86 2 4,97 OF 175 OF 4,82 22 [132 1,94 38 [4 5,12 223 | 214 2 5,42 OF 2,08 0 5,26 24 [4=2 2,27 40 [a 5,57 233 2,46 2 5,89 983.1.5 Welding of single bevel butt joint m/Mnr x 3,281 =fYMhr Mhcjm x 0,3048 = Mr/ft When the tank shell horizontal joints are welded, two different thickness of plate are mostly used (S # SI ). In that case a mean velue is used for manhour calculation, s b Deposit | HORIZ. - VERTIC. s b Deposit | HORIZ. - VERTIC. mm] mm | Weight 26) Imm} mm | Weight (26) [ka/m] | [Mhr7m] T[m/mnr] | [kaj] __[ [hey] | [m/mihr]_| 5 [o=i [0,205 0 1,872 122 |_0,244 18 [13 2,013 6 |_o+1 | 0,267 23 2,154) 122 | 0315 0 2,233 7 [_o=1 | 0,355 2a 2,39 12 | oi 23 2,547 o=1 | 0455 0 2,625 8 [122 | 0517 ala 2,798 223 | 058 2 2,971 ozil| 0545 0 3,049 9 [422 [ois 24 (4 3,237, 2=3 | 0,685, 2 3,426 o=1 | 0,643 0 3,273 to [12 [0721 ai 3,469 223 08 2 3,665 o=1 | 0749 0 3,505 u (1=2 [0835 21 3,709 23 | 0922 2 3,913 o=1 | ogo 0 3,744 a2 [1=2 [0985 ala 3,956. 223 | 1,079 2 4,168 o=1| 1,106 = 3,991 13 (132 [1,208 28 (1 4211 223 1,31 2 4431 o=1 | 1244 0 4,509) a4 (ie? [1354 3071 4,744 2=3 | 1,464 2 4,98 o=1 | 1,389 0 5,059 as [1 =2 [1,506 32a 5,31 223 | 1,624 2 5,561 oz1| 1542 0 5,64 a6 (12 [1,667 xi 5,907 2=3 [1793 2 6174 99Horizontal 4.1 Manual welding of slices of lower and upper section Vertical 4. WELDING OF SPHERICAL STORAGE TANKS Upper section Upper strip —— Equator Lower strip Lower section Piate Deposit | Rate Piate Deposit | Rate Piate Deposit] Rate Thickness | Weight ‘Thickness | Weight Thickness | Weight {mm} tkgim} | (Mhrim)_|_ fmm} tkgim} | (Mhrim) | fmm} (kgim_|_(Mhr/m} 14 073 24 182 32 3,04 15 0.78 25 7.94 34 3.48 16 0,93 26 2.12 35 3.65 17 1.0 27 2.26 36 3.97 18 111 28 2.43 37 44 20 131 29 2.54 38 4,23 22. 1,56 30 273 40 ATT 100 mm x 0,03937 = inch kg/m x. im/Mhe x 3,281 =fr/Mhr Mhr/m x 0,3048 = Marit 672 = Iosif4.2 Manual welding of vertical joint of Equator, upper and lower section Plate Thickness: [mm] EQUATOR [Mhe/m} UPPER STRIP [Mhe/m} LOWER STRIP [Mhe/m] kg/m x 0,672 m/Mhr x 3,28 hr/m x 0,3048 = 4.3 Manual welding of horizontal joints Plate Thickness TOWER SECTION LOWER STRIP LOWER STRIP] EQUATOR | UPPER STRIP EQUATOR _| UPPER STRIP | UPPER SECTION Imm] [Mhr/m} [Mhr7m] [Mhim] [Mhim] 14 15 16 17 18 20 2 24 25 26 7 28 29 30 32 34 35, 36 38 40 1015, MANUAL GAS CUTTING AND GAS CONSUMPTION Plate Guiting Rate Oxygen ‘eebylene ‘Thickness Speed [mm] [mf] [mbm] | Tko/mj* | tka/my 3 0,0323 0,0064 4 0,04 0,073 5 0,0466. 0,0082 6 0,0525 0,009 7 0,0625 0,0097_ 8 0,0715 0,0104 9 0,079 O,0111 10 0,0875 0,0117 i 0,096. 0,0123 12 0,106 0,0121 13 0,115 0,0135 14 0,126 0,014 15 0,1375 0,0145 16 0,14 0,015 7 0.1525 0,015 18 0,1745 0,0161 19 0,186 0,0167 20 0,197 0,0174 2 0,207 0,018 22 0,2175 0,0188 23 0,226 0,0195 24 0,237, 0,0202 25 0,244 0,0208 26 0,252 0,0215 27, 0,259 0,021 28 0,266 0,0227 29 0,273 0,0233 30 0,279 0,0238 31 0,285 0,0244 32, 0,29 0,0249 33, 0,295 0,0256. 34 03 0,0259 35, 0,304 0,0264 36 0,308 0,0268 37, 0,311 0,0272 38 0,314 0,0277 39 0,316 0,0281 40 0,318 0,0285 mmr x 3,281 = fer Minn x 0,3048 = Mee gj x 0,672 = Ibsife * Theoretical consumption of gas for machine gas cutting (ace. to Zivéié-Remenar) ‘The consumption of gas for manual cutting isc. [lll % higher. ‘To estimate the oxygen and acetylene needed for manual gas cutting double the above values. NOTE: Man hours [Mhr/m] are used for cutting only to 30 m, Man hours for larger lengths to be estimated according to the cutting speed [m/hr]. 102cot VIL, CORROSION PROTECTION Productivity Efficiency Percentage (PEP) = 80% 1. SAND BLASTING AND [ SURFACE AREA OF PIPING ELEMENTS: RATES FOR PIPES PAINTING OF PIPING [Pipe | Elbow |] TEE | Reducer] Flange | Valve | Blast and | Two Middle | Covering] TOTAL | TOTAL im__| rai,54 First Coat |__Coats Coat | Four Coat Four Coats Damm fecinch | OD=ram [ tme] [me] [fee fee [Df] [Mien] Mne/meT[ PMine fmf [Me 1s | a2" [213 | 0067 | 0,003 | 0,003 | 0,002_| 0,012 | 0,030 20 | 3/4" [26.7 | 0.083 [0,005 | 0,004 | 0,003 [0,017 [0,036 25 33.4 | 0.105 | 0,008 | 0,007 | 0,005 [0,020 | 0,043 32 42.2 | 0,132 | 0.013 | 0,011 | 0,006 | 0,023 | 0,054 20 48,3] 0,151 | 0,017 | 0,015 | 0,009 | 0,030 | 0,065 50 60,3 | 0,19 | -0,027_| 0,023 | 0,013 | 0,035 | 0,147 65 73 | 0,24 | 0.039 | 0,035 |_0,019 | 0.046 | 0.185 80 38,9_| 028 | 0,058 | 0,050] 0,022 [0,056 [0,173 100) 1143 | 0,36 |_0,097_|_0,082| 0.033 | 0,080 0,297 125; 141.3 | 0,44| 0,120 [0,124 | 0,050 [0,096 | 0,390 150 1683 |_0,53_| 210 | 0.178 | 0.067 | 0,120 | 0.460 200 2191 | 0,69 | 0,472 [0,302 | 0,094 | 0,170 | 0,660. 250 273 [086 [0,552 | 0,470_| 0,138 | 0,230 | 0,890 300 3239 | 102 [0.776 | 0,661 | 0,186 | 0,260 | 1,190 350 3556 | 112 | 0936 |_0,797 | 0,333 | 0,300 | 1570 400 4064 [1.28 [1.222 | 1,040 | 0,410 | 01350__| 1.790 450 457_| 1.43 | 1545 | 1,307 | 0,490 0,390_| 2,220 500) 308 | 160 1910 | “11626 | 0,732 | 0,420 21520 550) 559_|_175 | 2312 [1,957 | 0,800 0,460 | 3,220 600 610] 192 | 2,754 _| 2342 | 0,878 | 0,490 | 3,920 650 @60_|207_[ 3,223 | 2732 | 1.136 | 0,520 | 3,800 700) 7ii_| 224 [3,741 [3,85 [1,230 [0,560 | 3,850 750) 762_|~239_| 4.297 [3,642 [11312 [0,600 | 4330 800 Bis_| 256 | 4go1_| 4163 | 1,405 [0,630 | 4820 850 6a |27i_[ 5524 | 4683 | 1,488 [0,670 | 5,320 300 914 | 28 | 6,182 | 5265 | 1:581_| 0,700 | 5,820 950 965 | 3,03 | 6891 | 5848 | 1,653 | 0,740 | 6,450 1000 ois 3,20_|7638 [6,502 [1.757 [0,780 | 7.100 1050 1067[3,35_| 763974492444 [0,800 100 iis_[352_| 8425 | 78712252 [0,840 1150 1168 [ 3,66 [10,095 [8,550 2.342 | 0,980 1200. i219 _[3,3_| 10,996 [9,338 |~2,451_| 0,920 1350 1372_[431_| 13,930 [11,827 [2758 [1,020 500 | 607 [1520 [4,79 | 17,187 | 14,600 | 3,065 [1,120 1.1 RATES FOR PIPING ELEMENTS 1.2 MATERIAL CONSUMPTION - acc. to Item 2 (page 104) + Pipes: above table ~ Reducers: [Mbr/m2}x + Elbows: [Mhr/m2]x = Flanges: [Mnr/m2]x mx 10764 = sq ft ~ Tees: [Mhr/m2}x ~Valves: [Mhr/m2 Ix, Mar/m'x 0,0929 = Mht/sa f hr/m x 0,3048 = Mhrff2, SANDBLASTING AND PAINTING OF STEEL STRUCTURES 2.1 Sand blasting and primer: fi[Mhr/n?] +m [Mhr/m?] = ltiMhr/m"] Material Consumption: —slliceous sand for the purity grade SA2 1/2 + [kg/m'] or: —corrund (Al,0)for the purit y grade SA 2 1/2 + [kg/m’] ‘or: —ground dross for the purity grade SA2 1/2 + [kg/m] or: —hot (metal sand) > iim) 2.2 NextCoats 2.2.1. Upto 100 microns: by brush [Mhe/m’] by spray gun {(Mhe/m"] Material consumption: colour [kg/m] 2.2.2 ‘Above 100 microns: by brush ([Mhe/m] by spray gun [Mhé/m ] Material consumption: [ka/m*] NOTE: 1. Consumption of the abrasive material depends on the corrosion pitting of the structure, wind, space and the possibilty of regeneration of the abrasive used. 2. Paint consumption depends on the corrosion pitting, coat thickness, wind, and the manufacturer's instructions. 2.3. Timeallowances for job conditions 2.3.1 Workatelevations to 2m - no allowances 224m - +(m% 4+10m - +m% above 10m, - +m% 2.3.2. Workinside -with ventilation +/m% no ventilation + 2.3.3 Workin lumbered rooms (space obstruction) + [HN % 10424 244 MEASUREMENT AND CALCULATION OF QUANTITIES FOR CORROSION PROTECTION Machines, motors, pumps, conveyors A surface area of parallelopiped shape x 242. Steel Structure ~Heavy structure ~Mecium-weight structure ~ Light structure Floor grids: ~ Ladders and step iron = Mesh railings: Flat sheets: ~ Corrugated sheets: 2.4.3 Pipe Supports for piping toa” -for piping above 4” 3. SANDBLASTING AND PAINTING OF STO 3.1 Outer surfaces of storage tank -Sand blasting First coat ~Second coat ~ Third coat -Fourth finishing coat Total = 3.2 Inner surfaces of storage tank ~Sand blasting First coat IL+ IIL-+ IVcoat, Total = (above 60 kg/m): (31 + 60 kg/m): (to 30 kg/m): length x width x length x width length x height x actual painting area actual painting area x [m/ton] {mfton] SA2%: 75y: 40: 125p: 50 290: SA2%4: 40: 400. 4440p RAGE TANKS, [Mhr/m2] (Mhr/m2] [Mhr/m2] (Mhr/m2] [Mhr/m2] [Mhr/m2] (Mhr/m2] [Mhe/m2] Mhr/m2) [Mhr/m2] {nv /ton} [m‘/ton] {nv /ton] NOTE: These man hours refer to the climate conditions prev _ailingin the Centr al Europe. 105VIII. THERMAL INSULATION Productivity Efficiency Percentage (PEP) =85% Generally, specialized companies make calculations for insulation, This rule also applies if insulation accounts for a large portion of a project. When the scope of insulation is not so great or the bidding time is very tight, an estimator for the mechanical works should also provide the calculation ‘elements for the insulation. That is why I worked out the manhour rates for insulation based on the manhour rates of several specialized German insulation contractors. 1. THERMAL INSULATION FOR PIPING Prefabrication of the insulation holders, sheet cutting, placing mineral wool, aluminium foil cladding, installation of sheets and sealing with durable elastic compound. 