Technical Calculation and Estimator's Man-Hour Manual

 

TECHNICAL CALCULATION AND ESTIMATOR'S  MAN-HOUR MANUAL

Marko Buliæ

 

Marko Buliæ

TECHNICAL CALCULATION AND ESTIMATOR'S MAN-HOUR MANUAL

ERECTION OF PROCESS OR CHEMICAL PLANTS

I. II. III. IV.  V..  V  VI.

PIPING AB ABOVE GROUND PIPELINES STEEL ST STRUCTURES PROCESS EQUIPMENT STORAGE TANKS CYLINDRICAL AND AND SPHEROIDAL WELDING AND FLAME FLAME CUTT CUTTING ING

 VII.  VIII. IX. X.

CORROSION PROTECTION THERMAL INSULA INSPROTECT ULATION TIONION ESTIMATES PIPING ABOVE GROUND ESTIMATE POINTS FOR BUILD-IN ITEMS XI. WEIGHT FA FACTORS XIII. TEC XI ECH HNI NIC CAL CAL CALC CUL ULA ATIO ION N MANNER OF DATAS COMPILING XIII XI II.. MA MAN N HOU HOURS RS FO FOR R OVE OVERH RHAU AULS LS IN PETROCHEMICAL PLANTS XIV.. FACT XIV ACTOR ORS S AND AND MAN HO HOURS URS FOR PIP PIPING ING AND STEEL STRUCTURE WORKS IN CALL FOR   TENDERS OF “TECHNIP” “TECHNIP” COMPANY  COMPANY  XV. APPENDIX

ZAGREB, 2003. (Completed edition)  All right reserved.  This book, or parts thereof, thereof, may not be reproduced in any form without permission of the author.

 

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I II III IV  V  VI  VII  VIII IX X XI XII XII IIII XIV XI V

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PREFACE

 All 40 years of my working life, I spent on erection of different process plants most of which were oil 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 aware 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 reason for for collecting various technical bibliography bibliography,, standards, 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, I sought sou ght a compromise between different opinions and standpoints. Too 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, a 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 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, I used the English man hours of the th e 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, not es, I am the only author.  A complete edition of this t his manual in the Croatian language and its sections section s were published in 1997 and 2000. This is why I have not given a unified percentage of the production efficiency but each chapter has its own.

Marko Buliæ

Zagreb Croatia, 2003

2

 

CONTENTS page PREFACE...........................................................................................................................2 INTRODUCTION..............................................................................................................11  ABBREVIATIONS  ABBREVIA TIONS & UNITS........................................ UNITS........................................................................ .........................................................13 .........................13 CHAPTER I. PIPIN ING G ABOVE GROU OUN ND................................................................................14 DERIVED OPERATING TIME STANDARD FOR   TABLES  TABL ES FACT FACTOR OR OF BASIC ASSEMBL ASSEMBLY  Y  1. PIPES (ANSI B. 36.10) ...................................................................................14 1.1 PIPE - INST INSTALL ALLA ATION ON PROCE PROCESS SS PLAN PLANT T....... .............. .............. ............... ............... .............. ............... ............... ............1 .....14 4 1.2 PIPE - INST INSTALL ALLA ATION ON PIPE RACK OR SLEE SLEEPER PER WA WAY Y........ ............... .............. ............... ............... .............. .......15 15 2. FITTIN FIT TINGS GS (ANSI (ANSI B. 16.9)... 16.9)...... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ........ ....... ....... ........ ....16 16 2.1 ELBOWS..... ELBOW S............. ............... .............. ............... ............... .............. .............. ............... ............... .............. ............... ............... .............. ............... ...........16 ...16 2.2 CAPS........ CAPS. .............. ............... ............... .............. ............... ................. ................. ............... .............. ............... ................. ................ ............... ............... ........16 .16 2.3 TEES........ TEES ............... .............. ............... ............... .............. .............. ............... ............... .............. ............... ............... .............. ............... ............... .............1 ......17 7 2.3.1 STRAI STRAIGHT GHT TEE.. TEE.......... ............... ............... ............... ............... ............... .............. ............... ............... ............... ............... ............... ............... .........17 ..17 2.3.2 REDU REDUCED CED TEE.. TEE.......... ............... ............... ............... .............. ............... ............... ............... ............... ............... ............... .............. ............... ...........17 ...17 2.4 REDUCE RED UCERS RS - CON CONCEN CENTRI TRIC C AND ECCENTRI ECCENTRIC... C....... ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... .......1 ...18 8 1.1 1.2 1.3 1.4 1.5 1. 5 1.6

2.1 2.2 2.3 2.4 3.1 3.2 3.3 3.4 3.5 3.6 4.1 4.1 4.2 4. 2 4.3 4. 3 4.4

1. PIPES (DIN 2448/2458)..............................................................................19

PIPE - INST INSTALL ALLA ATION IN PROCE PROCESS SS PLAN PLANT T....... ............... ............... .............. ............... ............... ............... ............... ..........19 ...19 PIPE - INST INSTALL ALLA ATION ON PIPE RACK OR SLEE SLEEPER PER WA WAY Y........ ............... ............... ............... .............. ..............2 .......21 1 STEAM STE AM TRA TRACIN CING G (AN (ANSI SI & DIN DIN).. )..... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ......2 ..23 3 INSTRU INS TRUMEN MENT T AND CON CONTRO TROLL PIP PIPING ING.... ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... .....2 ..23 3 STEA ST EAM M DI DIST STRI RIBU BUTO TORS RS AN AND D CON CONDE DENS NSA ATE CO COLL LLEC ECT TOR ORS S FABRICATED FABRICA TED FROM PIPES AND FITTINGS...............................................................23 FITTINGS......................................... ......................23 STEAM STE AM DIS DISTRI TRIBUT BUTORS ORS AND CON CONDEN DENSA SATE TE COL COLLEC LECTO TORS RS FABR ABRICA ICATED TED FROM READY MADE DISTRIBUTORS FOR 4 CONNECTIONS.....................................23 2. FITTINGS (DIN)............................................................................................24 ELBOWS ELB OWS.... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ......2 ..24 4 CAPS.... CAPS ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .......2 ...24 4 TEES.. TEE S...... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .....26 .26 REDUCE RED UCERS RS - CON CONCEN CENTRI TRIC C AND ECCENTRI ECCENTRIC... C....... ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ .......2 ...28 8 3. FLANGES.......................................................................................................30 WELDING WELD ING NECKS NECKS........ ............... ............... ............... ............... ............... ............... ............... .............. ............... ............... ............... ............... ........30 .30 SLIP - ON.... ON............ ............... ............... ............... .............. ............... ................ ............... .............. ............... ............... ............... ............... ............... ........31 31 SOCKET SOCKE T WELD WELDING.. ING.......... ............... ............... ............... ............... ............... ............... ............... ............... ............... .............. ............... ............31 ....31 LAP LA P JOI JOINT NT + STU STUB B END END... ....... ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... .......3 ...31 1 BLIND BLI ND.... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ...31 31 ORIFICE ORIFI CE COMP COMPLETE. LETE........ ............... ................ ............... ............... .............. .............. ................ ............... ............... ............... .............. ...........31 ....31 4. SMALL FITTINGS...........................................................................................32 WELDOL WEL DOLETS ETS,, SOC SOCKOL KOLETS ETS,, NIP NIPOLE OLETS TS,, etc etc... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ...... ....... ........ ........ ........ ......3 ..32 2 HALF HAL F COU COUPLI PLINGS NGS FOR WEL WELDIN DINGS GS... ....... ........ ........ ....... ....... ........ ........ ........ ....... ....... ....... ....... ........ ........ ....... ....... ........ ........ ......3 ..32 2 FITTIN FIT TINGS GS WIT WITH H SOC SOCKET KET END ENDS.. S..... ...... ....... ........ ........ ....... ....... ........ ........ ........ ....... ....... ....... ....... ........ ........ ....... ....... ........ ........ ......3 ..32 2 THREADED THRE ADED FIT FITTING TINGS..... S............. ............... ............... ............... ............... ................ ............... ............... ................ ............... .............. ...........32 ....32 3

 

5. VALVES...........................................................................................................33

5.1 5.2 5.3 5.4 5.5 1.

VALVES WITH FLAN VALVES FLANGED GED ENDS ENDS....... ............... ............... .............. ............... ............... .............. ............... ............... .............. .............3 ......33 3 VALVES VAL VES WITH WELD WELDING ING ENDS ENDS....... ............... ............... .............. ............... ............... .............. ............... ............... .............. ............34 .....34 VALVES VAL VES FOR THRE THREADED ADED ENDS ENDS....... .............. ............... ............... .............. ............... ................ ............... .............. ............... ............34 ....34 PRESSURE PRES SURE GAUGE GAUGES.... S............ ............... ............... ............... .............. ............... ............... ............... ............... .............. ............... ................ ........34 34 THERMO THE RMOMET METERS ERS.... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ......34 ..34 RATES FOR TENDER CALCULATIONS...............................................................35 MANHOU MAN HOUR R ESTI ESTIMA MATE TE FOR INS INST TALL ALLA ATIO TION N OF OF PIPI PIPING. NG.... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ......3 ..35 5

2. 2.1 2.2 2.3 2.4 2.5 2.6 3. 4. 5. 6.

EFFECT AS EFFECT ASSES SESSM SMENT ENT FOR QUI QUICK CK CAL CALCUL CULA ATIO TION.. N..... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ .......3 ...36 6 PIPING IN PROCE PROCESS SS PL PLANT ANT....... ............... ................ ................ ............... ............... ................ ................ ............... ............... ..............3 ......36 6 PIPES PIP ES (CARBO (CARBON N STEEL STEEL - NOT NOT INSULA INSULATED TED)) - MEAN VALU VALUE.. E...... ........ ........ ....... ....... ........ ........ ........ ........ .....37 .37 FITTIN FIT TINGS GS (CARBON (CARBON STEEL) STEEL) - MEA MEAN N VA VALUE LUE.... ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ .......3 ...38 8 VALVES VAL VES - MEAN VAL VALUE..... UE............ ............... ................ ............... ............. .............. ................ ................ ............... ............... .............. ..........39 ....39 PIPE SUPP SUPPORT ORTS.... S............ ................ ................ ............... ............... ................ ................ ............... ............... ................ ............... ............... ...........39 ...39 AVERA AV ERAGE GE DIAMETE DIAMETER R - Ma Manne nnerr of Calculat Calculation ion.... ........ ........ ........ ........ ....... ....... ........ ....... ....... ........ ........ ........ ........ ....... ....39 .39 RATES RA TES FOR INS INST TALL ALLA ATIO TION N OF POL POLYET YETHYL HYLENE ENE PIP PIPING ING... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ .....40 .40 RATES RA TES FOR ERE ERECTI CTION ON OF PVC & FRP FRP PIP PIPING ING... ....... ........ ........ ........ ........ ....... ....... ........ ....... ....... ........ ........ ........ .......4 ...41 1 CARBON CAR BON STE STEEL EL PIP PIPING ING CEM CEMENT ENT LIN LINED ED INS INSIDE IDE... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....41 .41 PIPING PIP ING MAD MADE E OF OF STEE STEELL AND AND GRE GREY Y CAST CAST-IR -IRON. ON.... ....... ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ .......4 ...42 2