111 Pipe insulation Manhours per linear metre [Mhr/m] ping Tasulation Thickness [ml ND a [80 | 100 25 ry 32 14/4" Ea ET 50 2 65 23/2" 30 3 = = = 107 12 147 16" 18" 20" 24" 28" 3 36" 407 + Insulation of pipes and fittings, except for pipe bends is included. Insulation of valves not included. += Scaffolding not included. Mhr/m x 0,3048 = Mhr/ft 1061.2. Insulation of pipe bends ([Mhr / ea] Piping Insulation Thickness [mm] no [| o | 30] 2 60 too | 120 150 25 [1 [les [me = Le | =e es 32_{11/4"| i | = =| ee | 40_| 14/2" 350 2” 65_ | 21/2"| oe | oe [_d = | es | oe eo | 3” [oe [oe = Ee ess 100 [4 Ds | 5” [ee |e = ESTs Tess 150 7 = ase 200 | 8" | = Seats 250_[ 107 300 | 12” | i | = =| ee | 350_| 14” | |e = Ss 400 | 167 450 | 18” | i | = =| ee | 500 | 207 | |e = Ss ss 600 | 24” | i | = =| ee | 700_|_28” 300_|_ 32” [en | ee = Ee ess g00_| 36" | oe | = = | es | oe 1000[ 407 13. Valve Insulation ND | @ | [Mhr/ea] ND] @ | [Mhr/eal Factors ace. to Insulation Thickness 25 | 1" 300 | 12” 30mm |x. 32 faye | 350 [ 14” 40mm |x 40 [aye | 400 | 16” 50mm |x. 50] 2” 450 |_18” 60mm |x 65 [ 21/2" 500 | 207 ‘0mm |x go_| 3” = 600 | 24” 100 mm |x a = 700 | 28” 120mm |x 125 | 3" 800 | 32” 150mm |x 150 | 6" = ‘900 | 36” 200 | 8” = 1000 | 407 250 |_10" 1.4 Piping insulation based on the surface area 1.4.1 Surface area calculation ‘The pipe surface area is calculated by adding two insulation thicknesses to the pipe diameter. d,= pipe OD [mm] (dot 2t) x 3,14 Aa LORAIN im] tt = insulation thickness [mm] 1000 107Pipe bend surface area A= (d4-2t)(24 +t) x lm [my d= pipe OD [m] € = insulation thickness [m] - Valve surface area Surface area of 1 m pipe x 1.4.2. Manhour rates [Mhr/m?] Insulation Thickness [mm] 30. 40 «50-6080 100120150 [Mr 7m) Included: = pipes. - all fittings valves = insulation holders Notincludes: — - scaffolding 1.4.3 _ Division based on the operations = Insulation holders % -Prefabrication % Erection % = Mineral wool and al. foil % Sheets % -Prefabrication % - Erection % 2. THERMAL INSULATION OF VESSELS AND KILNS 2.1. Insulation with mineral wool, smooth aluminium sheets, durable elastic sealing including substructure Insulation Thickness [Mhr/m"] 80 mm 100 mm 120 mm 150 mm 180 mm 2.2 Insulation with mineral wool, trapezoidal galvanised E 40 sheets, 1-mm thickness, both side painting, durable elastic sealing substructure included, Insulation thickness [Mhr/m?] 80 mm 100 mm 120 mm 150 mm 180 mm mm x 0,03937 = inch Scaffolding not included. 108IX. ESTIMATES 1. ESTIMATE OF SCAFFOLDS Quick estimates of scaffolding and the scaffolds are very difficult to make and not reliable Estimators usually do not have the drawings, the dimensions and what is most important they do not have enough time to perform a proper calculation. Therefore, they have to make quick estimates of the quantities starting first with a decision on who is going to undertake the scaffolding. Will they subcontract this job to a specialist firm or do the scaffolding themselves? It is also necessary to see who will use the scaffolds. Will they be used for erection only, or for painting and insulation works as well? If there are several users, the rental period is longer butin that case the expenses can be shared. 1, ESTIMATES OF SCAFFOLDING WHEN CONTRACTED TO A SPECIALIST FIRM ‘The most usual categorization and the rates of the scaffolding specialist firms are: a) Scaffold Erection standing scaffolds [m’] cantilever scaffolds [m’] -hanging scaffolds [m’] - platform floors [m'] b) Scaffold Dismantling + same categorization as for erection ©) Rental ~ same categorization per week and month ‘The price of erection and dismantling of scaffolding varies by its height every [lll + lll m. When estimating the scaffolding quantity, the quantity for erection in [m"] and an average erection height are determined. 1.1 PIPINGIN PLANTS - Quantity [mt] piping weight “Type standing scaffolds +m % hanging scaffolds % cantilever scaffolds % platforms. landings % 1.2 PIPINGONPIPERACKS Quantity: Option Piperack surface area lll [nr] scaffold Option Is [m'/t] piping weight ~ Type standing scaffold % hanging scaffold -E % cantilevel scaffold +E % platforms floors % Height: + -Rental: average filial months 1.3. STEEL STRUCTURES ~ Quantity: [mt] structure weight “Type standing +[% hanging +1% cantilever =[% mex 35,32 platforms floors +l% m'x 10764 -Height: average -Rental: average weeks 1091.4 EQUIPMENT IN PETROCHEMICAL PLANTS When estimating the scaffolding for equipment erection one should know who is going to use the scaffolding, For instance, no scaffolding is required for erection of towers, but itis required for erection of connection piping, electrical installations, insulation or painting. The best way is to calculate all the equipment individually for each unit, Similarly, one should also determine the type of scaffolding, its height, and the rental time. When the scaffolding is used for the equipment erection only, it could be calculated in the following way: = Quantity [m’/ton] equipment weight -Type: standing % platform floors % -Height: m -Rental: month 2. _ ESTIMATE OF SCAFFOLDING WHEN DONE BY AN ERECTION COMPANY This kind of scaffolding erection is used less and less. If used, the scope of scaffolding should be estimated in the same way as for the first case. 2.1 PIPINGINPLANTS: {m/ton] piping quantity 2.2. PIPINGONPIPERACKS: Option Pipe rack surface area = [m'] scaffold Option 1 [ton] piping quantity 23 ‘STEEL STRUCTURES: + [m’/ton] structure quantity 24 EQUIPMENT IN PETROCHEMICAL INDUSTRY: + [m‘/ton] equipment quantity ({f used for the equipment erection only) When the scaffolding quantity is calculated in [m’] or [ri], which is more or less the sam e we should estimate the material needed for tubular or patent scaffolding, 2.5 TUBULAR SCAFFOLDING There are sets of tubular scaffolding with a lst of material needed such as tubes and clamps for 500 m’ (Iron Works. Sisak). If itis expected that the scaffolding will be erected and dismantled several times during the works execution, the following calculations should be considered 2.5.1. Tubularscaffold material (m’} + [m'] Total scaffolding: §=§$—————_ =_ mor nf ‘The scaffolding quantity to round up to hundred (100), mx 35,32 1102.5.2 Planking tops for scaffolding Scaffold quantity / 1m’ planking tops 2.6 SCAFFOLDING LABOUR Determine the number of scaffolding hours by calailating: Erection + dismantlin [Mhr/m’] or ni x elevation factor (for average elevation) (See "Equipment Scaffolding", page 72-73) After that, determine the labour needed for scaffolding and the means of transport. at2, ESTIMATE OF WELDING ROD CONSUMPTION AND ADDITIONAL WELDING MATERIAL 1.PIPING 1.1 WELD DEPOSIT [kg/weld] @ | sch] Sch) Sch Sch] Sch Sch] Sch] Sch io | 20 | 30 | sta | 40 | 60 | xs | 80 | 120] 160 | xs 2_| 0,009 0,026 | 0,026 0,043 | 0,043 0,104] 0,213] 3) 0,0it 0,057 | 0,057 0,085 | 0,085 0,255] 0,375| 4”_| 0,017 0,086 | 0,086 0,208 | 0,208| 0,383) 0,562] 0,835| o 0,303 | 0,303 0,558 | 0,558] 0,821] 1,215] 1,58 8” Oi61| 0,39 | 0,39 | 0,39 | 0717 | 0,717| 0,717| 1,565] 2,576] 2,03 10” 0,186| 0,493 | 0,45 | 0,45 | 0,83 | 0,83 | 1,215| 2,345] 3,674] 3,27 12” 0,239] 0,576 | 0,576| 1,061] 1,56 | 1,061 | 2,554] 3,81 | 6,776] 3,81 14” | 0,263 | 0,393/ 0,625] 0,635) 117] 1,719] 117 | 3,0 | 519 | 877 16” | 0,3 | 0,449] 0,726 | 0,726 1,34 | 2,935 | 1,338 | 3,783| 5,92 | 11,59 16” [0,337 | 0 505] 1,501 | 0,807| 1,5 [3,28 | 145 [54 | 958 {17,0 207 [0,376 | 0907] 1,67 | 0,907| 1,22 | 4,042 | 1,67 [9,743] 12,52[ 19,61 22” [0,413 | 0992| 1,84 | 0,998| 7,412| 52 | 1,84 | 10,72| 15,94] 24,56 24” [0,45 [1,089] 2,255 1,089] 3,42 [7,2 | 2,0 | 12,67] 21,42) 31,33 26” [0,73 | 2,172! 118 2,172 28” [4,27 _| 2,336| 3,43 | 1,27 2,336 30” [4,36 | 2,506) 3,674| 1,36 2,504 32” [1,459 | 2671] 3,92 | 1,45 | 4563 2,671 34” [1,542 | 284 | 4,164] 1,54 | 4.844 2,84 36” [1,633 | 3,003] 4,409 | 1,633] 6,554 3,003 ko/weld x 2,2046 = Ibs/weld The most difficult job for installation ofthis t ype of piping isto estimate welding rod consumption with regard to the piping weight. Since this estimate is not used for the welding rod procurement butf or calculation of price only, higher departures than the actual needs are allowed. 1.2 PIPINGINPLANTS 1.2.1. Ifthenumber of weldsisknown then they are calculated according to theT able 1.1 witha final increase of [iil + [1 % (for smaller modifications, repairs, losses, etc.) 1.2.2 _Ifthenumber of welds isnot known andit cannot be determined within a reasonable time, then the calculation should be done as follows: Welding rod weight = [lll + fll % piping weight or lil = llilfkg/ton] (Higher percentage is inversely proportionate to the pipe weight in relation to the total weight of piping). 1.2.3 Piping quantity per inchdiameter (ID) Welding rod weight = fil ka/ID] 1121.3. PIPING BETWEEN PLANTS AND PIPING ON PIPERACKS 1.3.1 Ifthe piping quantities are listed according to their diameters then the weld is assumed to come on average every 6 meters of the piping length. The number of joints estimated to be multiplied by the values from Table 1.1 and increased by %. 1.3.2 Ifonly the total piping weightis known: ‘Welding rod weight = % of the piping weight or [kg/ton} 1.4 PIPING (C.S.)- TOWN NETWORKS - The best way is to estimate the number of joints and to use the Table 1.1 for the quantity of welding rod, and to apply the increase of, %. 1.5 PIPELINES ~ For this type of pipelines the number of joints on the header line should alwa ys be calculated. The calculation will be done with the weights from Table 1.1 increased by [Till %. 1.6 PIPESUPPORTS 1.6.1 Support Fabrication Welding rod weight = % support weight or i + lifkg/ton) 1.6.2. Support Installation Welding rod weight = il + lNNN% support weight or ji + ilimifkg/ton] 2. STEELSTRUCTURES Fabrication Erection - Heavy structure oor jem (kg/ton] %or [kg/ton] ~ Medium-weight structure Sor (mm [kg/ton] %or [kg/ton] ~ Light structure Shor [kg/ton] %or Ikg/ton] 3. CYLINDRICAL STORAGE TANKS Welding rod weight = % storage tank weight 4, EQUIPMENTIN PETROCHEMICAL INDUSTRY Welding rod weight= % equipment weight 1133, ESTIMATE OF CONSUMPTION OF TECHNICAL GAS AND GRINDING PLATES PIPING Piping between plants and Erection | Equipiment _| Cylinde In town Pipe | of steel _| petrochemical] storage plants | networks | Pipelines _| supports | structures | plants tanks [Oxygen [kg/ton], [Acetylene | [kg/ton) Argon (2.*) | [kg/ton] [Grinding & | [pe/ton] cutting plates| 1, The quantities of other technical gas such as hydrogen, nitrogen, and CO, are negligible and 1 leave it up to the estimator to estimate their quantities or not 2.* The quantity of argon depends on the welding method and use of different types of materials. The above data of g/t is taken into account when there is some [1 % of stainless steel and when the root on ‘carbon steel is welded by TIG process. If the quantity of stainless steel is known, than the calculation is done by jill = ill kg/ton. 3. Technical Gas Data: = Oxygen 40 bottle, 150 bar = kg 50 lbottle, 200 bar kg -Acetylene40 Ibott le, 15 bar= kg 50 bottle, 15 bar= kg -Argon 40 bottle, 150 bar kg 40 | bottle, 200 bar kg 50 bottle, 200 bar = kg -00, 40 Ibottle, 60 bar= kg =Propane —smallbottle (27,2) kg (max.) large bottle (791) kg (max.) -Butane —smalibottte (27,21) kg (max.) large bottle (791) kg (max.) -Nitrogen40 Ibott le, 150 bar = kg 50 bottle, 200 bar = kg 1144, Calculating the quantities of nitrogen or air required for pressure testing ‘The quantity of nitrogen or air is calculated by the following formula: madi XV 100,000.) where! m =gasweight [kg] inal pressure [bar] starting pressure [bar] p. \V = system volume (to be tested) [mt] T =temperature [Kk] (= °C + 273,15) R = gas constant [3/koK] R= 287 ,0[3/koK] Reson 296,7 L/kgK] EXAMPLE: A 50 m' system should be tested to 10 bars. The pressure can be increased to 6 bars by air compressor. Outside temperature is c. 17 °C (290 °K). How much nitrogen and how many bottles do weneed? _ (10-6)x50% 100,000 290x 2967 = 232,44 kg the number of 40 I bottles, 150 bar: 232,44 /7,55 = 31 bottles ESTIMATE OF ELECTRICITY CONSUMPTION The client often requires an estimate of electricity consumption it has to provide and the estimator must fulfil that request. If he finds that the contractor will use its own power sources from generators and generating sets, then he will estimate only the part of electricity consumption from the power grid. The total ower requirements should be calculated on the basis ofan estimate of the welding rods needed 1.Piping 1.1 Inplants {kWh/kg] welding rod quantity 1.2 Piping between plants [kWh/kg] welding rod quantity 1.3 Pipelines [kWh/kg] welding rod quantity 2. Erection of steel structure [kWh/kg] welding rod quantity 3. Equipment erection [kWh/kg] welding rod quantity 4, Storage tank erection [kWh/kg] welding rod quantity kWh/kg x 0,4536 = kWh/lbs 1155. ESTIMATE OF CONSUMPTION OF FUEL AND LUBRICANT ‘The manufacturer provides the technical data on fuel consumed by the machinery. Such data can be used only if the motor operates continuously under the load foreseen by the manufacturer. However, this is not the case in practice because there are stoppages in operation and the machinery operates under different loads. Below is an estimate of the percentage use of the machinery and the means of transport that the estimator can evaluate at his discretion, 1. FUEL CONSUMPTION Machinery/Means Fuel [Consumption Huse Téay_[_Tmanith T, Power Plant 125 kW Diesel oi vn % 2. Diesel Welding Set 400.8 Diesel ol Mm % a B, Diesel [Compressor 7 m'}min Diesel ol ith % 5 t '4-Pipe Laying Machine| Diesel oil Vb % 5, Tractor 53 KW (72 4) Diesel oil vh % 6. Tractor 88 KW (120 HP) Diese of Wh % 7.Fork USE Diesel oi Uh % 8, Fork LiR'S Diesel of Th %e 9, Tank truck Diesel of 1100 km] Gaara 10.Tuck 75 Diesel of i/100-km| = km/day Li Truck 10% Diesel of 17100 km] =a km/day 12. Taller truck Diesel oi 1/100 km| S- Eskm/day | n= # 13. Pickup Gasoine (7100 km] m= hkm/day A 14. Passenger van 6 + 1 seat Gasoline 1/100 km] m= km/cay | = HH 15, Passenger ar | Gasoline 1/100 km] pss km/day | Ms NOTE: The fuel consumption for other machinery (cranes, shovels, dredgers and the like) is not calculated because the price of fuel and lubricants is already contained in the rental fee. 2. LUBRICANT CONSUMPTION Since oil and grease are also used for other purposes at the job site and not only for the. machinery, the price of lubricants can be calculated as 116 % of the fuel prices.6, TOOL COST ESTIMATE AT THE JOB SITE It is not either possible or necessary to make detailed lists of small tools to be used at the job ste. In practice, only 50% of tools is purchased for a specific job and c. 50% of tools is used from the previous job sites. It can also be taken into account that c. 60 = 70 % of tools will be left in good condition and reused (er sold). For that reason, the cost of tools should be calculated in the following way: Type of job 1. Piping 11 inplents 1.2 piping between plants. 1.3 pipeline. enone een 2. Erection of steel structure. 3. Equipment erection... 4. Storage tank erection ~ * There are more tools and devices used at erection of storage tanks that are not included inthis table. [US§/h] in 2002 7. ESTIMATE OF SAFETY AT WORK MEANS ‘The means for safety at work are: 1. For personal protection2.F _or protection at different jobs = protective clothing protection masks welding aprons ~ protective shoes welding masks -welding gloves - protective gloves ~glass -welding clothes ~ protective goggles ~goggles -belts = raincoats or overalls -rubber boots -waistcoats protective helmets -ete. ‘The estimator should evaluate the yearly costs per each labourer for maximum number of labourers. Costs per labourer/year: ~climate similar to Croatia -US$ = climate colder than in Croatia -US$ = climate warmer than in Croatia -US$ 8, ESTIMATE OF ERECTION TIME ‘When the erection time is not mentioned in the call for tenders, the estimator should estimate it. In the magazine" R” of April 1985, there isa formula for calculating the time required for erection of piping: p=t,” where D rection time in weeks (50 hour week) hours requir ed acc. to the calculation My opinion is that this formula should be used to calculate the erection time only for the works up to 110.000 hours . For the works above 10,000 hours the erection time should be increased by c. 20% in the. following way: D=tex 117‘The table below contains the erection time in weeks (a 50 hour week) for a range from 1.000 to 1.000.000 hours of work. Total Erection time Manhours| Weeks | Months 1,000 1,500 2.500 4.000 6.500 10,000 15,000 25.000 40.000 65.000 100.000 150,000 250.000 400,000 650.000 1,000,000 ‘9, SELECTION OF HOISTING MACHINERY (CRANES, FORK LIFTS, ETC.) When determining manhour rates, the costs of hoisting equipment have a significant impact. It is therefore very important to make a careful and realistic estimate of the type of crane, number of cranes and the time of use of the crane, forklift and the like. It is not a problem to determine the type of individual hoisting machine, the time and the power required for hoisting a given piece of equipment but this job is, much more difficult when it has to be done for the entire project. During all the years of my service, I never found any trace of that issue. Talking to colleagues of mine I heard different opinions and methods for making estimates. Some make estimates based on weight and they consider that a crane should lift between. 150 and 300 kg/hour. Others take into account the number of labourers and say that one crane should be sufficient for serving 6 to 20 labourers. There are no tables for any of these methods, I thought something should be done about it so I tried to describe the way I did it in my calculations and estimates hoping that younger colleagues would elaborate this better in future, ‘When selecting the cranes care should be taken of the crane type because of very different rental costs. As for the operating costs, the cranes can be grouped from the cheapest to the most expensive. TYPE CAP CAPACITY (OF CRANE Lt] Ot] 30t] 45t | Got | Bot] Loot |isot] >isot BUILDINGCRANES) 4 | 4] 5] 5 }—-]—-|)—-|—-| — TOWER, PORTAL TP)iy;i/i/i)-/-|-|— CRANES. MOBILECRANE | 3 | 3 | 2| 3 | 3 | 2 |2=3/ 2] 3 PROJECTION MOBILECRANE | 2 | 2 | 4| 4] 4 | 3 [2z3/ 3] 2 trussed boom caverriark | —|—|3)2)|2/i]i]i|] 2 trussed boom (They are grouped according to “Montage Geratebuch”, Issue 1985) 118‘The most suitable trucks for up to 2-ton cargo are those with a hydraulic jack. Forklifts are very suitable for the cargoes from 2 to 8 tons. ‘To make an optimum selection of the cranes, it is important to fully familiarize with the project for which a calculation is made, The estimator should devise a concept of the erection method and possible erection technique as well as probable work organization, Before selecting the cranes, an average number of production labourers should be determined. 9.1 SELECTION OF THE LARGEST CRANE ‘Any erection project should be firstly identified the heaviest equipment and cargoes, Thereupon, the crane type and capacity are selected (or a combination of two cranes) thus identifying the largest and the most expensive crane. Care should be taken of the place of erection, elevation, possible access to the crane, access roads, rental possibiltes, lifting technology, working time, etc. The time for using the largest crane should be estimated by iting the heaviest pieces of equipment {above i tons if possible). In this case the next largest crane that will stay longer at the job site could be of smaller capacity (c. ill+ fil tons) and as a result thereof its monthly rental fee would be lower as well 9.2 PIPINGINPLANTS 9.2.1. PREFABRICATION ‘The use of a crane is not important during the piping prefabrication, The use of one forklift of tons could be considered. From time to time, a smaller crane of to tons and HTAB truck could be used of which for prefabrication and "for erection. ‘Twenty five labourers should be allocated to one piece of lting equipment. 