7. 8. 9. 10. 11. 12.. 12

RATES FOR PIP RATES PIPING ING BAS BASED ED ON INC INCH-D H-DIAM IAMETE ETER R (ID) (ID).... ........ ........ ........ ........ ........ ....... ....... ........ ....... ....... ........ .....43 .43 RATES RA TES FOR UNI UNITS TS OF OPE OPERA RATIO TION N - BAS BASED ED ON INC INCH-D H-DIAM IAMETE ETER R (ID) (ID).... ........ ........ ....... ....... ........ ....44 44 RATES RA TES FOR PIP PIPING ING WEL WELDIN DING.. G...... ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ .......4 ...46 6 MAN HOURS HOURS FOR FOR WELDING WELDING OF PIPING PIPING.... ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ......4 ..47 7 WORK WOR K CALCUL CALCULA ATIO TION N - MAN MAN HOURS HOURS FOR FOR PIPIN PIPING G MODIF MODIFICA ICATIO TION N AT AT SITE.. SITE...... ........ ........ .....48 .48 INST IN STAL ALLLATI TION ON OF PI PIPI PING NG AB ABOV OVE E - GR GROU OUND ND Prefabrication and installation breakdown..............................................................49

CHAPTER

II. PIPELINES...................................................................................................50

1. 2. 3. 4. 5. 6. 7. 8. 8.1 8.2 8.3 8.4 8.5 8.6

PIPE TRA PIPE TRANSP NSPOR ORT T.... ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....50 50 PIPE PIP E STRINGIN STRINGING.. G...... ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ......5 ..51 1 BENDIN BEN DING G OF PIPES PIPES... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ .....51 .51 PIPE PIP E JOI JOINTI NTING. NG..... ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ......5 ..52 2 WELDIN WEL DING.. G...... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .......5 ...53 3 WRAPPI WRA PPING. NG..... ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ...53 53 LAYIN LA YING G IN TRENCH. TRENCH.... ....... ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... .....5 ..53 3 SPECIA SPE CIALL POI POINTS NTS... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ......5 ...54 4 BORING BOR ING UNDER UNDER ROADS ROADS AND RAI RAILRO LROADS ADS... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....54 54 BREAK BRE AK OUT OF ROA ROADS. DS.... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....54 54 CONNEC CON NECTIN TING G PIP PIPELI ELINE NE SEC SECTIO TIONS. NS..... ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....54 54 CROSSING CROS SING WA WATERC TERCOURSE OURSES..... S............ ............... ............... ............... ............... ............... ............... .............. ............... ............... ..........55 ...55 INSTALA INST ALATION TION OF CLEAN CLEANING ING ST STA ATIONS TIONS....... ............... ............... .............. ............... ............... ............... ............... ..............5 .......55 5 PUTTIN PUT TING G UP PIP PIPELI ELINE NE MAR MARKER KERS.. S...... ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ......5 ..55 5

8.7 9. 10.

OTHER SPECI OTHER SPECIAL AL POINT POINTS.... S........... ............... ............... .............. ............... ............... ............... ............... ............... ............... ............... .........55 .55 PRESS PRE SSURE URE TES TESTS TS.... ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....56 56 PRELIM PRE LIMINA INARY RY AND FINISHIN FINISHING G WOR WORKS KS.... ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ .....56 .56 4

 

CHAP APTE TER R CH

III. II I. ST STEE EEL L STR STRU UCT CTU URE ERE EREC CTI TION ON...................................................................57 1. BASIC MAN HOURS - UNIT ...........................................................................57

1.1 1.2 1.3 1.4 1.5 1.6

SORTING SORTIN G THE STR STRUCT UCTURE URE... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ....57 57 PRE-ER PRE -ERECT ECTION ION OF STR STRUCT UCTURE URE.... ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ .......5 ...57 7 TRANSP TRA NSPOR ORT T OF STRUCTUR STRUCTURE E TO ERECTIO ERECTION N PLACE.. PLACE..... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ .....57 .57 INSTALL INST ALLA ATION OF ANCHO ANCHOR R BOL BOLTS.. TS.......... ................ ............... ............... ................ .............. .............. ............... ............... ..........57 ..57 STRUCT STR UCTURE URE ERE ERECTI CTION. ON..... ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ...57 57 INSTALL INST ALLA ATION OF LOS LOST T FORM FORMWORK. WORK........ ............... ................ ............... ............... ................ ................ ............... ..............5 .......58 8

1.7 1.7 1.8 1.9

4.1 4.1 4.2 4. 2 4.3 4.4 4. 4

INSTALL INST ALLA ATIO TION N OF WIR WIRE E ROP ROPE E CL CLAMP AMPS.. S...... ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ......5 ..58 8 REAMING REAMI NG OF HOLE HOLES..... S............ ............... ................ ............... .............. .............. ............... ................ ............... ............... .............. .............5 .......58 8 BOLTING BOL TING FROM SCAF SCAFFOLDI FOLDING.... NG........... ............... .............. .............. ................ ............... ............... ................ .............. .............. .........58 .58 2. ERECTION OF MISCELLANEOUS STEEL STRUCTURES.................................59 BASIC MANH MANHOUR OUR RA RATES.. TES......... .............. ............... ................ ............... .............. .............. ............... ................ ............... ............... ...........59 ...59 3. CORRECTION FACTORS................................................................................59 4. STEEL STRUCTURES IN OIL REFINERIES AND PETROCHEMICAL PLANTS ...61 LIGHT LIG HT STR STRUCT UCTURE URE (to 30 kg/ kg/m). m).... ....... ........ ........ ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ......6 ..61 1 MEDIUM MED IUM-W -WEIG EIGHT HT STRUCT STRUCTURE URE (31 ÷ 60 kg/m).... kg/m)........ ........ ........ ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ....61 61 HEAVY STRUCTURE (above 60 kg/m).............................. kg/m)............................................................... .........................................61 ........61 MISCEL MIS CELLA LANEO NEOUS US STR STRUCT UCTURE URES.. S...... ........ ....... ....... ........ ........ ........ ........ ........ ....... ...... ....... ....... ....... ........ ........ ........ ........ ........ ....... ....61 .61

4.5 4. 5

PIPE PIP E HAN HANGER GERS S AND SUP SUPPOR PORTS TS... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....61 .61

2.1

5. ERECTION AND DISMANTLING OF

MISCELLANEOUS STEEL STRUCTURES.............................................................62

5.1 5.2 5.3

ERECTION ERECTI ON OF STEEL STEEL STRU STRUCTU CTURES RES - ACC. ACC. TO THE THE WEIGH WEIGHT T... ....... ........ ........ ........ ........ ....... ....... ........ ......6 ..62 2 MISCELLANEOUS STRUCTURES.............................................................................62 REMOV REM OVAL AL OF STEEL STEEL STRU STRUCTU CTURE RE AND AND MISCEL MISCELLA LANEO NEOUS US ITEMS ITEMS... ....... ........ ........ ........ ........ ....... ....... .....66 .66

CHAP CH APTE TER R

IV.. EREC IV ERECTI TION ON OF OF EQUI EQUIPM PMEN ENT T IN PE PETR TROC OCHE HEMI MICA CAL L INDU INDUST STR  R   Y ....................67 ....................67 1. STATIONARY EQUIPMENT............................................................................67

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1. 7 1.8 1.9

ALL EQU EQUIPM IPMENT ENT TO 0,5 TO TON... N...... ....... ........ ........ ........ ........ ....... ....... ........ ....... ...... ....... ........ ........ ........ ........ ........ ....... ....... ........ ....... ...67 67 TOWERS above 0,5 TON........................................................................................67 TOWE TO WERS RS CONSIST CONSISTING ING OF MOR MORE E PIE PIECES CES.... ........ ........ ........ ........ ........ ....... ....... ........ ........ ....... ...... ....... ........ ........ ........ ......6 ..67 7 PACKAGE PAC KAGE UNIT UNIT....... ............... ................ ................ ............... .............. .............. ............... ................ ............... ............... ............... .............. ..........67 ...67 OTHER OTH ER EQUIP EQUIPMENT MENT....... ............... ................ ............... ............... ................ ............... ............... ................ ............... ............... ................ .........67 .67 BRIDGE BRIDG E CRANE CRANES..... S............ ............... ................ ............... ............... ................ ............... ............... ................ ............... .............. .............. ..........67 ...67 LIFTS LIF TS.... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ .....67 .67 ELECTROST ELECT ROSTA ATIC PRECI PRECIPIT PITA ATORS TORS....... ............... ............... .............. ............... ............... ............... ............... .............. .............. .........68 ..68 MARINE MAR INE LOA LOADIN DING G ARM ARMS.. S...... ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... .......6 ...68 8 2. ROTARY EQUIPMENT....................................................................................68 2.1 CENTRIFUG CENTR IFUGAL AL PUMP PUMPS..... S............ ............... ............... ............... ............... ............... ............... .............. ............... ............... ............... ............68 ....68 2.1. 2. 1.1 1 MA MAN N HOU HOURS RS BA BASE SED D ON ON POW POWER ER [kW]....................................................................68 2.1. 2. 1.2 2 MA MAN N HOU HOURS RS BA BASE SED D ON WE WEIG IGHT HT [kg]....................................................................69 2.1.3 MAN HOURS BASED ON THE CAPACITY CAPACITY....... ............... ............... .............. ............... ............... ............... ............... ..............6 .......69 9 2.2 COMPRESS COMPRE SSORS ORS.... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .....7 .70 0 2.2.1 COMP COMPRESS RESSORS ORS DRIVEN DRIVEN BY ELEC ELECTRIC TRIC MOTOR..... MOTOR............ .............. ............... ............... ............... ............... .............. .......70 70 2.2.2 COMP COMPRESS RESSORS ORS DRIV DRIVEN EN BY GAS TURBINE........ TURBINE............... ............... ............... ............... ............... .............. ............... ..........70 ..70 5

 

3.

TOWERS

&

VESSELS

-

INSTALLATION

OF

INTERIOR

COMPONENTS & EQUIPMENT...........................................................................71

3.1 3.2 3.3 3.4 4.1

INSTALL INST ALLA ATIO TION N OF TRAYS TRAYS AND DEM DEMIST ISTERI ERING NG PADS.. PADS..... ....... ........ ........ ........ ........ ........ ........ ........ ........ ....... ...... ...71 71 VESSELS VESS ELS & TOW TOWER ER PA PACKINGS CKINGS........ ................ ................ ............... ............... .............. .............. ............... ............... ................ ........... ...71 71 OPENIN OPE NING G AND CLOSING CLOSING OF MAN MANHOL HOLES ES.... ....... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ....... ....... ........ ....71 71 ERECTI ERE CTION ON OF PLATFO PLATFORMS RMS,, LADDER LADDERS S AND FLOOR FLOOR GRIDS GRIDS.... ....... ....... ........ ........ ........ ........ ........ ........ ........ ....72 72 4. EQUIPMENT SCAFFOLDING.........................................................................72 TUBULAR TUBUL AR SCAF SCAFFOLD FOLD........ ................ ............... ............... ............... .............. ............... ............... ............... ............... ............... ............... ..........7 ...72 2

4.2

PATENT PA TENT SCAFF SCAFFOLDIN OLDING..... G............. ................ ............... .............. .............. ............... ................ ............... ............... ............... .............. .........73 ..73

CHAP CH APTE TER R

V. ST STORA ORAGE GE TA TANK NKS S - CY CYLI LIND NDRIC RICAL AL AND SP SPHE HEROI ROIDA DAL L.................................74

1. 1.1 1. 1 2. 2.1 2.2 2.3 2.4

APPROX APPR OX.. WEIG WEIGHT HTS S AND AND EREC ERECTI TION ON EFF EFFEC ECTS TS OF OF CYLI CYLIND NDRI RICA CALL STOR STORAG AGE E TAN TANKS KS.. ..... ..... ...7 .74 4 STA ST ATI TIST STIC ICAL AL PAR ARTI TICI CIP PATI TION ON OF ST STOR ORAG AGE E TAN TANK  K  COMPONENTS IN TOTAL WEIGHT..........................................................................75 ERECTI ERE CTION ON OF CYL CYLIND INDRIC RICAL AL ST STORA ORAGE GE TANK ANKS S - DET DETAIL AILS.. S..... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....76 76 PRELIMINAR PRELI MINARY Y WORK WORKS..... S............ ............... ................ ............... ............... ................ ............... ............... ................ ............... .............. .........76 ..76 STORAGE STO RAGE TANK BOT BOTTOM TOM....... ............... ............... ............... ................ .............. .............. ............... ............... ................ .............. ........... .....76 76 STORAGE STO RAGE TANK SHEL SHELL..... L............. ............... ............... ............... .............. ............... ............... ............... ............... ............... ............... ..........7 ...77 7 WIND WIN D BINDING BINDINGS S - RINGS FOR FOR SHELL SHELL STIFFEN STIFFENING ING.... ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ...77 77

2.5 2.6 2.7 2. 7 2.8 2.9 2.10 3.