9.2.2 ERECTION {At piping erection, the larger the piping diameter the greater need for a crane. The cranes of larger capacity are required for larger outreach and height otherwise relatively smaller cranes could satisfy the requirements. ‘Twenty labourers per crane. ‘One truck with HIAB for lil: illlabourers but only its Crane capacity to be determined as follows: % to t % to t % to t 9.2.3. PREFABRICATION AND ERECTION For technical calculations, both prefabrication and erection are considered together. This type of calculation applies when there are not enough data or time to make a calculation, which is the most often case. ‘The means for hoisting should be determined in the following way: + forktift3 + 5t labourers per forklift - truck with "HIAB" labourers per truck - mobile crane labourers per crane of which % -tolmit capacity % -tommit " % -tommt ” 1199.3. PIPING BETWEEN PLANTS Lower capacity cranes will mostly satisfy the requirements for erection of this kind of piping. The ‘scope of prefabrication is smaller, and therefore the calculation should be made as follows: truck with "HIAB" labourers per truck ~carcrane labourers per crane of which %-toll—it capacity %- tol t capacity 9.4 PIPELINES At pipeline laying special cranes are used for unloading, loading, pipe stringing and performance of special points. Generally, car crane renting should be avoided whenever a continuous work is not possible. ‘This refers particularly to the works on right-of-ways where the pipe layers and trucks with HIAB are used, Consequently, estimator can rely on crane for some activities only, which should be elaborated separately. AAll manuals for calculations of pipeline erection provide for special elaboration of each activity from pipe transportto pressure testing. 9.5 ERECTION OF STEEL STRUCTURES Erection of steel structures is not actually possible without cranes. The costs of machinery account for the largest portion of the man-hour rate. The use of truss boom cranes and particularly tower building cranes is possible. The truss boom cranes are suitable because of lower rental costs and the tower building cranes for their very high efficiency and outreach. ‘The cranes should be calculated as follows: heavy steel structure + labourers per crane =medium-weight steel structure + labourers per crane -lightsteel structure + labourers per crane 9.6 INSTALLATION OF PROCESS EQUIPMENT At installation of process equipment firstly we should identify the largest crane (item 9.1.) and then decrease the total number of hours and the average number of labourers for the foreseen heavy equipment respectively. ‘The cranes for other equipment to be calculatedas follows: crane on: labourers of which: %~ for the second largest er ane (c.. +t) % for'i™iter anes %- for iter anes 9.7 ERECTION OF CYLINDRICAL STORAGE TANKS ‘Special attention should be paid to the selection of a crane for erection of cylindrical storage tanks. This type of crane cannot be selected according to the number of labourers but according to the type, diameter, height, arrangement, and the number of storage tanks, etc. ‘A mobile crane with a truss boom of maximum|-ton capacity is the most adequate when we install cone storage tank. If there is @ group or a series of storage tanks, we should consider using tower cranes of sufficient reach and on tracks, if possible and necessary. If there are several storage tanks, we shall need another smaller crane for loading and unloading the plates and getting them closer. Generally, an adequate erection conceptis required and each activity should be supported with an adequate crane. On average, jl = illlabourers should be allocated per one crane. When erecting spherical storage tanks (balls) the same measures for crane selection apply. 12010, UNLOADING, HANDLING AND SORTING OF THE MATERIAL Almost all manhour rates include the erection activities from withdrawal of the material and ‘equipment from the investor's store to the completion according to detail design. We shall often come across a request in tendering documents to offer unloading, handling and sorting of the material. (The quantity/volume ratio see page 213.) 10.1 MATERIAL FOR PIPING Unloading [Mhr/ton] Handling and sorting Piping in plants 60% andabove [Mhr/ton] Piping between plants 60% andabove [Mhr/ton] Pipeline 60% and above [Mhr/ton] 10.2 STEEL STRUCTURE - Unloading [Mhr/ton] -Handiing and sorting Heavy structure (above 60 ka/m) [Mhr/ton] Medium-weight structure (31 + 60 kg/m) [Mhr/ton] Light structure (to 30 kg/m) [Mhr/ton] 10.3 PROCESS EQUIPMENT Unloading Bulk material (packings) [Mhr/ton] Equipment to 5 [t/pc} [Mhr/ton] Equipment 5 + 10[vpc] [Mhr/ton] Equipment above 10 [t/pc] [Mhr/ton] Handling and sorting: Bulk material (packings) [Mhrfton] Equipment to 5 [t/pc] [Mhrfton] Equipment 5+ 10[t/pc] [Mhrfton] Equipment Sorting near foundationabov 10 (Ypc} [Mhrfton] Equipment Sorting at store above 10 ['/pc] [Mhr/ton] 10.4 CYLINDRICAL STORAGE TANKS “Unloading: [Mhrfton] = Handling and sorting: near foundation [Mhr/ton] - Handling and sorting: in store [Mhrfton] 12111, TEMPORARY WORKS, SPACE REQUIRED AND CONNECTIONS AT THE SITE OPTION £ OPTION 2 1. TEMPORARY WORKS OFFICE BUILDINGS & CANOPIES [ m'] CONTAINERS [pc] TI MANAGEMENT SITE OFFICES ‘Average number of staff T container forlloffice workers X=. 1.2 SITE OFFICES No of foremen T container forlforemen XE SelM 1.3 LOCKER ROOM Maximum number oF T container for i direct workers x 0,3 = om labourers 14 TOOLS STORE ‘Average number o workers | 1 office + 1 cargo container for x Seen direct labourers TS ENCLOSED STORE ‘Average number of T cargo container for workers xjii=......m? direct labourers 1.6 SANITARY FACILITIES: T container for im workers 7 MESS ROOMS ‘Average number of workers T container form workers XIE snnn 1.8 PREFABRICATION HANGAR | Average number of workers x mm 1.9 MAINTENANCE WORKSHOP ‘m for each maintenance worker (electrician, mechanic) 1 container forlimaintenance workers (electrician, mechani 1.10 CANOPIES FOR TECHNICAL GAS ‘Average number of workers x sot 1.11 ENCLOSED STORE FOR CAPITAL EQUIPMENT ‘On principle, the investor is| responsible for providing such store) The store area to be determined as follows: Total weight of erection equipment (piping + steel structure + equipment) in tons x@initon 1222. AREA NEEDED METHOD OF CALCULATING THE AREA IN [m.] 2:1 OUTDOOR AREA FOR THE JOB SITE MANAGEMENT SITE OFFICE BUILDINGS ‘A sum of net area from each item: 11413416417 increasedi=itimes 2.2 OUTDOOR AREA FOR WORKSHOPS AND BULKING OF EQUIPMENT ‘Assum of net area from each item: 144184194110 increasedi=itimes 2.3 OUTDOOR AREA FOR |SORTING PREFABRICATED ITEMS Double the area of item 2.4 OUTDOOR STORE AT THE J0B SITE Generally, every job site has a few plants. On each plant the contractor needs a fenced area for storing the capital equipment and consumables. The area for that purpose would be: lll + lll m’ 2.5 OUTDOOR AREA FOR Job sites to: Mi direct labourers 7 PARKING MACHINERY direct labourers m above: ll direct labourers m 2.6 OUTDOOR REA FOR STORING [CAPITAL EQUIPMENT 1,5 m® per ton of capital equipment 3. CONNECTIONS NEEDED METHOD OF ESTIMATE [3.1 POWER CONNECTIONS: I main connection: maximum number of welding rectifiers x Ill kVA Connections at the plants: at least loft kVA power connection for each plant [3.2 PROCESS WATER CONNECTIONS If there is a hydrant network: determine the quantity required. If there is no hydrant network: determine the quantity needed, storing in water storage tanks or supply by tank lorries. [3-3 DRINKING WATER CONNECTIONS ‘Quantity: I + itre/man/day Connections: every sanitary facility lm + [3.4 SEWERAGE CONNECTIONS ‘connection for each sanitary facility [3.5 TELEPHONE LINES ‘telephone lines at least 12312, ESTIMATE OF THE NUMBER OF WELDS AND RADIOGRAMS FOR PIPING Data on the number of welds are not often given in the call for tenders. Of course, this cannot be calculated without complete detail documentation. To make a technical calculation an estimator needs the data on the number of welds. If he wants to estimate the quantity of radiograms, he should know only the quantity of butt welds and if he wants to calculate precisely the quantity of welding rads and electric power, he should know the quantity of all types of welds. The estimate of the quantity of other types of welds such ‘as nozzle welds and socket welds, the estimator can base on the butt welds quantity. ‘The quantity of butt welds can be estimated in several ways: 1. ESTIMATE OF BUTT WELDS BASED ON A LIST OF MATERIAL - PIPES, FITTINGS AND FLANGES 1.1. Piping in plants = Pipe weld/24 m - Bends weld/piece Tees weld/piece - Pipe caps weld/piece = Reducers weld/piece - Weldolets weld/piece - Neck flanges weld/piece 1.2, Piping between plants piperacks and sleeper ways = pipes to 3" 1 weld) fmm - pipes 1 weld/ =m + pipes 8"-10" 1 weld) fmm - pipes 12"-14" 1 weld/ [1m ~ pipes above 16" 1 weld/ =m - fittings and flanges: as for the piping in a plant (item 1.1.) 1.3. Combined piping (in plants and between the plants) Ifthere are no separate lists of materials for piping in the plant and for the piping between the plants, but we know there are both of them, the quantity of butt welds should be calculated as follows: Pipes: calculate 1 weld to the lengths that are twice the length ofthe piping between the plants (item 1.2) If the estimator can estimate proportional relations of two kinds of piping then he can make the calculation with other piping lengths as well - Fittings and flanges: As for the piping in plants (item 1.1) 2. ESTIMATE OF BUTT WELDS BASED ON ALIST OF MATERIAL FITTINGS AND FLANGES ONLY Bends weld/piece = Tees weld/piece - Pipe caps weld/piece + Reducers weld/piece = Weldolets. weld/piece - Neck flanges weld/piece ‘The pipe-to-pipe welds are not considered because it is deemed that the quantity of such welds is deemed to be similar to the number of fitting-to-fitting welds, This is the most widely used method for estimating the butt welds. I know from experience that this method s nota reliable one. If applied, it should be calculated in the folowing way: = Piping in the plant: decrease the weld number by c% = Combined piping (in plants and between the plants); increase by ci% 1243. ESTIMATE OF BUTT WELDS BASED ON THE PIPING LENGTHS + MEASURED ON THE LINE AXIS 1 butt weld/lenath [m] Diameter Plant Une Combined | Town network to11/2" * 10" 12 14 16" 18" 20" 24" 28" 30" 32" ‘above 34" “In tre case of to 11/2" piping the ftings are mostly with the socket welds and therefore there ae fewer butt welds 4, ESTIMATE OF TOTAL WELDS (ALL TYPES) This estimate can be used for calculation of welding rod consumption (item 2, page 112) and the power consumption costs (item 4, page 115). ‘Once the quantity of butt welds is calculated by any of previously described methods, the quantity of other welds can be calculated as well. This is done in such a way that the quantity of butt welds is increased by the following percentage: - Piping in plants: + - Piping between plants (piperacks and sleeper ways): = Combined piping: + ~Town networks: + KKK 5. ESTIMATE OF RADIOGRAMS ON THE PIPING ‘The number of radiograms depends on the media, working pressure, working temperature, materials and special safety regulations. Generally, the estimator i.e. the process engineer determines the percentage of radiographic tests and include them in the piping line lst. The percentages are different and can vary from 5% to almost 200%. (200% is in special cases when highly alloyed materials are used and the radiography is required before and after thermal treatment of the weld). 125‘The following table is mostly used to determine the percentage of radiographic inspection, WORKING ITYPE OF ‘TEMPERATURE Class 3 Class 2 Class 1 STEEL [ec] 1251 | 150% | 1501 | 300% | 6001 | 29001 ICARBON - 20 + 100 0% 5% 5% 5% 10% 100% ISTEEL 101 = 300 0% 5% 5% 10% 30% 100% 301 + 400 10% 30% 30% 100% [c- STEEL Low = 455-21 _ 5% 10% 30% 100% [TEMPERATURE = 20 = 300 = 5% 10% 30% 100% Mo - STEEL 301 + 450 — 10% 30% 100% 100% = 20 + 450 = 30% 30% 100% 100% lcrMo-steeL | 451+580 | — 30% 100% | 100% 100% [AUSTENITE = 99 = 500 0% 5% 10% 30% 30% 100% ISTEEL 501 — 30% 30% 100% 100% (STAINLESS) - | _ 196 = = 30% 100% | 100% 100% Source: Code for Pressure Piping, Petroleum Refinery Section ANSI B31.3, Chapter VI If we know the quantity of butt welds according to their diameter, material and class, then it will not be difficult to determine the number of welds to be tested. In most cases, however this information is not available and cannot be determined within the scheduled time, Because of that the estimator will monitor and develop statistics of the projects executed, he will ask for professional opinions of more experienced colleagues, and decide for an average percentage of radiography. When the estimator determines the percentage, he will calculate the number of radiograms according to the table below. ‘The number of radiograms and lengths of films according to API -STD.1104 (‘ZIT" - Institute for Welding, Testing and Technology - Zagreb) Outside Number of diameter radiograms to 11/2" (40 mm) (ellipse) 2". 3.1/2" (50-90 mm) (ellipse) 4s (100-140 mm) e-7 (150-190 mm) erst" (200-280 mm) 12" - 13" (300-360 mm) 14" - 18" (360-450 mm) Film size 10X 12 em 10 X 16 cm 10 X 16 cm. 10X 24cm 10 X 32 cm 10 X 40 cm, 10 X 48 cm. 20" (500 mm) and more: Number of films depends on diameter 10 X 48 cm. 20" = 22" (500-550 mm) (600-700 mm) (750-850 mm) (900-1000 mm) (1050-1150 mm) (1200-1300 mm) When the quantity of radiograms is calculated, it should be increased by: 10 X 48 cm 10 X 48 cm 10 X 48 cm 10 X 48 cm 10 X 48 cm. 10 X 48 cm % for weld repair % for incorrectly issued orders % or undefined needs and samples % for certifying processes and welders % Total 126X. PIPING ABOVE GROUND ESTIMATE POINTS OF BASIC ERECTION ITEMS. The estimate points of basic erection items are used for payment and monitoring of the works progress during erection of piping above ground, One estimate point equals one man hour (Mhr) at Productivity Efficiency Percentage (PEP) of 90% for unit quantity and for carbon steel. ‘The tables contain the values of erection items for dimension used most frequently in erection of piping. Any intermediate value can be calculated for the needs of an estimate or derived by interpolation. Under the section EXPLANATION TO THE ERECTION ITEMS, the estimate points and the related activities are given for items 1.1 to 7.5 ‘The same section (items 8.1 = 8.8) provides the method for calculating the activities derived from basic items. The influence of different materia is calculated by the material multiplier factors (factors for different kind of materials) (F) for items 2.2 to 3.8, By way of an exception, the factors (k) on the page 142 are used for items 1.1 to 1.3. ‘The section FORMS FOR CALCULATION OF MAN-HOUR RATES contains the erection items on which basis the time required for installation of each piping element's calculated. These forms have been used to calculate all man hour rates in the section, EXPLANATION TO THE ERECTION ITEMS (Basic Erection/ Installation Items) 1.0 PIPING 1.1 PIPE INSTALLATION IN PLANTS Withdrawal from the store, hauling to the erection site, alignment, temporary supporting and fastening are calculated on the basis of listed lengths excluding fittings, flanges, valves, etc. Compensation: per linear meter of pipe 1.2 PIPE INSTALLATION ON PIPERACKS ‘The work is identical to PIPE INSTALLATION IN PLANTS. Compensation: per linear meter of pipe 1.3 PIPEDISMANTLING Dismantling works including necessary reconditioning work for parts to be reutiized, hauling to a storing place and unloading Compensation: per linear meter of pipe 2.0__ FITTING Valid only for welded fittings, Not valid for parts such as weldolets, sockolets, nipolets, einforced nozzles, half couplings, etc. Similarly, not valid for fittings with a socket joint and thread. If reductions are made on the pipe directly itis considered as a fitting with two welds), The rate for reducer is taken’ for the biggerr diameter. Fittings are considered only those MITRE BENDS that are delivered ready for installation, which means they are listed in the bill of material as a finished part. Mitre bends contracted for field fabrication will be considered as pipes from which the bends must be made. If this is the case, the calculation should be made according to the table (pipe laying, welds, pressure test), 1272.1. ADJUSTMENT OF FITTINGS WITH ONE CONNECTION END Adjustment of fittings with one connection end, a pipe cap ora flange for instance, is included in welding soit isnot compensated separately, 2.2. ADJUSTMENT OF FITTINGS WITH TWO CONNECTION ENDS It includes measurement, angularity and ovality check of ends, ifnecessary correction work matching by cutting, bevelling, cleaning and fitting. This refers to pipe elbow, bend, reduction and mitre elbow (bends made from pipe segments) Compensation: per item 2.3 ADJUSTMENT OF FITTINGS WITH THREE CONNECTION ENDS It includes a check of dimension, checko _fovality of ends, check of one angularity _, ifnecessary correction works (possible cutting as well) matching by cutting, bevelling, cleaning and fitting. Itrefers to T-piece andY-piece. ‘Compensation: per item, 3.0_ PIPE WELD MAKE-ON AND WELDING Tt includes all necessary preheating and possible protection from inclement weather . Heat treatment in terms of stress relieving not included 3.1. BUTTWELD MAKE-ON AND WELDING Measurement, placing and sortin g of pies, marking of cut tingline, cut ting, deburring, remo val of paint, cleaning, alignment, adjustment, temporary supporting, tack welding, check, and welding, Itincludes also possible stress relieving at flanges. ‘Compensation: per weld Weld joint at installation of prefabricated sections: 2xitem 3.1 3.2. FILLET (SOCKET) WELD - MAKE-ON AND WELDING It includes the same activities as for BUT WELD. Itapplies to the items with socket weld end ‘connection (sock et weld flanges, sock et couplings, etc. ). Following fix ed wall thicknesses ar evvalidf or different outside diameters of pipes: toDN <800r <3": all materials PNto160bar or 3000 Ibs: t=39mm PNto320bar or 6000 Ibs t=6.4mm Above DN to 80 or 3” - CrNITi- steels (Schedule) PNto100bar orto 600 Ibs t= Schi0s PNabove 100baror aboy e600 Ibs t=STD 128-allother material PN to 100 bar or to 600 Ibs t=sTD PNabove 100bar or above 600 Ibs t=xXS