FIXED ROOF ROOF........ ............... ............... ............... ............... ............... .............. ............... ............... ............... ................ .............. .............. ................ ........78 78 FLOATING FLOA TING ROOF ROOF........ ............... ............... ................ ............... .............. .............. ............... ................ ............... ............... .............. .............. ..........79 ..79 AUXILI AUX ILIAR ARY Y ST STRUC RUCTUR TURE.. E..... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ...... ....... ........ ........ ....... ....... ........ ........ ........ ....... ....... ....... ....80 .80 CONNEC CON NECTIO TIONS NS AND OPE OPENIN NINGS GS.... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ....... ....... ........ ........ ....... ....... ........ ........ ........ .....81 .81 STORAGE STO RAGE TANK EQUIP EQUIPMENT MENT........ ................ ............... ............... ................ .............. .............. ............... ............... ................ ..............8 ......82 2 FINISHING FINIS HING WORK WORKS...... S.............. ............... ............... ............... ............... ................ ............... ............... ............... ............... ................ .............8 .....83 3 ERECTI ERE CTION ON OF SPH SPHERI ERICAL CAL AND SPH SPHERO EROIDA IDALL ST STORA ORAGE GE TANK ANKS.. S..... ....... ........ ....... ....... ........ ........ .......8 ...84 4

CHAP CH APTE TER R

1. 2. 3. 4. 5. CHAP CH APTE TER R

1. 2. 3. CHAP CH APTE TER R

1. 2.

VI.. WEL VI WELDI DING NG AN AND D FLA FLAME ME CU CUTT TTIN ING G................................................................85

MANUAL ARC WEL MANUAL WELDIN DING G OF OF CYLI CYLINDR NDRICA ICALL TANK TANKS S - SM SMAW AW... ....... ........ ........ ....... ....... ........ ........ ........ ....... ......8 ...85 5 SUBMER SUB MERGED GED ARC WEL WELDIN DING.. G...... ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....90 90 WELDIN WEL DING G WITH WITH SEM SEMIAU IAUTO TOMA MATIC TIC (GM (GMAW AW).. )...... ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ .....95 .95 WELDIN WEL DING G OF SPH SPHERI ERICAL CAL ST STORA ORAGE GE TANK ANKS.. S...... ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ .......1 ...100 00 MANUAL MAN UAL GAS CUT CUTTIN TING G AND GAS CON CONSUM SUMPTI PTION. ON.... ....... ........ ........ ........ ....... ....... ........ ........ ....... ...... ....... ........ ....102 102 VII. VI I. CO CORR RROS OSIO ION N PR PROT OTEC ECTI TION ON......................................................................103

SAND BLA SAND BLASTI STING NG AND PA PAINT INTING ING OF PIP PIPING ING.... ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ....103 103 SAND SAN D BL BLAST ASTING ING AND PA PAINT INTING ING OF STE STEEL EL STR STRUCT UCTURE URES.. S..... ....... ........ ........ ........ ....... ....... ........ ........ ......1 ..104 04 SAND SAN D BLA BLASTI STING NG AND PA PAINT INTING ING OF ST STORA ORAGE GE TANK ANKS.. S..... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ...105 105 VIII VI II.. TH THER ERMA MAL L IN INSU SULA LATI TION ON..........................................................................106

THERMALL IN THERMA INSUL SULA ATIO TION N FO FOR R PIPIN PIPING.. G...... ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ......1 ..106 06 THERMA THE RMALL INSU INSULA LATIO TION N OF OF VES VESSEL SELS S AND AND KIL KILNS. NS..... ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....10 .108 8

6

 

CHAPTER

IX. ESTIMATES.................................................................................................109 1. ESTIMATE OF SCAFFOLDS...........................................................................109

1. 2.

ESTIMA ESTI MATE TES S OF SCA SCAFF FFOL OLDI DING NG WHE WHEN N CONT CONTRA RACT CTED ED TO TO A SPEC SPECIA IALI LIST ST FIR FIRM. M... ..... ..... ....1 ..109 09 ESTIMA EST IMATE TE OF SCA SCAFFO FFOLDI LDING NG WHE WHEN N DON DONE E BY AN ERE ERECTI CTION ON COM COMP PANY ANY.... ....... ....... ........ ......1 ..110 10 2. ESTIMATE OF WELDING ROD CONSUMPTION  AND ADDITIONAL WELDING MATERIAL ........................................................112

1. 2.

PIPING.... PIPING ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ......1 ..112 12 STEEL STE EL STR STRUCT UCTURE URES.. S...... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....11 .113 3

3. 4.

CYLINDRIC CYLIND RICAL AL STORA STORAGE GE TANK TANKS.. S...... ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ....113 113 EQUIPM EQU IPMENT ENT IN PETR PETROCH OCHEMI EMICAL CAL IND INDUS USTRY TRY.... ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ .....11 .113 3 3. ESTIMATE OF CONSUMPTION OF TECHNICAL GAS AND GRINDING PLATES..........................................................................114 4. ESTIMATE OF ELECTRICITY CONSUMPTION.............................................115 5. ESTIMATE OF CONSUMPTION OF FUEL AND LUBRICANT .........................116

1. 2.

10.1 10.2 10.3

FUEL CONSUMP FUEL CONSUMPTIO TION.. N...... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ......1 ..116 16 LUBRIC LUB RICANT ANT CON CONSUM SUMPTI PTION. ON..... ........ ........ ........ ........ ........ ........ ....... ....... ....... ....... ........ ........ ........ ........ ........ ........ ....... ....... ........ ....... ...116 116 6. TOOL COST ESTIMATE AT THE JOB SITE ...................................................117 7. ESTIMATE OF SAFETY AT WORK MEANS...................................................117 8. ESTIMATE OF ERECTION TIME ...................................................................117 9. SELECTION OF HOISTING MACHINERY .....................................................118 .....................................................118 SELECT SEL ECTION ION OF TH THE E LA LARGE RGEST ST CRANE.... CRANE........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ......1 ..119 19 PIPING PIPIN G IN PLAN PLANTS.. TS.......... ................ ............... ............... ............... .............. ............... ............... ............... ................ .............. .............. ..........119 ..119 PIPING PIP ING BET BETWEE WEEN N PL PLANT ANTS. S..... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ......1 ..120 20 PIPELIN PIPE LINES. ES..... ........ ......... ......... ........ ........ ......... ......... ........ ......... ......... ........ ......... ......... ........ ......... ......... ........ ......... ......... ........ ......... ......... ........ .....12 .120 0 ERECTI ERE CTION ON OF STE STEEL EL ST STRUC RUCTUR TURE.. E..... ....... ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ......1 ...120 20 INSTALL INST ALLA ATION OF PROCE PROCESS SS EQUIP EQUIPMENT MENT........ ............... ............... ............... ............... ............... .............. ............... .........120 .120 ERECTI ERE CTION ON OF CYL CYLIND INDRIC RICAL AL STORAGE STORAGE TANKS TANKS.... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ........ .....12 .120 0 10. UNLOADING, HANDLING AND SORTING OF THE MATERIAL .....................121 MATERIA MA TERIALL FOR FOR PIPING. PIPING........ ............... ............... ............... ................ ............... ............... ............... ............... ................ ............... ..........121 ...121 STEELL STRUC STEE STRUCTURE TURE........ ............... ............... ................ ............... ............... ............... ............... ................ ............... ............... ............... .........121 ..121 PROCESS PROCE SS EQUIPMENT EQUIPMENT........ ............... ............... ............... ............... ............... .............. ............... ............... ............... ................ .............. ......121 121

10.4

CYLINDRICA CYLIN DRICALL STORAGE STORAGE TANKS ANKS....... ............... ............... ............... ................ .............. .............. ............... ............... ................ ........121 121

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9. 7

11. TEMPORARY WORKS, SPACE REQUIRED  AND CONNECTIONS AT THE SITE ...................................................................122

1. 2. 3.

TEMPORARY TEMPOR ARY WORKS WORKS... ....... ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....122 122 AREA ARE A NEE NEEDED DED.... ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... .....12 .123 3 CONNEC CON NECTIO TIONS NS NEEDE NEEDED. D.... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ......1 ..123 23 12. ESTIMATE OF THE NUMBER OF WELDS  AND RADIOGRAMS FOR PIPING....................................................................124

1. 2.

ESTIMA ESTI MATE TE OF BU BUT TTW TWEL ELDS DS BA BASE SED D ON ON A LI LIST ST OF MA MATE TERI RIAL AL - PIPES, FITTINGS AND FLANGES.........................................................................124 ESTI ES TIMA MATE TE OF BU BUT TTW TWEL ELDS DS BA BASE SED D ON ON A LI LIST ST OF MA MATE TERI RIAL AL

3. 4. 5.

- FITTINGS AND FLANGES ONLY ONLY............................ ............................................................ ...............................................124 ...............124 ESTIMA EST IMATE TE OF BUT BUTTWE TWELDS LDS BAS BASED ED ON TH THE E PIPI PIPING NG LEN LENGTH GTHS.. S...... ........ ........ ....... ....... ........ ........ .......1 ...125 25 ESTIMA EST IMATE TE OF OF TOT TOTAL AL WELD WELDS S (ALL (ALL TYPE TYPES). S).... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ......1 ..125 25 ESTIMA EST IMATE TE OF RAD RADIOG IOGRAM RAMS S ON ON THE THE PIP PIPING ING... ....... ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ...125 125 7

 

CHAPTER

1.1 1.2 1.3 2.1 2.2 2.3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3. 7 3.8

X. PIP IPIN ING G ABOVE GRO ROU UND

EXPLANATION TO THE ERECTION ITEMS............................................................127 1.0 PIPING......................................................................................................127 PIPE INST INSTALL ALLAT ATION ION IN PLAN PLANTS... TS.......... ............... ............... ............... ................ ............... ............... ............... ............... ...........127 ...127 PIPE INST INSTALL ALLA ATION ON PIPER PIPERACKS. ACKS......... ............... ............... ............... ............... ................ ............... ............... ............... .......127 127 PIPE PIP E DIS DISMAN MANTLI TLING. NG..... ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ....127 127 2.0 FITTING.....................................................................................................127 ADJUST ADJ USTMEN MENT T OF FITTIN FITTINGS GS WITH WITH ONE ONE CONNEC CONNECTIO TION N END... END....... ........ ....... ....... ........ ........ ........ ....... ......1 ...128 28 ADJUSTMEN ADJUST MENT T OF FIT FITTIN TINGS GS WITH WITH TWO TWO CONNEC CONNECTIO TION N ENDS. ENDS..... ........ ........ ........ ....... ....... ........ ........ ....128 128 ADJUST ADJ USTMEN MENT T OF FI FIT TTIN TINGS GS WITH WITH THREE THREE CONN CONNECT ECTION ION ENDS ENDS... ....... ........ ........ ....... ....... ........ ........ ....128 128 3.0 PIPEWELD MAKE-ON AND WELDING .......................................................128 BUTT BUT T WE WELD LD MAKE-ON MAKE-ON AND WEL WELDIN DING.. G...... ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ .......1 ...128 28 FILLET FIL LET (SOC (SOCKET KET)) WELD WELD - PERFORM PERFORMANC ANCE E AND WELDI WELDING. NG.... ....... ........ ....... ....... ........ ........ ....... ....... ....... ....12 .128 8 MITRE MIT RE WELD MAKE-ON MAKE-ON AND WEL WELD. D..... ........ ....... ....... ........ ........ ........ ....... ....... ........ ....... ....... ........ ....... ....... ........ ........ ........ .....12 .129 9 NOZZLE NOZ ZLE WELD WELD MAK MAKE-O E-ON N AND WELDIN WELDING.. G...... ........ ....... ....... ....... ....... ........ ........ ........ ....... ....... ........ ........ ....... ....... ....... ....12 .129 9 WELDOLET WELD OLET,, NIPOL NIPOLET ET - INST INSTALL ALLA ATION AND WELD WELDING... ING........... ............... ............... ............... ............... .........129 .129 REINFO REI NFORCE RCEMEN MENT T PAD MAKE-ON MAKE-ON AND WELDIN WELDING.. G...... ........ ....... ....... ........ ........ ........ ....... ...... ....... ........ ........ ........ ....129 129 SEALL RING SEA RING MAKE-O MAKE-ON N AND WELD WELDING ING (ACC (ACC.. TO DIN DIN 2695) 2695).... ........ ........ ........ ....... ....... ........ ........ ........ ......1 ..129 29 INSER INS ERT T RIN RING G (FO (FOR R AL ONL ONLY). Y).... ....... ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... .....1 ..130 30

3.9 3.10

WELD CUT WELD CUTTIN TING G FOR MOD MODIFI IFICA CATIO TIONS. NS.... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ...130 130 MATERIA MA TERIALL MULTIPL MULTIPLIER IER FACT FACTORS ORS (f)............ (f)................... ............... ............... ............... ................ ............... ............... ...........130 ...130 4.0 FLANGED AND THREADED JOINTS, BENDING OF PIPES..........................130 4.1 ÷ 4.3 FLANG FL ANGED ED JOINT.... JOINT........ ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... .......1 ...130 30 4.4 INST INS TALL ALLA ATIO TION N OF OF MEAS MEASURI URING NG ORI ORIFIC FICES, ES, BL BLANK ANKING ING PL PLA ATES TES,, etc. etc..................... ....130 4.5 PIPE BENDING....................................................................................................130 4.6 PREP PR EPA ARA RATI TION ON OF TH THRE REA ADE DED D END NDS S....................................................................131 4.7 THREADED CONNECTION MAKE-ON....................................................................131 4.8 DISAS DIS ASSEM SEMBLI BLING NG Item 4.1 ÷ 4.4 and 4.7.... 4.7........ ....... ....... ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ....131 131 5.0 VALVES......................................................................................................131 5.1 VALVE IN INSTALLATION (WITH AND WITHOUT HAND DRIVE)..................................131  VALVE  VAL VE INSTALLA INSTALLATION TION WITH ACTUATORS 5.2 ACTUATORS (SOLENOID, AIR)...................................131 AIR)........................ ...........131 5.3 BUTTERFLY  VAL  VALVE VE INSTALLATION INSTALLATION WITH ACTUATOR.............................................131 5.4 BUTTERFLY  VAL  VALVE VE INSTALLATION INSTALLATION........................................................................131 5.5 CONTROL  VAL  VALVE VE INST INSTALLA ALLATION TION..........................................................................131 5.6 SAFET Y  VAL  VALVE VE INST INSTALLA ALLATION TION.............................................................................132 5.7 H YDRANT INSTALLATION....................................................................................132 5.8 SPINDL SPI NDLE E EXT EXTENS ENSION IONS.. S..... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... .......1 ...132 32 5.9 DISMANTLI DISM ANTLING NG OF VA VALLVES... VES........... ............... ............... ................ ............... ............. .............. ................ ................ ............... ............13 .....132 2 6.0 PRESSURE TESTING..................................................................................132 6.1 PRESSURE PRES SURE TEST TEST........ ................ ............... ............... ............... .............. ............... ............... ............... ................ ............... .............. .............. ........132 .132 6.2 SERVICE SERVI CE TEST TEST....... ............... ................ ............... ............... ............... ............... ................ ............... ............... ............... ............... ................ ..........132 ..132

8

 

7.0 MISCELLANEOUS.......................................................................................132

7.1 7.2 7.3 7.4 7.5 8.1

SUPPORTS SUPPOR TS - FABR ABRICA ICATIO TION N AND WELDING WELDING.... ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... .....1 ..132 32 SUPPORT SUPPO RT INST INSTALL ALLA ATION (WIT (WITHOUT HOUT FA FABRICA BRICATION) TION)....... ............... ............... ............... ................ .............. .......132 .132 INST INS TALL ALLA ATIO TION N OF SPRING SPRING HANGERS HANGERS AND SUSPE SUSPENSI NSIONS ONS.... ........ ........ ....... ....... ........ ........ ........ ........ ......1 ..133 33 GRINDI GRI NDING NG OF EXCES EXCESS S MATER MATERIAL IAL ON WELDI WELDING NG ROOTS ROOTS.... ........ ........ ........ ........ ........ ....... ....... ........ ........ .....13 .133 3 INSTRU INS TRUMEN MENT T CON CONNEC NECTIO TION N - DRI DRILLI LLING. NG..... ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ....133 133 8.0 ACTIVITIES DERIVED FROM BASIC ITEMS .............................................133 PIPES...............................................................................................................133

8.1.1 PIPE HAND HANDLLIN LLING G AND AND CUT CUTTING TING IN PREF PREFABRICA ABRICATION TION...........................................133 8.1.2 INST INSTALL ALLA ATION OF PREF PREFABRICA ABRICATED TED SPOOL SPOOLS S.........................................................133 8.1. 8. 1.3 3

SPA SP ATI TIAL AL SHI SHIFT FTIN ING G OF PIP PIPES ES...............................................................................133

8.1.4

MAKE-ON OF OUTSIDE PIPE FOR A DOUBLE-WALL PIPING (JACKETED PIPING)................................................................................134

8.1.5 8.1 .5 MAKE-O MAKE-ON N AND INST INSTALL ALLA ATIO TION N OF LINE LINE PIPIN PIPING G DN 20/25 ON JACKETED PIPING..........................................................................134 8.2 MIS ISC CELLANE NEO OUS FIT ITT TINGS............................................................................134 8.2.1 HALF COUPL COUPLINGS INGS....... ............... ................ ................ ................ ............. ............. ................ ................ ................ ............... ............. .............1 .......134 34 8.2.2 WELD COMP COMPENSA ENSATOR TOR........ ................ ................ ............... ............... ............... ............... ................ ................ ................ ............. ...........1 ......134 34 8.2.3 WELD METER RUNS.............. RUNS..................... ............... ................ .............. ............. ............... ................ ................ ................ ............. ..........13 .....134 4 8.2.4 PREFABRICA PREFABRICATED TED OF SPOOLS FOR WELDING... WELDING.......... ............... ................ ................ ................ ................ ...............1 .......134 34 8.2.5 MEAS MEASURING URING ORIFICES ORIFICES - MEASURING MEASURING FLANGES FLANGES........ ................ ............... ............... ................ ................ .............13 .....135 5 8.3 WELDING.............. ............................. ............................. .......................... .......................... ............................ ........................... .....................13 ........135 5 8.3.1 TACK WELDING ON VAL VALVE VE SIMU SIMULA LATORS TORS....... ............... ............... ............... ............... .............. ............... ............... ..........13 ...135 5 8.3.2 LONG LONGITUD ITUDINAL INAL WELDS WELDS ON PIPE HALF SHELLS SHELLS........ ............... ............... ............... ............... ............... .............. .......135 135 8.3.3 THER THERMOME MOMETER TER BRANCH (TI).............. (TI)..................... ............... ............... ............... ............... .............. ............... ............... ...........13 ....135 5 8.3.4 PREF PREFABRIC ABRICAT ATED ED WELDS WELDS AT INST INSTALL ALLA ATION OF PREFABRICATED SECTIONS (SPOOLS).................................................................135 8.4 FLANGED JOINTS............................................................................................135 8.4.1 8.4. 1 REPL REPLACEME ACEMENT NT OF BOL BOLTS.. TS.......... ................ ............... ............... ............... .............. ............... ............... ............... ............... .............. .......135 135 8.5 VALVES.............................................................................................................136 8.5.1 ROT ROTAT ATING ING THE VAL VALVE VE INST INSTALL ALLA ATED TED....... ............... ............... ............... ............... ............... ............... .............. ............... .........136 .136 8.5.2 EXP EXPANSIO ANSION N JOINTS WITH FLANGED FLANGED ENDS..... ENDS............. ............... ............... ............... .............. ............... ............... .........136 ..136 8.6 WALL PASS FOR PI PIPES...................................................................................136 8.7 MISCELLANEOUS.............................................................................................136 8.7.1. 8.7 .1. FA FABRICA BRICATION TION AND INSTALL INSTALLAT ATION ION OF PIPE HOLDERS, HOLDERS, HANGERS, AND SUPPORTS (to 100 kg per item)...................................................136 8.7.2 8.7 .2 DISM DISMANTLI ANTLING NG OF PIPE HOLDERS HOLDERS,, HANGERS, HANGERS, AND SUPPOR SUPPORTS... TS.......... ............... ................ .............13 .....136 6 8.7.3 8.7 .3 HOLE DRILLING DRILLING IN CONCRETE..... CONCRETE............ ............... ................ ............... .............. .............. ............... ................ ............... ...........13 ....136 6 8.8 EXTRAS............................................................................................................136 8.8.1 8.8 .1 CHA CHANGE NGE IN BILL BILL OF QUAN QUANTIT TITIES IES BEF BEFORE ORE THE CLIENT'S APPROVAL FOR FABRICATION..............................................................136 8.8.2 8.8 .2 CHA CHANGE NGE IN ISO ISOMET METRY RY PRI PRIOR OR TO THE CLIENT'S APPROVAL FOR FABRICATION...............................................................136

9

 

8.8.3 .3 HAND HAND DRAF DRAFTIN TING G OF ISO ISOMET METRY RY ACC ACCORD ORDING ING 8.8  TO THE CLIENT'S INSTRUCTION...................................................................... INSTRUCTION..................................... .....................................137 ....137 8.8.4 INST INSTALL ALLA ATION OF MISS MISSING ING MA MATERIA TERIAL..... L............. ............... ............... ................ ................ ............... ............... ..............1 ......137 37 8.8.5 PIPING MODIF MODIFICA ICATION. TION......... ............... ............... ................ ............... ............... ................ ............... ............... ................ ................ .........137 .137 8.8.6 SAND BLASTIN BLASTING G HANDLING, HANDLING, PRIMER PRIMER COAT COAT ON PIPING, PIPING, AND PIPE SUPPOR SUPPORTS... TS........... ........137 137 8.8.7 8.8. 7 UNDER UNDERGROUN GROUND D PIPING PIPING........ ............... ............... ................ ............... ............... ................ ............... ............... ................ .............. .........137 ...137 8.8.8 8.8 .8 FACT ACTORS ORS FOR FOR CALCUL CALCULA ATIO TION N OF MAN MAN HOURS HOURS FOR  FOR  PREFABRICATION AND INSTALLATION OF PIPING................................................138 TABLE Item. 3.10 MULTIPL. FACTORS FOR DIFF. KIND OF MATERIALS .................139 FORMS FOR CALCULATION OF MAN HOUR RATES ...................................................142