Slip-on flanges according to ANSI B16.5 and plain flanges according to DIN 2655 and 2656 will be compensated twice Compensation: per weld 3.3. MITREWELD MAKE-ON AND WELDING ‘As for BUTT JOINT ‘Compensation: per weld 3.4. NOZZLEWELD MAKE-ON AND WELDING. Header line measurement, marking of bore, cutting of bore, paint cleaning, matching up branch, tack-welding, levelling, alignment, welding. Nozzles without reinforcement are considered according to the outside diameter and the branch wall thickness. Nozzles with reinforcement are considered according to the larger outside diameter and larger wall thickness. This value is then added the value of the REINFORCEMENT PAD. The value for inciined nozale joints is increased by 50%. Compensation: per weld 3.5. WELDOLET, NIPOLET - INSTALLATION AND WELDING Header line measurement, marking of bore, cutting of bore, grinding, removal of paint, matching- up weldolet, sockolet, etc., tack-welding, levelling and welding. For calculation of a joint with a branch connection, take the outside diameter and the wall thickness of the branch connection. With nipolets, sockolets and thredolets to DN 80 or 3 the following will be used instead of the connecting branch wall thickness: 3mm ‘Oomm \Wall thickness as for SOCKET JOIN Compensation: per item valid above DN 80 or 3”, 3.6 REINFORCEMENT PAD MAKE-ON AND WELDING Fabrication of reinforcement pad according to to drawing: cutting out from the remaining pipe (pipe same as header line), edge working, drilling and threading of vent hole, matching-up, tack welding, welding closing of vent hole with mastic. Factor for this item is considered for outside diameter of branch connecting and the wall thickness of reinforcement pad. For a complete reinforced branch connection with pad NOZZLE JOINT should be added. Compensation: per tem 3.7 SEALRING MAKE-ON AND WELDING (ACC, To DIN 2695) Cleaning of seal ring faces, positioning of seal ring, tack welding and welding. After connecting two flanges and tightening: tack welding and welding ofinterfacing seal rings. Because of welding, the bolts will be removed and retightened, ‘Compensation: per item (without flanged joint) Basis for the number of factors is a standardized wall thickness of 4 mm. They are printed in the tables only ‘once per diameter of pipe, The flange joint is compensated subject to the nominal pressure. 1293.8 INSERTRING (FOR ALUMINIUM ONLY) (Cutting of insert rings to necessary length and matching up, welding of longitudinal seams and tack welding to the pipe. Compensation: per item Basis for the number of factors isa standardized wall thickness of 4 mm. They are printed in the tables only once per diameter of pipe. 3.9 WELD CUTTING FOR MODIFICATIONS Measurement, marking of cutting line, removal of paint, machine cutting, removal of remaining welding seam, and preparation of the cutting face for joining. ‘Compensation: per item - cutting. This item is considered once only for each weld to be cut. It is used only when the piping parts are reutilized. 3.10MA TERIAL MULTIPLIER FACTORS (f) Allvalues in the tables are valid for carbon steel. For different kind of materials a special table is given under the section MATERIAL MULTIPLIER FACTORS (3.10). Itis calculated by multiplying the carbon steel value by the factor (f) from the table 3.10. Valid for items 3.1 to 3.8 only, 4.0 _ FLANGED AND THREADED JOINTS, BENDING OF PIPES 4.1443 FLANGEDJOINT Cleaning of flange faces, preparation and positioning of gasket, lubrication of bolts with graphite grease, fitting and tightening of bolts. Compensation: per joint This item includes all flanged joints regardless of the flange type. Values for higher pressure are obtained by multiplying item 4.3 value by the following factors: Item 4.3% 1,3 for PN 160 ANSI_900 Item 4.3x 1,7 for PN 250 ‘ANSI 1500 Ttem4.3x2,2 for PN 320 +400 ANSI 2500 4.4 _ INSTALLATION OF MEASURING ORIFICES, BLANKING PLATES, ett. Make-on as for FLANGED JOINT. Additional installation of all intermediate rings and plates such as blanking plates, measuring rings, safety rings, measuring orifices and the like. This item is only an addition to the flanged joint values. 45 PIPEBENDING 1. (For pipesto DN 50 0r2”) Pipe measurement, bending according to the standards. 2. (For pipes above DN 50 or 2” to DN 200 or 8”) ‘These pipes are mostly bent for fire protection of cylindrical storage tanks, Values are compensated per [m of bending angle] 1304.6 PREPARATION OF THREADED ENDS Pipe handling, placement, measurement, marking the spooling length, cutting, threading, thr ead and cut deburring Compensation: per item 4,7 THREADED CONNECTION MAKE-ON ‘Thread cleaning, preparation of thread according to specification, screwing in, and tightening Compensation: per joint This iter will also be compensated for dismantling of threaded connection (unions with gasket, etc). 48 DISASSEMBLING Item4.1+44and47 Joint disconnection, dismantling, transport of dismantled material to the advised storing place and unloading. ‘Compensation: per item 5.0__ VALVES 5.1 VALVE INSTALLATION (WITH AND WITHOUT HAND DRIVE) Valves, gate valves, cocks, faucets, non-return valves, dampers, str ainers, level indicators, lev el controllers, floats, etc, Checking, blowing out, remo valof possiblef oreign objects, check open/close operations, supporting, fastening of hand wheel or installation of hand wheelsor handles. Compensation: per item 5.2 VALVEINSTALLATION WITH ACTUATORS (SOLENOID, AIR) Avalve with an actuat or means all pneumatic-, mot or or manual gear oper ated valves for open- close operations. Activities are the same asf or the V ALVES, This item is compensated only f or complete valves including actuator. Compensation: per item 5.3 BUTTERFLY VALVE INSTALLATION WITH ACTUATOR ‘As for VALVE WITH ACTUATOR Compensation: per item For this position, only one flanged joint will be compensated, 5.4 BUTTERFLY VALVE INSTALLATION ‘As for VALVE. Compensation: peritem ‘Same as under BUTTERFLY VALVE WITH ACTUATOR. 5.5 CONTROL VALVE INSTALLATION ‘As for VALVE. Additional: special protection and dismantling for pressure tests, Compensation: per item 1315.6 SAFETY VALVE INSTALLATION As for VALVE. ‘Additional: dismantling for calibration and reassembling. For safety valves, it will be compensated according to the nominal diameter of the pressure side (inlet). Compensation: per item 5.7 HYDRANT INSTALLATION Asfor VALVE. ‘Compensation: per item 5.8 SPINDLE EXTENSION According to the dimensions it refers to the extensions between 1 and 3 meters. Compensation: per item 5.9 DISMANTLING OF VALVES ‘The scope of works includes: dismantling, cleaning by blowing or purging, transport and unloading at an intermediate storage place. Disassembling of connections will be compensated as for DISASSEMBLY OF PIPE CONNECTIONS. Compensation: per item 6.0_PRESSURETESTING 6.1 PRESSURE TEST Pressure test with water and water mixtures, air, Inert gas, or steam. It includes the make-on of provisional connections for filing and draining, installation of blanking plates, removal of items exempted from pressure test, filing and venting of system, pressure increase to specified level. Pressure and leak test to be applied to all welds, flange and threaded joints - following the regulation. In case of pneumatic or gas test all connections are to be leak tested with a foaming agent. Carrying out the inspection of tests following the regulations, draining of system, removal of blanking plates, installation of parts, which were removed prior to pressure test and installation of flange unions with specified gaskets, bolts and nuts have to be tightened, Unlock spring hangers and spring supports, Remove temporary piping test components. ‘Compensation: per meter of pipe 6.2 SERVICE TEST Service test isa leak test with air or gas at a low pressure setting, It is done when not performed with the pressure test and when required by the specification. Compensation: per meter of pipe 7,0__ MISCELLANEOUS 7-1 SUPPORTS - FABRICATION AND WELDING Fabrication, matching up, welding. Fabricated from the remaining pipes. Compensation: per item 7.2. SUPPORT INSTALLATION (WITHOUT FABRICATION) Installation of supplied supports fabricated by other contractors, bolting, placing the insulating parts, ‘complete welding and possible adjustment. Removal of temporary supports included as well ‘The values are the manhour rates that is the man hours per kg respectively. 1327.3 INSTALLATION OF SPRING HANGERS AND SUSPENSIONS ‘The installation is the same as for the SUPPORT INSTALLATION. In addition adjust ment of prestressing. 7.4 GRINDING OF EXCESS MATERIAL ON WELDING ROOTS Careful grinding of excess material on welding roots of specified welds, removing grinding dust. Thisis particularly used with rubber-lined piping and with installation of measuring flanges. Compensation: per weld 7.5 INSTRUMENT CONNECTION - DRILLING Drilling, deburring of instrument connection in pipe according to the given bore in flange, removal of driling chips, Compensation: per drilled hole 8.0 ACTIVITIES DERIVED FROM BASIC ITEMS PIPES In the following items, only the lengths of straight run pipes included in the bill of quantities are compensated (cutting lengths as listed). Fittings, flanges and the lke will not be compensated. 