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0

PIPES..... PIPES. ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .....14 .142 2 FITTIN FIT TINGS. GS..... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .......1 ...142 42 FLANG FL ANGES. ES..... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....143 143 SMALL SM ALL FIT FITTIN TINGS. GS..... ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ .....14 .143 3 VALLVES VA VES... ....... ........ ........ ........ ........ ....... ....... ........ ....... ....... ....... ...... ....... ....... ....... ....... ....... ....... ....... ........ ....... ....... ....... ...... ....... ....... ....... ....144 144 PIPE PIP E EXPANS EXPANSION ION JOINT JOINTS S AND FLOW FLOWRA RATE TE METER METERS.. S...... ........ ........ ....... ....... ........ ....... ....... ........ ....145 145 OTHER OT HER INS INST TALL ALLA ATIO TION N WOR WORKS. KS..... ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....14 .145 5 ESTIMA EST IMATE TE POIN POINTS TS FOR FOR BUIL BUILDD-IN IN ITEM ITEMS S OF A. A. G. PIPI PIPING. NG.... ....... ........ ....... ....... ........ ......1 ..147 47

CHAPTER

XI. WE WEIGHT FA FACTORS.....................................................................................203

CHAP CH APTE TER R

XII. XI I. TEC TECHN HNIC ICAL AL CA CALC LCUL ULAT ATIO ION N MANN MANNER ER OF OF DATA DATA COMP COMPIL ILING ING..................210

CHAP CH APTE TER R

XIII. XI II. MA MAN N HOUR HOURS S FOR FOR OVER OVERHA HAUL ULS S IN PE PETR TROC OCHE HEMI MICA CAL L PLA PLANTS NTS..............214

1. 2. 3. 4.

1. 2. CHAP CH APTER TER

PIPING.... PIPING ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ......2 ..203 03 STEEL STE EL STRUCTUR STRUCTURES. ES..... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ........ .....20 .206 6 PROCES PRO CESS S EQU EQUIPM IPMENT ENT.... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ...208 208 CYLIND CYL INDRIC RICAL AL STORA STORAGE GE TANK TANKS.. S...... ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ...209 209

PIPING ERE PIPING ERECTI CTION ON AND DIS DISMAN MANTLI TLING. NG.... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ .....21 .214 4 MAN MA N HOUR HOURS S FOR FOR OVER OVERHA HAUL UL OF OF EQUI EQUIPM PMEN ENT T IN PET PETRO ROCH CHEM EMIC ICAL AL PLA PLANT NTS. S... .... ..... ..... ...2 .229 29 XIV.. FAC XIV FACTO TORS RS AN AND D MAN MAN HO HOUR URS S FOR FOR PI PIPI PING NG AN AND D STEE STEEL L STRUCTURE WORKS IN CALL FOR TENDERS OF "TECHNIP" COMPANY ......230 ......230

 A. B. CHAPTER

1. 2. 3. 4. 5.

PIPING BETWEEN PLANTS AND IN PLANTS................................ PLANTS...........................................................230 ...........................230 STEEL STE EL STR STRUCT UCTURE URE ERE ERECTI CTION. ON.... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ......2 ..232 32 XV. APPENDIX..................................................................................................233  

ISO R7 DIN 244 2448/2 8/2458 458 SUM SUMMAR MARY Y OF OF PIP PIPE E SCH SCHEDU EDULED LED SIZ SIZES. ES..... ........ ........ ....... ....... ........ ........ ......2 ..233 33 ANSII B 36. ANS 36.10 10 SUM SUMMAR MARY Y OF PIP PIPE E SCH SCHEDU EDULED LED SIZ SIZES. ES.... ....... ........ ........ ....... ....... ........ ........ ........ ....... ....... ......2 ..235 35 PIPE PIP E AND AND FIT FITTIN TINGS GS DIM DIMENS ENSION IONS S - TABL ABLE E MANU MANUAL. AL.... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ......2 ...236 36 STEE ST EELL STR STRUC UCTU TURE RE - SU SURF RFAC ACES ES OF OF SECT SECTIO IONS NS in in m2/m /m.. ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ...23 237 7 CONVER CON VERSIO SIONS NS BET BETWE WEEN EN ENG ENGLIS LISH H AND (SI (SI)) ST STAND ANDARD ARDS S UNI UNITS TS.... ........ ........ ........ ....... ....... .......2 ...238 38

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 PERCENT PERCENTAGES AGES (PEP (PEP,, Leistungsfähigkeit - Prozentsatz), but to precisely determined deter mined below stated PEPs.  The standard ranges of productivity efficiency percentages are: 1. Very low 10 2. Low 41 3. Average 61 4. Very good 81 5. Excellent 91 6. Ex Extraordinary 101

÷ ÷ ÷ ÷ ÷ ÷

40 % 60% 80% 90% 100% 120%

Man hours in this Manual refer to the following Productivity Efficiency Percentages:

1. PIPING ABOVE GROUND IN PLANTS 1.1 Calculation based on the estimate points of basic erection items and man hours and effects effects derived thereby PEP PE P = hig high h av aver erag age e 80 80% % 1.2 Calculation based on man hours and effects for quick calculation and special man hours PEP PE P = hig high h av aver erag age e 75 75% % 1.3 Calculation based on man man hours for piping piping per inch - diameter (ID) PEP PE P = hig high h av aver erag age e 80 80% % 1.4 Calculation based on man hours for units of operation PEP = very good

85 %

2. PIP PIPELI ELINES NES PEP PE P = hig high h av aver erag age e 75 % 3. STEEL STRUC STRUCTURES TURES PEP PE P = hig high h av aver erag age e 75 % 4. PROCE PROCESS SS EQUIPMENT EQUIPMENT IN PLANTS PLANTS PEP = average

70%

5. CYLINDRICAL STORAGE TANK TANKS S PEP = very good

85 %

6. WELD WELDING ING AND CUTTING CUTTING PEP = average

70 %

7. CORROSION PROTECTION PEP PE P = hig high h av aver erag age e 80 % 8. THERMAL INSULATION PEP = very good

85 % 11

 

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. P. this is a leading l eading element, which I shall not consider) 1. 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 h igh and dry? Does it involve a plant already in operation? Will 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 Estim ate the perce percentage ntage accord according ing to PEP table. When we have consid considered ered and analy analysed sed 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. 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.

12

 

 ABBREVIATIONS  ABBREVIATIONS & UNITS

PEP = Productivity efficiency percentage Mhr = Man Hours mm = millimeters = 0.03937 inches m = linear meters = 3.281 feet km = kilometers = 0.6214 miles m2 = square meters meters = 10.76 10.764 4 feet m3 = cubic meters meters = 35.314 35.314 feet feet ft = linear feet = 0.3048 meters l = liters = 61.023 cu inches = 0.03531 cu feet = 0.2642 u.s. gal kg = kilogram = 2.2046 lbs lbs = pound = 0.4536 kg t or ton = metric tons = 1000 kg ea = each pc = piece PN = pressure nominal or NP bar = 14.5 psi ( lb/sq in) Dn = diametar nominal OD or do = outer diametar ID = inch diametar MID = meter inch diametar t = thickness mm  V = volume max. = maximum min. = minimum ø = phi (Greek) = round kW = kilowatts = 1.341 horse power kWh = kilowatthours kVA = kilovoltampers kg/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).

13

 

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%

    1. PIPES (ANSI B 36.10) 1.1 PIPE INSTALLATION ON PROCESS PLANT

  Dn-mm ø-Inch OD-mm Sch 10   15 1/2” 21,3   20 20 3/4” 26,7 0,41   25 1” 33,4 0,45 0,   32 32 1 1/4” 42,2 0,48   40 40 1 1/2” 48,3 0,50   50 2” 60,3 0,53 0,   65 2 1/2” 73 0,59   80 3” 88,9 88 0,64

1   4  

                                   

100 125 150 200 20 2 50 25 300 350 400 4 50 500 5 50 600 650 65 7 00 70 7 50 75 800 80 850 85 900 90

4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24” 26” 2 8” 28 30” 32” 34” 36”

114,3 141,3 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 81 864 86 914 91

Sch 20

Sch 30

[Mhr/m]

Std

00,,69 0,78 0, 1,32 1,57 1,81 2,23 2,50 2,76 3,39 3,68 3,97 5,18 5,54 5 ,90 5, 6,25 6,60 6,94

1,98 2,21 2,44 2,67 2,90 3,12 3,79 3,79 4,30 4 ,5 6 4, 4 ,8 1 4, 5,06 5,

Man hour included next activities : - handling - on-site transport - prefabrication

CARBON STEEL - NONWRAPPED - ABOVE GROUND Sch 40 Sch 60 XS Sch 80 Sch 100 Sch 120 Sch 140 Sch 160 0,41 0,42 0,43 0,42 0,44 0,47 0,46 0,48 0,52 0,50 0,53 0,57 0,53 0,57 0,62 0,57 0,63 0,74 0,68 0,76 0,85 0,76 0,87 1,02 0,88 1,02 1,14 1,51 1,95

1,49 1,76 2,12 2,49 2,79 3,42 4,11 4,47 5,25

2,28 2,49 2,79 3,09 3,39 3,68 3,97 4,26 4,55 4 ,84 4, 5,13 5,41 5,69

6,51 6 ,94 6, 7,35 7,77 8,18

FOR PREFABRICATION : 8% FOR INSTALLATION : 92%

1,73 2,37 2,97 3,38 4,08 4,98 5,83 6,73 7,90

2,40 2,75 3,37 4,06 4,64 5,24 6,09

7,90 8,35 9,40

1,04 1,22 1,44 1,96 2,37 2,75 3,00 3,37 3,74 4,11 4,47 4,83 5,18 5,54 5,90 6,25 6,60 6,94

2,65 3,42 3,97 4,89 5,90 7,01 8,21 9,50

2,19 3,03 3,95 4,68 5,70 6,95 8,31 9,63 11,44

1,18 1,43 1,69 2,49 3,38 4,48 5,26 6,48 7,95 9,44 11,05 13,15

2,69 3,82 4,90 5,82 7,36 8,81 10,69 12,43 14,66

Sch 5S 0,42 0,43 0,45 0, 0,48 0,49 0,52 0, 0,58 0,62

1,48 1,81 2 ,20 2, 2,83 3,82 4,48

00,,67 0,78 0, 0,83 1,00 1,26 1,54 1,69 1,92 2,11 2,47 2,67 3,10

4,10

  Materials Materials:: - alloy steel - prewrapped - galvanized - aluminium alloy

- e  errection - w  weelding - p  prressure testing

1,31 1,63 1,96 2,90 4,16 5,49 6,36 7,98 9,78 11,78 13,80 16,32

XXS 0,45 0,49 0,55 0, 0,64 0,69 0,81 0, 1,00 1, 1,19

STAINLESS STEEL Sch 10S Sch 40S Sch 80S 0,43 0,44 0,45 0,44 0,46 0, 0,48 0,48 0, 0,50 0,52 0, 0,51 0,54 0,58 0,54 0,57 0,61 0,57 0, 0,62 0,69 0, 0,63 0,74 0,82 0,68 0,82 0,94 0,74 0,84 0,89 1,12 1,38 1,65 1,84 2,05 2,26 2,65 2,88 3,38

0,95 1,10 1,24 1, 1,64 2,12 2,48

1,12 1,33 1 ,5 7 1, 2,14 2,58 2,99

4,66

ø-Inch 1/2”   1/ 3/4”   1”   1 1/4”   1 1/2”   2”   2 1/2”   3”   4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24” 26” 28” 30” 32” 34” 36”

                                   

k 

[Mhr/m] x 1,10 [Mhr/m] x 1,15 (underground install.) [Mhr/m] x 0,70 [Mhr/m] x 0,85

Mhr/m x 0,3048 = Mhr/ft

 

1. PIPES (ANSI B. 36.10) 1.2 INSTALLATION ON PIPE RACK OR SLEEPER WAY

1    5  

Dn-mm ø Inch  15 1/2”  20 3/4”  25 1”  32 1 1/4”  40 1 1/2”  50 2”  65 2 1/2”  80 3” 100 4” 125 5” 150 6” 200 8” 250 10” 300 12” 350 14” 400 16” 450 18” 500 20” 550 22” 600 24” 650 26” 700 28” 750 30” 800 32” 850 34” 900 36”

OD-mm 21,3 26,7 33,4 33 42,4 48,3 60,3 73 88,9 114,3 141,3 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

Sch 10

Sch 20

Sch 30

St d

0,44 00,,48 0,52 0,55 0,60 0, 0,66 0,73 0, 0,81 0,91

2,33 2,61 2,89 3,18 3,46 3,74 4,49 4,81 5,12 5,43 5,74 6,04

1,54 1,85 2,14 2,61 2,93 3,25 3,98 4,34 4,69 6,11 6 ,5 4 6, 6,98 7,41 7,83 8,25

1,72 2,04 2,47 2,90 3,26 3,99 4,81 5,25 6,19 7,73 8,24 8, 8,75 8, 9,26 9,76

Man hour include the next activities: - handling - e  errection - on-site transport - w  weelding - prefabrication - p  prressure

2,65 2,90 3,26 3,62 3,98 4,34 4,69 5,04 5,39 5,75 6,10 6,45 6,79

testing

FOR PREFABRICATION : 8% FOR INSTALLATION : 92%

[Mhr/m]

  Sc h 4 0 0,43 0,45 0,50 0,55 0,58 0,64 0,76 0,85 1,00 1,16 1,31 1,74 2,25 2,78 3,19 3,93 4,75 5,44 6,18 7,22

9,44 10,00 11,32

CARBON STEEL - NONWRAPPED Sch 60 XS Sch 80 Sc Schh 10 1000 0,44 0,47 0,52 0,58 0,62 0,70 0,83 0,96 1,16 1,37 1,64 1,98 2,25 2,52 2,73 2,73 3,07 3,52 3,45 3,18 3,99 4,67 3,93 3,48 4,66 5,58 4,78 3,93 5,81 6,88 5,89 4,37 7,09 8,52 6,94 4,81 8,52 10,35 8,09 5,25 10,10 12,14 9,60 5,68 11,83 14,68 6,11 6,54 6,98 7,41 7,83 8,25

  Materials Materials:: - alloy steel - galvanized - aluminium alloy

Schh 12 Sc 1200

1,31 1,61 1,92 2,88 3,97 5,37 6,36 7,97 9,96 12,01 14,28 17,33

Schh 14 Sc 1400 Sc Schh 16 1600 0,45 0,49 0,55 0,62 0,67 0,80 0,93 1,13 1,46 1,84 2,25 3,14 3,40 4,55 5,01 5,93 6,76 7,15 7,92 9,24 10,17 11,24 12,72 13,92 15,64 16,42 18,64 19,77 22,52

XXS XXS 0,47 0 ,5 2 0, 0,59 0, 0,68 0,75 0,88 1,10 1,32 1 ,6 6 1, 2 ,0 6 2, 2,55 2, 3,32 4,55 5,37

Sch 5S Sch 0,45 0,47 0,50 0,53 0,56 0,60 0,67 0,72 0,80 0,93 1,00 1,22 1,54 1,88 2,05 2,34 2,59 3,00 3,26 3,74

4,93

STAINLESS STEEL Sch 10 Sch 10SS Sc Schh 40 40SS Sc Schh 80 80SS 0,46 0,47 0,48 0,48 0,49 0,51 0,52 0,54 0,56 0, 0,57 0,59 0,63 0,60 0,63 0,67 0,64 0 ,6 9 0, 0,75 0,72 0,82 0,90 0,78 0,92 1,04 1, 0,87 1,08 1 ,26 1, 0,98 1,25 1 ,49 1, 1,06 1,41 1,77 1, 1,34 1,88 2,43 1,66 2,43 2,95 1,98 2,86 3,44 2,21 2,47 2,73 3,19 3,47 4,04

5,54

ø In Inch ch 1/2”   3/4”   1”   1 1/4”   1 1/2”   2”   2 1/2”   3”   4”   5”   6”   8”   10”   12”   14”   16”   18”   20”   22”   24”   26”   28”   30”   32”   34”   36”  

k 

[Mhr/m] x 1,10 [Mhr/m] x 0,70 [Mhr/m] x 0,85

Mhr/m x 0,3048 = Mhr/ft

 

2. FITTINGS (ANSI 36.10) 2.1 ELBOWS [Mhr/ea]

1    6  

DN-mm   15   20   25 25   32   40   50 50   65   80 80   100   125   150   20 200   250   300   35 350   40 400   45 450   50 500   55 550   600   650   700   750   800   850   900

ø-Inch ø-Inch 1/2” 3/4” 1” 1 1/4” 1 1/2” 2” 2 1/2” 3” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24” 26” 28” 30” 32” 34” 36”

OD-mm 21,3 26,7 33,4 42,2 48,3 60,3 73 88,9 114,3 141,3 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

  Sc h 1 0

FOR PREFABRICATION : FOR INSTALLATION:

Sch 20

Sch 30

1,43 1,63 1,88 2,06 2,36 2,73 3,13 3,66 4,24

1100,83 12,30 12 13,77 15,25 16,73 18,21

6,73 8,27 9,75 11,55 13,14 14,71 17,56 19,28 20,99

7,20 8,79 10,65 12,42 14,13 17,08 20,44 22,46 26,42

Std

Sch 40 1,29 1,45 1,65 1,91 2,10 2,43 2,90 3,37 4,03 4,75 5,41 7,26 9,40 11,20 11,62 12,42 13,38 14,13 16,42 15,84 19,86 17,56 22,89 19,28 26,13 20,99 30,69 22,69 24,40 26,12 27,84 29,55 31,24

Sc h 6 0

7,97 10,98 14,00 16,09 19,75 24,60 29,33 34,58 41,71

CARBON CARBO N STEEL XS Sch 80 Sch 100 1,31 1,47 1,69 1,97 2,18 2,54 3,07 3,62 4,44 5,34 6,38 8,87 9,87 10,98 12,25 14,10 13,00 16,17 19,11 14,41 19,13 23,33 16,42 24,23 29,36 18,42 30,12 37,32 20,44 36,90 46,45 22,46 44,59 55,63 24,48 53,24 69,23 26,46 28,48 30,50 32,51 34,53 36,52

[Mhr/ea] x 0,50

2.2 CAPS

Sch 120

Sch 140 S ch ch 160 1,33 1,52 1,75 2,05 2,29 2,80 3,34 4,11 5,39 6,95 8,66 12,42 13,64 18,74 21,04 25,20 29,58 31,24 35,45 41,89 47,23 52,31 61,09 66,97 77,56 80,85 94,82 100,27 118,15

4,91 6,10 7,35 11,31 16,04 22,39 27,16 34,97 45,07 55,74 67,89 85,02

XXS

1,86 2,23 2,50 3,02 3,88 4,76 6,18 7,83 9,94 13,22

Sch 5S 1,60 1,78 2,00 2,31 2,52 2,89 3,34 3,82 4,46 5,21 5,79 7,39 9,22 11,08 12,32 14,09 15,76 17,85 19,57 21,91

28,29

  f  1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

Materials:: Materials

- Cr-Mo alloy steel - Copper alloy - Killed C.S.

85% 15%

STAINLESS STEEL STAINLESS Sch 10S Sch 40S S ch ch 80S 1 ,60 1, 1,62 11,,64 1,79 1,81 1,84 2,04 2,06 2 ,11 2, 2,35 2,39 2,46 2,57 2,63 2,72 2,95 3,03 3 ,17 3, 3,41 3,62 3,84 3,92 4,21 4 ,53 4, 4,57 5,03 5,55 5,30 5,93 6,67 5,90 6,76 7,97 7,63 9,08 11,09 9,48 11,74 13,73 11,33 14,00 16,25 12,69 14,41 16,12 18,36 20,13 22,76

30,27

- High temp. alloy steel - Alloy steel Ni - Aluminium alloy

ø-Inch 1/2”   3/4”   1”   1 1/4”   1 1/2”   2”   2 1/2”   3”   4”   4” 5”   5” 6”   6” 8”   10”   12”   14”   16”   18”   20”   22”   24”   26” 28” 30”   32” 34” 36”

         

  f  1,00 ÷ 1,80 1,60 1,50

 

2. FITTINGS (ANSI B.36.10) 2.3 TEES 2.3.1 STRAIGHT TEE [Mhr/ea]

1   7  

Dn-mm   15   20   25   32   40   50   65   80   10 100   12 125   15 150   200   250   300   350   400   450   500   550   600   650   700   750   800   850   900

ø-Inch OD-mm 1/2” 21,3 3/4” 2 6,7 1” 33,4 1 1/4” 42,4 1 1/2” 48,3 2” 60,3 2 1/2” 73 73 3” 88,9 4” 114,3 5” 141,3 6” 168,3 8” 219,1 10” 273 12” 323,9 14” 355,6 16” 406,4 18” 457 20” 508 22” 559 24” 610 26” 660 28” 711 30” 30 762 32” 813 34” 864 36” 914

  S ch ch 10

Sc h 2 0

FOR PREFABRICATION : 85% FOR INSTALLA INSTALLATION TION : 15%

Sch 30

2,11 2,40 2,77 3,02 3,47 4,00 4,58 5,36 6,20

15,85 18,01 20,16 22,33 24,49 26,66

2.3.2 REDUCED TEE

9,88 12,14 14,30 16,97 19,29 21,60 25,85 28,38 30,91

10,60 12,92 15,68 18,29 20,81 25,22 30,26 33,24 39,20

CARBON STEEL Sch 40 Sch 60 1,91 2,14 2,43 2,82 3,09 3,57 4,26 4,94 5,92 7,26 6,98 9,04 7,95 10,70 11,77 13,86 16,28 16,51 17,16 20,79 18,29 19,75 23,90 20,81 24,30 29,39 23,33 29,47 36,70 25,85 34,00 43,84 28,38 38,85 51,76 30,91 45,72 62,56 33,40 35,93 38,46 40,99 43,51 46,00 St d

[Mhr/ea] x 0,95

XS

Sch 80 1,94 2,17 2,49 2,91 3,20 3,73 4,52 5,33 6,56 7,88 9,44 13,15 16,28 18,21 19,26 24,11 21,32 28,54 24,30 36,24 27,27 45,14 30,26 55,40 33,24 67,05 36,23 80,17 39,17 42,16 45,14 48,13 51,12 54,06 Materials:: Materials

- Cr-Mo alloy steel - Copper alloy - Killed C.S.