8.1.1 _ PIPE HANDLING AND CUTTING IN PREFABRICATION Make-on: Prefabrication as for Item 1.1. Transport to a spools storing place. Compensation: fll x number of points Item 1.1 = [hours per meter of pipe] Itis compensated only ifthe installation is not done by the prefabrication labour, 8.1.2 _ INSTALLATION OF PREFABRICATED SPOOLS, Make-on: Installation as for Item 1.1, Transport from the spools storing place to the place of installation. Compensation: a2" +5" xnoofpointsItem 1.1 = [hours per linear meter of pipe] 26" +10" xnoofpoints tem 1.1 = [hours per linear meter of pipe] o12"+14" xnoofpointsItem 1.1 = [hours per linear meter of pipe] @ above 16” xnoofpointsitem 1.1 = [hoursper linear meter of pipe] Valves and pipe supports will be compensated separately. Itwill be compensated only if another company does the prefabrication. + Alternative: Activity 8.2.4 8.1.3 SPATIAL SHIFTING OF PIPES Make-on: Spatial shifting of already installed piping, dismantling and installation of holders, installation of additional steel packers. Compensation; [ll x no of points Item 1.1 (1.2) 1338.1.4 MAKE-ON OF OUTSIDE PIPE FOR A DOUBLE-WALL PIPING (JACKETED PIPING) ‘Make-on: Cutting, placement, positioning the outside pipe with double-vall piping (jacketed piping). Compensation: _fllxno of points Itemn1. (1.2) Itis compensated only if the installation is not done by the prefabrication labour, 8.1.5 MAKE-ON AND INSTALLATION OF LINE PIPING DN 20/25 ON JACKETED PIPING Make-on: Asfor Item 1.1 Compensation: flxno of points Item 1.1 (1.2) for union fittings between the jacketed pipes xno of points Item 1.1 (1.2) for union fittings on valves and fittings 8.2 MISCELLANEOUS FITTINGS 8.2.1 HALF COUPLINGS ‘The connecting seam between a half coupling and a header pipe is a fillet weld. To allow for the additional work as drilling the hole etc. a butt weld according to Item 3.1 will be compensated, The following points for nominal diameter of half-coupling or adequate outside diameter of connecting pipe (not the header pipe) and wall thickness are used: PN to 3000 Ibs : t PN to 6000 Ibs : t 0,6 mm. 38mm, NOTE: The wall thicknesses considered for compensation are fictitious. There are no points for these thicknesses. Therefore, the points for the closest thickness are taken and divided with that thickness and multiplied by fictitious thickness of 10.6 mm or 13.8 mm dependent on the half- coupling category, The result is the points for a joint between the half coupling and the header pipe. Item 3,2 is followed for compensation of next socket joint of pipe. Compensation: Points peritem 8.2.2 WELD COMPENSATOR Make-on: Measurement, positioning, supporting of weld compensators Compensation: flixno of points Item 2.2 8.2.3 WELD METER RUNS Make-on: Measurement, placement positioning and supporting of weld meter runs Compensation: imix no of points Item 2.2 8.2.4 PREFABRICATED OF SPOOLS FOR WELDING Make Finding of prefabricated piping sections, transport, measurement, placement, positioning, supporting, and fastening Compensation: flix no of points Item 2,2 [Mhr/spool) Valves and pipe supports are compensated separate. Itis compensated only if another company does the prefabrication. + Alternative: Activity 8.1.2 1348.2.5 MEASURING ORIFICES - MEASURING FLANGES, This item includes the operations for performance of a flanged measuring orifice, which is ‘assembled at the site from individual parts excluding the measuring orifice plates and the meter runs delivered as an assembly. Weld both flanges according to the existing specification of the measuring orifice and grind the excess material on the welding roots. Drill holes for instrument connection for slip-on flanges and remove drilling chips, weld outgoing instrument connections and close off (watertight welding) the flange hole not used, make-on of flange joint by installing a measuring orifice. (Battery limits of the works marked on drawing) Compensation of instrument connection assembly: xItem 4.1 (4.20r4,3) + Item 4.4 Inaddition the points for the following to be included: Grinding of excess material on the welding root along the flange seam according to the nor diameter of the flange. xltem 7.4 Grinding and removal of drilling chips on the measuring line connection according to the nominal diameter of flange. xltem 7.5 8.3 WELDING 8.3.1 TACK WELDING ON VALVE SIMULATORS, Make-on: as Item 3.1 Compensation: jsiiix no of points Item 3.1 8.3.2 LONGITUDINAL WELDS ON PIPE HALF SHELLS Make-on: Asitem 3.1 Compensation: [lillx no of points Item 3.1 fr both longitudinal welds 8.3.3 THERMOMETER BRANCH (TI) Welding of a thermometer branch to a pipe DN 150 and above is compensated instead of a nozzle Joint xsocket ointof corresponding Item 3.2 (s = 6,4 mm). Compensation: Points per item 8.3.4 PREFABRICATED WELDS AT INSTALLATION OF PREFABRICATED SECTIONS (SPOOLS) Performance:As Item 3.1 Compensation: jx no of points Item 3.1 8.4 FLANGED JOINTS 8.4.1 REPLACEMENT OF BOLTS Performance: Take out of bolts, preparing them or reutilization, bolt greasing, placing, and tightening Compensation: lll xno of points of corresponding Item4 .1,4.20r4.3 1358,5 VALVES 8.5.1. ROTATING THE VALVE INSTALLED Make Positioning, supporting, fastening Compensation: iil xno of points Item 5.1, 5.2, 5.3, 5.4, 5.5, 5.60r5.7 8.5.2. EXPANSION JOINTS WITH FLANGED ENDS Make-on: Asitem5.1 Compensation: flixno of points Item 5.1 8.6 WALL PASS FOR PIPES Make-on: Fabrication and installation of wall passes. Use of larger diameter pipes or sheet metal bending, wall breaking, setting the pass in position and fastening. Compensation: x no of points Item 3.1 for corresponding diameter of he header line 8.7_ MISCELLANEOUS 8.7.1 FABRICATION AND INSTALLATION OF PIPE HOLDERS, HANGERS AND SUPPORTS. (to 100 kg per item) Make-on: as Item 7.2 inclusive of fabrication according to the Client's drawings. Compensation: i xno of points Item 7.2 the Client supplies the material xno of points Item 7.2 ifthe Client supplies the material 8.7.2. DISMANTLING OF PIPE HOLDERS, HANGERS AND SUPPORTS Performance: Dismantling holders and return the usable parts to the store, Compensation: fj xno of points of corresponding Pos 7.2 8.7.3 HOLE DRILLINGIN CONCRETE Performance: Drilling a hole and inserting a screw anchor Compensation: li xpointsforholes to 10mm xpointsforholes 12+ 16mm xpointsforholes above 16mm. 88 EXTRAS 8.8.1 CHANGE IN BILL OF QUANTITIES BEFORE THE CLIENT'S APPROVAL FOR FABRICATION Compensation: The change in bill of quantities is compensated by lm points per piping item. 8.8.2 CHANGE IN ISOMETRY PRIOR TO THE CLIENT'S APPROVAL FOR FABRICATION Compensation: The change in isometry is compensated by [ll points per pipe item 1368.8.3 HAND DRAFTING OF ISOMETRY ACCORDING TO THE CLIENT'S INSTRUCTION Hand drafting (sketches) of isometry including a bill of quantities is calculated with f@ points per sketch and bill 8.8.4 INSTALLATION OF MISSING MATERIAL Make-on: Subsequent installation of the piping parts in already prefabricated and installed piping. Compensation; Subsequent installation of the piping parts is compensated by ill x number of points of corresponding installation item and the installation and/or welding item. 8.8.5. PIPINGMODIFICATION Make Modification works on already installed piping at the Client's request. As-built documentation of the modifications made in isometry and billof items. Compensation: OPTION I: Modification on finished and installed piping is paid according to the calculation xnumber of points ofthat item. For handling only the straightrun pipes are considered, OPTION IT: Calculation according to the table "Man hours for piping modification at ste," Page 48 8.8.6 SANDBLASTING HANDLING, PRIMER COAT ON PIPING, AND PIPE SUPPORTS Performance: Designation of prefabricated sections and pipe supportson the protected side, Preparation of piping for sandblasting and application of primer. Protection of sealing surfaces and bevelled welding edges against damage and protection against ingress of sand into the piping. ‘Transport of piping to the sandblasting and painting site. Co-ordination and work with sandblasting/painting company. Compensation: Sandblasting handling and corrosion primer is compensated at [lll [Mhr/ton] of prefabricated material. 8.8.7 UNDERGROUND PIPING This refers to the piping laid in an excavated trench in the plant but its not valid for pipelines. They are calculated as the piping above ground with a % increase. A precondition is that the pipes are already wrapped in which case there is no need to calculate separately the wrapping of joints separately. Ifthe pipes are not prewrapped, the insulation shall be calculated separately. 1378.8.8 FACTORS FOR CALCULATION OF MAN HOURS FOR PREFABRICATION AND INSTALLATION OF PIPING The estimate points for basic erection items and the rates derived for the piping elements will ive the total values for prefabrication and for installation. Sometimes the rates are requested to be given separate for prefabrication and separate for installation, which is done in the following way: 1, PIPES (Item 1.1; 1.2) Pipe handling is one installation item, which is performed both in prefabrication and in installation. Thatis why the estimate points and the rates have to be divided. Prefabrication: (m%) factor Installation: (m%) factor FITTINGS (Item 2.2; 2.3) Prefabrication: factor Installation: factor 3. JOINTS-WELDING (Item3.1 3.9) Prefabrication factor Installation: factor 4, FLANGES AND OTHER (Item 4.1 4.7) Prefabrication factor Installation: factor 5, VALVES INSTALLATION (Item 5.1 5.8) Prefabrication factor (exception) Installation: factor 6. TESTS (Item6.1; 6.3) Prefabrication: factor Installation factor MISCELLANEOUS = (Item 7.1) Prefabrication: factor Installation factor ~ (tem 7.2; 73) Prefabrication: no Installation factor (Item 7.4; 75) Prefabrication: factor Installation factor 8. OPTION: According to the unit rates per each component, 2 division to prefabrication and installation, page 49. 