Sch 100

14,67 21,04 28,60 34,95 44,07 56,14 70,00 83,92 104,60

Sch 120

7,26 9,04 10,92 16,87 24,01 33,62 40,80 52,64 67,98 84,19 102,65 128,73

Sch 140

18,57 28,14 37,91 47,04 63,22 79,04 101,35 122,46 152,02

Sch 160 1,97 2,24 2,59 3,02 3,38 4,14 4,93 6,08 8,00 10,34 12,92 20,43 31,65 44,60 53,47 71,37 92,45 117,52 143,80 179,35

XXS 2,33 2,75 3,30 3,70 4,47 5,75 7,07 9,21 11,69 14,88 19,80

Sc h 5 S 2,36 2,62 2,95 3,39 3,70 4,23 4,89 5,59 6,52 7,61 8,46 10,78 13,47 16,19 17,96 20,55 22,99 26,05 28,57 32,02

41,41

 

STAINLESS STEEL Sch 10S S ch ch 40S Sch 80S 2,37 2 ,39 2, 2,42 2,64 2,67 2,72 3,00 3,04 3,11 3,46 3,52 3,64 3,78 3,86 4,00 4,33 4,46 4,67 5,00 5,32 5,65 5,73 6,18 6,66 6,70 7,40 8,19 7,75 8,72 9,85 8,62 9,94 11,79 11,15 13,37 16,44 13,86 17,32 20,35 16,57 20,64 24,08 18,53 21,03 23,54 26,83 29,42 33,33

44,44

f 

1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

- High temp. alloy steel - Alloy steel Ni - Auminium alloy

  f  1,00 ÷ 1,80 1,60 1,50

ø -I -Inch 1/2”   3/4”   1”   1 1/4”   1 1/2”   2”   2 1/2”   3”   4”   5”   6”   8”   10”   12”   14”   16”   18”   20”   22”   24”   26” 28” 30”   32” 34” 36”

         

 

2. FITTINGS (ANSI)   2.4 REDUCERS - CON ONCE CEN N TR TRIC AN D EC ECCE CEN N TR TRIC [M [Mhr hr/e /eaa]

1    8  

Dn-mm   20   25   32   40   50   65   80   100   125   150   200   25 250   300   350   400   450   500   550   600   650   700   750   800   850   900

ø-Inch OD-mm 3/4” 26,7 1” 3 3,4 33 1 1/4” 42,2 1 1/2” 48,3 2” 6 0,3 2 1/2” 73 3” 8 8 ,9 88 4” 114,3 11 5” 141,3 6” 168,3 16 8” 219,1 10” 273 12” 323,9 14” 355,6 16” 406,4 18” 457 20” 508 22” 559 24” 610 26” 660 28” 711 30” 762 32” 813 34” 864 36” 914

Sch 10

Sch 20 Sc S ch 3 0

Std

1,68 1,94 2,16 2,42 2, 2,80 3,21 3, 3,69 4 ,28 4,

12,70 14,29 15,88 17,48 19,08

8,32 9,95 11,73 13,57 15,28 17,69 20,17 22,04

8,87 10,74 12,71 14,60 17,15 20,60 23,54 26,82

1111,38 13,02 13 14,60 14 16,46 16 18,31 18 20,17 20 22,04 22 23,89 25,73 27,59 29,46 31,32 33,16

Sch 40 1,51 1,70 1,96 2,20 2,48 2,93 3,43 4,01 4,76 5,48 7,07 9,24 11,62 13,78 16,40 19,96 23,51 26,94 31,23

F OR OR PR PREFAB RI RICATIO N : FOR FO R IN INSSTALL LLAATI TION ON::

Sch 60

10,52 13,82 16,61 19,76 24,44 29,72 35,22 42,05

CARBON CARB ON ST STEE EELL Sch 80 Sch 100 1,53 1,74 2,02 2,27 2,58 3,08 3,66 4,38 5,31 6,33 8,51 11,02 11,72 13,30 13,26 15 15,73 18 1 8,39 1 5,12 19,51 23,47 15 16,98 23 23,94 29 29,12 19,16 30 30,00 36 36,85 21,35 36 36,99 46 46,30 23,54 44 44,98 56 56,42 2 5,74 54,01 69,03 27,92 30,09 32,29 34,48 36,68 38,86 XS

Sch 120

5,98 7,27 10,40 15,18 21,30 27,42 34,36 44,27 55,76 68,39 84,61

17,30 24,36 31,26 40,48 52,14 66,03 81,84 100,29

Materials:

Man hour include next activities: - handling - on-site transport - prefabrication

-

erection welding pressure testing

Sch 140

 

- Cr-Mo alloy steel - Copper alloy - Killed C.S

Sch 160 1,57 1,80 2,10 2,38 2,79 3,38 4,08 5,17 6,71 8,45 12,42 19,25 28,07 36,02 45,78 59,98 76,78 95,48 117,98

XXS 1,89 2,25 2,59 3,02 3,79 4,73 5,95 7,62 9,63 12,91

Sch 5S 1,85 2,07 2,37 2,64 2,96 3,42 3,92 4,49 5,24 5,93 7,37 9,22 11,21 12,87 14,48 16,34 18,37 20,43 22,63

STAI ST AINL NLES ESSS ST STEE EELL Sch 10S Sch 40S SScch 80S 1,86 1,88 1,91 1, 2,10 2,12 2,17 2,42 2,46 2,52 2,70 2,75 2,84 3,02 3,10 3,23 3,50 3,66 3,85 4,01 4,29 4,58 4,61 5,02 5,48 5,36 5,95 6,64 6,04 6,85 7,92 7,56 8,84 10,64 9,49 11,56 13,77 11,49 14,23 16,58 13,22 14,87 16,72 18,85 21,02 23,41

f 

1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

85 % 15% 15 %

- High temp. alloy steel - Alloy steel Ni - Aluminium alloy

ø-Inch 3/4”   1”   1 1/4”   1 1/2”   2”   2 1/2”   3”   4”   5”   6”   8”   10”   12”   14”   16”   18”   20”   22”   24”   26” 28” 30” 32” 34” 36”

  f  1,00 ÷ 1,80 1,60 1,50

 

  1. PIPES (DIN

2448/2458)

1.1 INSTALLATION IN PROCESS PLANT 

1    9  

Dn-mm O DD-mm   15 21,3   20 20 26,9   25 25 33,7   32 32 42,4   40 48,3   50 60,3   65 73,1   65 65 76,1   80 88,9   100 114,3   125 139,7   150 168,3   200 219,1   250 273   300 323,9   350 355,6   400 406,4   450 457   500 508   550 559   600 610

t - Std|Ext 2\2 2\2,3 2\2,6 2\2,6 2,3\2,6 2,3\2,9 2,6\2,9 2,6\2,9 2, 2,9\3,2 3,2\3,6 3,6\4 3, 4\4,5 4,5\6,3 5\6,3 5,6\7,1 5,6\8 6,3\8,8 6,3\10 6,3\11 6,3\12,5 6,3\12,5

  650   700   750   800   850   900

7,1\14,2 7,1 7, 8 8 8 ,8 10 10

660 77111 762 813 81 864 914 91

 

2 0,39 0,41 0,43 0,45 0,47 0,50 0,53 0,54 0,57 0,62

Man hour include next activities: - handling - on-site transport - prefabrication

2,3 0,40 0,41 0,44 0,46 0,48 0,51 0,55 0,56 0,59 0,64

FOR PREFABRICA PREFABRICATION TION : 8% FOR INSTALLATION : 92%

[Mhr/m]

CARBON STEEL - NONWRAPPED - ABOVE GROUND - WALL THICKNESS 2 - 12,5 mm 2 ,6 2,9 3 ,2 3,6 4 4 ,5 5 5,6 6 ,3 0,40 0,41 0,41 0,42 0,42 0,43 0,43 0,42 0,43 0,43 0,44 0,44 0,45 0,46 0,47 0,48 0,44 0,45 0,46 0,46 0,47 0,48 0,49 0,50 0,52 0,47 0,48 0,49 0,50 0,51 0,52 0,54 0,55 0,57 0,49 0,50 0,51 0,52 0,54 0,55 0,57 0,58 0,60 0,52 0,54 0,55 0,56 0,58 0,60 0,62 0,64 0,66 0,56 0,58 0,59 0,61 0,63 0,65 0,67 0,70 0,73 0,57 0,59 0,60 0,62 0,64 0,66 0,69 0,71 0,74 0,61 0,62 0,64 0,66 0,68 0,71 0,74 0,77 0,80 0,66 0,68 0,70 0,73 0,75 0,79 0,82 0,86 0,90 0,71 0,73 0,76 0,79 0,82 0,86 0,90 0,94 0 ,9 9 0, 0,78 0,83 0,84 0,88 0,92 0,96 1,02 1,07 1, 0,97 1,02 1,12 1,12 1,24 1,24 1 ,3 1 1, 1,14 1,20 1,25 1,39 1,39 1,47 1,56 1, 1,30 1,37 1,43 1,53 1,59 1,69 1 ,8 1 1, 1,43 1,50 1,57 1,71 1,74 1,84 1 ,9 8 1, 1,66 1,74 1,90 2,06 2,06 2 ,2 1 2, 1,83 1,92 2,10 2,27 2,27 2,44 2,10 2,10 2,22 2,34 2,65 2,65 2,40 2,53 2,90 2,90 2,59 2,73 2,90 3,10 2,92 3,12

 errection - e  weelding - w - p  prressure

testing

3,50

3,10 3,31 3,52 3,72

3,88

4,13

  Materials Materials:: - Stainless steel - High temp. alloy steel - Prewrapped - Galvanized - Aluminium alloy

3,32 3,54 3,76 3,98 4,20 4,41

7,1

8

8,8

10

11

12,5

0,62 0,69 0,76 0,78 0,84 0,95 1,05 1,14 1,40 1,67 1,92 2,10 2,34 2,59 2,83 3,08 3,32

0,64 0,72 0,79 0,81 0,89 1,00 1 ,1 1 1, 1 ,2 1 1, 1 ,4 9 1, 1,78 1, 2 ,06 2, 2,38 2, 2 ,66 2, 2,95 3,04 3,31 3,57

0,66 0,74 0,82

0,69 0,77 0,87

0,70 0,80 0,90

0,70 0,81 0,95

0,92 1,05 1,17 1,27 1,57 1,88 2,17 2,48 2,86 2 ,95 2, 3 ,23 3, 3,51 3, 3,78 3,

0,97 1,12 1,25 1,37 1,73 2,04 2,40 2,75 3,07 3 ,3 2 3, 3 ,5 0 3, 4 ,0 5 4, 4,11 4,

1,02 1,17 1,31 1,44 1,96 2,16 2,50 2,90 3,17 3 ,52 3, 3 ,73 3, 4,25 4, 4,53 4,

1,08 1,25 1,41 1,56 2,00 2,37 2,75 3,00 3,37 3,74 4,11 4,47 4,83

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 1 39,7 13 168,3 16 2 19,1 21 273 3 23,9 32 355,6 35 406,4 40 4 57 45 5 08 50 559 55 610 61

3,56 3,79 4,03 4,27 4,51 4,74

4,06 4,33 4,61 4,88 5,15 5,10

4,36 4, 4,53 4,91 4,88 5,45 5,42

4,70 4, 4,71 5,34 5,30 5,77 5,89

4,90 4, 5,02 5,64 5,66 6,00 6,28

5,18 5,54 5,90 6,25 6,60 6,94

660 66 711 762 813 864 914

0,53

k 

[Mhr/m] x 1,10 [Mhr/m] x 1,10 [Mhr/m] x 1,15 (underground install.) [Mhr/m] x 0,70 [Mhr/m] x 0,85