138TABLE Item, 3.10 (pages 147 + 202) MULTIPLIER FACTORS FOR DIFFERENT KIND OF MATERIALS FOR ITEMS 3.1 TO 3.8 (f) Group of materials (GM) Carbon steel (CS) Chrom-molybden alloy steel (CR) = Copper alloy (CU) Low temp. alloy steel (N), (N41), (TT) = Stainless steel (CN) High temp. alloy steel (W), (W1), (W2), (W3) + Nickel alloy (NI) ‘Aluminium alloy (AL) © GM DIN - MATERIAL WS -No ‘ASTM - material CARBON STEEL cs S135 41,0308 A53 St35.8 71,0305 ‘A106 Gr. A, A234 Gr. WPA S372 Torte 'A53 Gr. A RSt 37-2 1.0038 A135 RRoSt 37 -2 41,0174 ‘A283 Gr. B, C (killed) A285 Gr. B (killed) S142 4.0132 ‘A53 Gr. B RSt42-2 7,0042 ‘A135 Gr. B A181 Gr. Class 60 ‘Stas 71,0408 (A53 S458 71,0405 ‘A106 Gr B, A234 Gr, WPB C2i 7.0432 ‘A105 C22 41,0402 A181, A234 22.8 1,046 A105, A181 Gr. Il Hil 7,0425 ‘GTI Gr. CASS, CBEO B65 [STAINLESS STEEL CN X2 Cini 1911 1.4306 ‘A182 Gr. F304L, (X2 CrNi 18 9) ‘A269 Gr. TP3O4L, A312 Gr. TP3O4L, A403 GrWP304L X2 CrNiMo 17 132 ‘A269 Gr. TP316L, (X2 CrNiMo 18 10) 4.4404 A312 Gr TPS16L, X2 CrNiMo 18 14 3 (X2 CrNiMo 18 12) 4.4435, AISI Gr. 316L X2 CrNiMON 17 13 1,491 AISI Gr. 316N XS CrNi 18 10 ‘A182 Gr. F304, (XS CrNi 18 9) 41,4301 ‘A269 Gr. TP304, A312 GrTP304, A358 Gr. 304, ‘A403 Gr WP304, WP304H 139oO GM DIN - MATERIAL WS-No ‘ASTM - material STAINLESS STEEL CN XB CrNiMo 17 12.2 TA40T ‘Ai62 Gr, F316, (X5 NiCrMo 18 10) A269 Gr. TP316, A312 Gr. TP316, A368 Gr. 316 X2 CrNiMON 22 5 14462 ‘A789? XS.NICrMoCuNb 2018] 1,4505 2 ‘6 CrNiNb 18 10 1,455 ‘i682 Gr. F347, (X10 CrNiNb 18 9) ‘A269 Gr TP347, A358 Gr. 347, ‘A358 Gr. 348, ‘A403 Gr. WP347, A403 Gr, WP348, X6 CrNiTi 18 10 1.4544 ‘A182 Gr. F321, X10 CrNiNb 18 9) A269 Gr. TP321, A312 Gr. TP321, A358 Gr. 321, ‘A403 Gr. WP321, Ad03 Gr. WP321H. X6 GrNIMOT 17 122 14871 ‘A312 Gr. TP316H, (X40 CrNiMoTi 18 10) ‘A403 Gr. WP316 X10 CrNiTi 18 10 41,6903 AISI Gr. 321 © GM DIN - MATERIAL, WS -No ‘ASTM - material (Cr= Mo ALLOY STEEL CR X20 GrMoV 121 1.4922 2 ‘All customary steels with head alloying element "Cr, referes to key for steels. © GM DIN MATERIAL, WS-No "ASTM - material COPPERALLOY cu CUNT 10 FE 2,0872 B46 - C7060 CCUNI 30 FE, 2,0882 ‘SB111 - C71500 466 - C7150 © GM DIN - MATERIAL, WS - No ‘ASTM - material LOW TEMPERATURE STEEL N TON 14 75637 ‘A335 Gr. 3, A334 Gr. 3 ‘A350 Gr. LF3, ‘A420 Gr. WPL3 T4Ni6 17,5622 ‘A333 Gr. 9, A334 Gr. 9, ‘A403 Gr. TP316H Ni XENTS 75022 ‘ASSS Gr. 8, A334 Gr. 8 ‘A420 GR. WPL8 T TTStE29 71,0488 ‘A333 Gr. 6, A334 Gr. 6, ‘A420 Gr. WPL6 TTSIE35 1,0366 ‘A333 Gr. 1, A334 Gr. 1 TTSt 35V 41,0356 ‘A350 Gr. LF1 TTst 41V 41,0437 ‘A350 Gr. LF2 TTSt E44 41,0437 A420 TTSt E36 1,0566 ‘A671 GR. CD70, ‘A691 Gr, CMSH70 140© eM DIN- MATERIAL WS -No ‘ASTM - material TIGH TEMPERATURE ALLOY STEEL Ww 70 Grito 11 T7276 ‘Ai62 Gr. FSA 10 CrMo 9 10 1,738 A182 Gr. F22 (A234 Gr. WP22 A335 Gr. P21 A335 Gr. P22 72 GiMo 195 17362 ‘A182 Gr. F5, A234 Gr. WPS, A335 Gr. PSb, A335 Gr. PSd 15 NiGuMoNb 5 76368 ? 17 CrMoNb 10 4,766 2 20CrMoV 135 4779 2 /X8 CrNiNb 16 13 1,4961 ? X8 CrNiMoNb 16 16 1,4981 ? X8 CrNiMoVNb 16 13. 1,4988 2 X12 CrMo 9 1 7.7386 ‘At62 Gr. FO A213 Gr. 79 wi TEMoa Teas ‘A182 Gr. F1, A335 Gr. WPI, A335 Gr. Pt, ‘A691 Gr, CMES. we 13 CrMo 44 1.7335 ‘A182 Gr, F12 A234 Gr. WP11, A335 Gr. P2, A335 Gr. P11 A335 Gr. P12, 691 Gr 1CR ws 14 MoV 63 47715 2 GM DIN- MATERIAL WS -No ‘ASTM - material [ALUMINIUM ALL( AL ALMG 3 3,3535, Alloy 5052-0 ALMG 4.5 Mn Alloy 5083-0. ALMG 5. 2 cM DIN- MATERIAL WS -No ‘ASTM - material NIGKELALLOY NI XIONiGrAITI 3220 | 1.4876 Ineoloy 800 NiCr 21 Mo 2.4858 Incoloy 825 NiCr 22 Mo 9 Nb 2.4856 Ineoloy 625 141FORMS FOR CALCULATION OF MANHOUR RATES (Derived Erection Items) Productivity Efficiency Percentage (PEP) = 80% 1.0 PIPES 1.1 INPLANT Item 1.1xk + Item 3.1/24xk + Item 6.1 + Item 6.3 = [Mhr/m] 1.2 ONPIPERACK Item 1.2xk + Item 3.1/6xk + Item 6.1 + Item 6.3 = [Mhr/m] 13 STEAMTRACING (Item 1.1xk + Item 3.1/6 xk+ Item 6.1 + Item 6.3) x2,5 = [Mhr/m] MATERIALS. © [carbon steel 1,00 [stainless steel 1,10 alloy stee! 110 prewrapped (undergr, install 115 [galvanised 0,70. Cet = iD [aluminium 0,85 Mhifm x 0,3048 = Mhe/fe 2.0_ FITTINGS 2.1 PIPE BENDS ELBOWS 45° and 90° (Item 2.2 + Item 3.1.x 1,8) xf = [Mhr/ea] 2.2. PIPECAPS (Item 2.2/2 + Item 3.1) xf = [Mhr/ea] 23. TEE-PIECES 2.3, STRAIGHT TEES (Item 2.3 + Item 3.1x2,75) xf = [Mhr/ea] 2.3, 2REDUCED TEES (Item 2,3 + Item 3.1 x2,5) x= [Mhr/ea] 24 REDUCERS CONCENTRICAND ECCENTRIC (Item 2,2 + Item 3.1 for 0+ Item3.1 for )xf = [Mhr/ea] MATERIALS (f) ‘See section FACTORS FOR DIFFERENT MATERIALS FOR ITEMS 3.1 TO 3.8 (f) page 139 + 141. 1423.0 31 3.2 33 34 35 3.6 37 40 41 42 43 FLANGES NECK (Item 3.1 + Item 4.1 + 4.3) xf = [Mhr/ea] SLIP-ON, PLAINE (Item 3.2x2 + Item 4.1 + 4.3) [Mhr/ea] SOCKET (tem 3.2 + Item 4.1 = .3)xf= [Mhr/ea] FREE FLANGE + CIRCUMFERENCE (Bérdel) (Item 3.1 + Item 4.1 +4.3)x0,9xf=[Mhr/ea] BLIND FLANGE Item 4.1 + 4.3x1,3 = [Mhr/ea] MEASURING ORIFICE ASSEMBLY (Item 4.1 +4.3 + Item 3.1 + Item 7.4 + Item 7.5 + Item 4.4) x2.xf = [Mhr/foint] FLANGES - handlingonly 20% of [Mhr/ea] SMALLFITTINGS WELDOLETS, SOCKOLETS, NIPOLETS Item 2.2 + Item 3.5x f= [Mhr/ea] HALF COUPLINGS FOR WELDING Item 2.2 + Item 3.5.x 0,85 xf = [Mhr/ea] FITTINGS WITH SOCKET ENDS 4,3.1WITH ONE END (Item 2.2.x 0,5 + Item 3.2 (for "XS")) xf = [Mhr/ea] 4,3.2WITH TWO ENDS (Item 2.2 + Item 3.2 (for "XS") x 2) xf = [Mhr/ea] 4.3.3WITH THREE ENDS (Item 2.3 + Item 3.2 (for "XS") x3) xf = [Mhr/ea] 1434.4 FITTINGS WITH THREADED ENDS 4.4.1 WITHONEEND Item 4.6x0,5 + Item 47 = [Mhr/ea] 4.4.2 WITHTWO ENDS Item 4.6 + Item 4.7 x2 = [Mhr/ea] 4.4.3 WITH THREE ENDS Item 4.6x1,5 + Item 47 x3 = [Mhr/ea] 5.0 _ VALVES 5.1 WITHFLANGED ENDS 5.1,1VAL VES, GATES, COCKS, NON-RETURN VALVES, DAMPERS, FILTERS, STRAINER: Ttem 5.1 x VF = [Mhr/ea] 5.1,2CONTROLV ALVES Item 5.5 x VF = [Mhr/ea] 5.1.3SAFET Y VALVES Item 5.6 x VF = [Mhr/ea] 5.1.4HYDRANTS Item 5.7 x VF = [Mhr/ea] \VF-Factor for installation NDto 100, ND above 200 of flanged valves tod” o above 10” NP 6+ 16 OF 1,00 1,00 NP 25 = 40 300# 121 110 NP 64 400-# 141 T16 NP100 600 1,44 121 NP 160 900 # 1,66 1,33, NP-250 1500 # 1,90. 1,46 NP320 2500 # 2,19 1,61 5.2 WITH WELDING ENDS BUTT WELD 5.2.1NP 6 + 100, LB 150 + 600 (Item 3.1 (for"STD") x2 + Item 5.1) x = [Mhr/ea] 5.2.2NP 160 , LB 900 (Item 3.1 (for XS") x2 + Item 5.1) xf = [Mhr/ea] 5.2.3NP 250 + 320, LB 1500 + 2500 (Item 3.1 (for "XXS") x2 + Item 5.1) xf = [Mir/ea] 1445.3. WITHWELDINGENDS SOCKET WELD (Item 3.2 (for "XS") x2 + Item 5.1) xf = [Mhr/ea] 5.4 WITHTHREADED ENDS Item 4,7 x2 + Item 5.1 = [Mhr/ea] 6.0 __PIPEEXPANSION JOINTS AND FLOWRATE METERS: 6.1 WITHFLANGED ENDS (Item 4.1 +4,3x2 + Item 5.1) x 1.5 = [Mhr/ea] 6.2 WITHWELDING ENDS (Item 2.2 + Item 3.1) x2,3xf = [Mhr/ea] 7.0 OTHER INSTALLATION WORKS 7:1 MAKE-ON OF BRANCH CONNECTION 7.1.190® BRANCH C ONNECTION Item 3.4 xf = [Mhr/joint] 7.1.290° BRANCH C ONNECTION WITH REINFORCEMENT (Item 3.4 + Item 3.6) xf = [Mhr/joint] 7.1,3INCLINED BRANCH C ONNECTION Item 3.4x2x = [Mhr/joint] 7.1.4INCLINED BRANCH CONNECTION WITH REINFORCEMENT (Item 3.4 + Item 3.6) x2.xf = [Mhr/joint] 7.L.SEXTRUDED BRANCH CONNECTION Item 3.4x2,5xf = [Mhr/joint] 7.2. PIPEBENDING 7.2. BENDING BY A PIPE BENDING MACHINE Item 4. = [Mhr/bending] 7.2.2BENDING ALON G RADIUS (r- above 2000 mm) Item 4.5 = [Mhr/m] m= length of pipe bent part 1457.3. STRESS RELIEVE IN CONNECTION PIPING ON ROTARY EQUIPMENT Item 5.1x3 = [Mhr/ea] 7.4 FIELD FABRICATION OF CONCENTRIC AND ECCENTRIC REDUCERS. 7.4.ACONCENTRIC REDUCER Item 3.5 Mhr/ea] 7.4.2. ECCENTRIC REDUCER Item3.5x 1,2 = [Mhr/ea] 7.5 FABRICATION OF MITRE BENDS FROM PIPES Item 3.3x 1,2 = [Mhr/joint] 146aot 'S. ESTIMATE POINTS FOR] Casts oar BUILD-IN ITEMS OF 103 137 ABOVE-GROUND PIPING Ti tae [ayy 22 [an a za] az ‘Schedule 10s [40 STD |60"xS|_105_|40 STO| 80 xS|-55. 0S Ten] tat Buildin Kame 027] a6 | oa7 [oso 0,63 | 079 [0.65 Tory 10 i [om | PIPE= LAYING IN FIELD 12 23 22 23 31 32 | each | FILLET (SOCKET) WELD 33 | each MITRE WeLD 34 | each |NOZZLE WELD 35 | piece |WELDOLET, NIPOLET - WELDING 3.6 | piece | SADDLE REINFORCEMENT - WELDING 37 | each |SEAL RING - WELDING 3.8 | piece | INSERT RING (ONLY FOR ALU) 39 | piece |WELD CUTTING IN ALTERATIONS. 3.10 | mutipIMATERIAL MULTIPLIER FOR ITEM 3.1 T0.3.8, a1 [each 42 | each 43 | each 4a | each |oRtrice pLare INSERTE 145 | bend |PIPE BENDING FOR below 45°, FOR > 45° x2 46 | piece [PIPE THREADING a7 {ING ON THREADED CONNECTION 4B ISASSEMBLY : 0,7 x PTS, ITEM 4,1 TO 4,4 AND 47 5 | plece | VALVE - INSTALLING 040 52 | piece | VALVE WITH DRIVE - INSTALLING oa 53 | piece | BUTTERFLY VALVE WITH ORIVE - INSTALLING 0,05 54 | piece | BUTTERFLY VALVE - INSTALLING 0.02 55 | piece |CONTROL VALVE 039 5.6 | piece |SAFETY VALVE bas 57 | piece |HYDRANT 019 5'8 | picce | VALVE SPINDLE EXTENSION LENGHTS 1-2-3 m 056 | 0,78 078 78 | 1,00 5.9 | piece [DISASSEMBLY : 0 x PTS. ITEM. 5.1 T0 58 641 | m PRESSURE TEST (WATER, AIR, STEAM, GAS) 008 004 62 | m__|seavice test 0,03 0.03 71 | piece | SUPPORT FABRICATION 0.26 0,26 7.2 | kg | SUPPORT INSTALLATION oi oat 73 | kg _ | SPRING SUSP, AND HANG, - BUILD-IN AS ITEM 7.2 74 | piece |WELD ROOT GRINDING oat oan oat 2.5 | piece [GAUGE CONNECTION DRILLING 0,30 ou oat