Mhr/m x 0,3048 = Mhr/ft

           

 

1. PIPES (DIN 2448/2458) 1.1 INSTALLATION IN PROCESS PLANT

2    0  

Dn-mm   15   20   25   32   40   50   65   65   80   100   125   150   200   250   300   350   400   450   500   550   600   650   700   750   800   850   900

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 66 711 762 813 864 914

  t - Std|Ext 14,2 2\2 2\2,3 2\2,6 2\2,6 2,3\2,6 2,3\2,9 0,87 2,6\2,9 1,01 2,6\2,9 2,9\3,2 1,14 3,2\3,6 1,34 3,6\4 1,52 4\4,5 1,69 1, 4,5\6,3 2,11 5\6,3 2,55 2, 5,6\7,1 5, 2,97 5,6\8 3,24 6,3\8,8 3,64 6,3\10 4,06 6,3\11 4,44 6,3\12,5 4,83 6,3\12,5 5,25 7,1\14,2 5,61 7,1 6,00 8 6,38 8 6,77 6, 8 ,8 7,15 10 10 7,52

16

CARBON STEEL - NONWRAPPED - ABOVE GROUND - WALL THICKNESS 14,2 - 60 mm 17,5 20 22,2 25 28 30 32 36 40

1,22 1,43 1,

1,50

1,81 2,28 2,76 3,21 3,74 3,96 4,40 4,83 5,33 5,70 6,54 7,00 7,45 7,90 7, 8,35 8,79

1,96 2,49 2,93 3,42 4,00 4,22 4,69 5,16 5,63 6,09 6,94 7,40 8,40 8,60 9,00 9,59

Man hour include next activities: - handling - on-site transport - prefabrication

FOR PREFABRICATION : 8% FOR INSTALLATION : 92%

[Mhr/m]

2,20 2,69 2, 3,22 3 ,76 3, 4,45 4,65 5,00 5,70 6,22 6,73 7,84 8,34 8,85 9,15 9,45 9,94

- e  errection - w  weelding - p  prressure

2,50 2,83 2, 3,47 4,06 4,85 5,03 5,60 6,17 6,73 7,29 8,54

3,32 3,82 4,48 5,26 5,50 6,13 6,76 7,38 8,00

3,72 4,16 4,90 5,82 6,48 6,95 7,31 8,21 8,70

5,49 6,02 6,98 7,45 8,31 9,13 9,50

6,00 6,36 7,36 7,95 8,81 9,63 11,44

7,00 7,96 8,81 9,44 10,75 12,14

9,00 9,78 10,69 11,05 12,85

45

50

55

60

65

11,00 11,78 12,43 13,65

13,00 13,80 14,66

15,00 16,32

17,50 17

70

9,49 1 0,57 10

testing

  Materials Materials:: - Stainless steel - High temp. alloy steel - Prewrapped - Galvanized

  k  [Mhr/m] x 1,10 [Mhr/m] x 1,10 [Mhr/m] x 1,15 [Mhr/m] x 0,70

- Aluminium alloy

[Mhr/m] x 0,85

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

Mhr/m x 0,3048 = Mhr/ft

 

  1. PIPES (DIN 2448/2458) 1.2 INSTALLATION ON PIPE RACK OR SLEEPER WAY

FOR PREFABRICATION : 8% FOR INSTALLATION : 92%

[Mhr/m]

  CARBON STEEL - NONINSULATED - WALL THICKNESS - 2 mm - 12,5 mm

2   1  

 Dn-1m 5 m O2D1-,m3m   20 26,9   25 33,7   32 42,4   40 48,3   50 60,3   65 73,1   65 76,1   80 88,9   10 100 114,3 125 139,7   15 150 168,3   20 2 00 219,1   25 250 273   30 3 00 323,9   35 3 50 355,6   40 400 406   45 4 50 457   50 5 00 508   55 550 559   60 600 610   65 650 660   70 700   750   80 800   85 850   90 900

711 762 813 864 914

t - S2t\d2|Ext 2\2,3 2\2,6 2\2,6 2,3\2,6 2,3\2,9 2,6\2,9 2,6\2,9 2,9\3,2 3,2\3,6 3,6\4 4\4,5 4,5\6,3 5\6,3 5,6\7,1 5,6\8 6,3\8,8 6,3\10 6,3\11 6,3\12,5 6,3\12,5 7,1\14,2

0,242 0,44 0,47 0,50 0,53 0,57 0,61 0,62 0,67 0,74

02,,432 0,44 0,47 0,51 0,54 0,58 0,63 0,64 0,68 0,75 0,83

02,,463 0,45 0,48 0,52 0,54 0,59 0,64 0,65 0,70 0,78 0,85 0,95

02,4,93 0,46 0,49 0,53 0,55 0,60 0,66 0,67 0,72 0,80 0,87 0,99 1,19 1,41 1,62 1,78

7,1 8 8 8 ,8 10

Man hour include next activities: - handling - on-site transport - prefabrication

- e  errection - w  weelding - p  prressure

testing

03,4,24 0,46 0,49 0,54 0,56 0,61 0,67 0,68 0,73 0,81 0,89 1,01 1,23 1,47 1,69 1,85 2,07 2,28 2,60

03,,464 0,47 0,50 0,55 0,58 0,63 0,69 0,70 0,75 0,84 0,92 1,04 1,33 1,52 1,75 1,92 2,15 2,37 2,60

04,44 0,47 0,51 0,56 0,59 0,64 0,70 0,72 0,78 0,87 0,95 1,09 1,33 1,66 1,85 2,06 2,31 2,55 2,72 2,96 3,20

04,4,55 0,48 0,52 0,57 0,60 0,66 0,73 0,74 0,80 0,90 0,99 1,13 1,45 1,66 1,91 2,09 2,47 2,73 2,85 3,10 3,35 3,59

0,545 0,49 0,53 0,58 0,62 0,68 0,75 0,76 0,83 0,93 1,03 1,18 1,45 1,74 2,01 2,20 2,47 2,73 3,17 3,48 3,52 3,78

5,6 0,50 0,54 0,60 0,63 0,70 0,77 0,79 0,86 0,97 1,07 1,24 1,53 1,84 2,14 2,34 2,63 2,91 3,17 3,48 3,73 4,00

3,84 4,33

4,04 4,30 4,56

4,82

5,08

4,28 4,56 4,83 5,11 5,38

  Materials Materials:: - Stainless steel - High temp. alloy steel - Prewraped - Aluminium alloy

6,3

7,1

8

8 ,8

10

11

12,5

0,65 0,73 0,80 0,82 0,90 1,01 1,12 1,31 1,72 1,95 2,25 2,47 2,77 3,07 3,37 3,67 3,97 4,26

0,67 0,75 0,84 0,86 0,94 1,07 1,18 1,38 1,72 2,07 2,40 2,77 3,12 3,46 3,60 3,92 4,24 4,81

0,70 0,78 0,87

0,72 0,81 0,90

0,74 0,84 0,95

0,76 0,88 0,99

0,77 0,89 1,04

0,98 1,12 1,25 1,45 1,81 2,18 2,53 2,90 3,22 3,66 3,80 4,14 4,48 5,00

1,02 1,17 1,31 1,56 1,98 2,35 2,78 3,09 3,37 3,89 4,11 4,76 4,85 5,54

1,08 1,25 1,40 1,64 2,15 2,49 2,90 3,19 3,67 4,10 4,37 5,00 5,38 5,84

1,12 1,31 1,47 1,77 2,20 2,73 3,18 3,48 3,93 4,37 4,81 5,25 5,68 6,11

1,19 1,40 1,58 1,90 2,27 3,00 3,31 3,65 4,08 4,57 4,99 5,44 6,00 6,34

O2D1-,m3m 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660

4,56 4,85 5,15 5,44 5,73

5,15 5,48 5,82 6,15 6,12

5,25 5,88 6,02 6,55 6,48

5,57 6,32 6,30 7,09 7,02

5,93 6,52 6,71 7,29 7,47

6,54 6,98 7,41 7,83 8,25

6,79 7,22 7,67 8,11 8,54

711 762 813 864 914

0,55

k 

[Mhr/m] x 1,10 [Mhr/m] x 1,10 [Mhr/m] x 0,70 [Mhr/m] x 0,85

Mhr/m x 0,3048 = Mhr/ft

 

1. PIPES (DIN 2448/24 58) 1.2 INSTALLATION ON PIPE RACK OR SLEEPER WAY

2   2  

Dn-mm   15 15   20 20   25 25   32 32   40   50 50   65 65   65   80 80  100

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3

t - Std|Ext 2\2 2\2,3 2\2,6 2\2,6 2,3\2,6 2,3\2,9 2,6\2,9 2,6\2,9 2,9\3,2 3,2\3,6

  115205  200  250  300  350  400  450  500  550  600  650  700  750  800  850  900

116389,,73 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 86 864 914

43\,64\,45 4,5\6,3 5\6,3 5,6\7,1 5,6\8 6,3\8,8 6,3\10 6,3\11 6,3\12,5 6,3\12,5 7,1\14,2 7,1 8 8 8,8 10

  1144,2

16

17,5

1,27 1,49

1,36 1,60

1,69

11,,7904 2,44 3,11 3,48 4,11 4,44 4,77 5,70 6,22 6,42 7,00 7,76 8,27 8,79 9,30 9,79

2,06 2,62 3,20 3,74 4,38 4,63 5,16 5,69 6,66 6,73 7,77 8,33 8,89 99,,44 10 10,00 1100,54

20

FOR PREFABRICATION : 8% FOR INSTALLATION : 92 9 2%

[Mhr/m] CARBON STEEL - NONINSULATED - WALL THICKNESS 14,2 - 60 mm 22,2 25 28 30 32 36 40

45

50

55

60

0,96 1,11

  Man hour hour include next activitie activities: s: - handling - on-site transport - prefabrication

2,25 2,88 3,41 3,99 4,68 4,95 5,52 66,,09 7, 7,00 7, 7,22 8,37 8,83 9,29 9,74 11,04

- er  erection - w  weelding - pr  pressure

2,45 3,14 3,77 4, 4,42 5,27 55,,50 6,00 6,78 7,41 8,04 9, 9,46 9,69 9,92 10,54 10,40 1111,76

2,55 3,32 4,08 4,81 5,57 5,98 6,69 7,39 8,09 8,78 10 10,46

3, 3,66 4, 4,55 5,37 5,82 6,61 7,39 8,18 8,96 9,73

3,96 5,01 5,93 7,15 7,97 8,52 9,75 10,10 11,00

6,46 7,45 8,47 9,96 10,75 12,14 11,83

6,76 7,82 9,00 10,66 11,35 13,14 13,68

8,02 9,44 11,24 12 12,01 14 1 4,28 14,68

10,17 12,72 13,92 15,36 16,00

14,00 15,64 16,42 17,33

17,00 18,64 19,77

20,00 22,52

25,00

11,52 11,16 12,87   Materials Materials:: - Stainless steel - High temp. alloy steel - Galvanized   - Aluminium alloy

testing

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 113698,,73 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

k 

[Mhr/m] x 1,10

Mhr/m x 0,3048 = Mhr/ft

[Mhr/m] x 0,70 [Mhr/m] x 0,85

 

  1. PIPES (ANSI and DIN) 1.3 STEAM TRACING

0,61 0,67 0,72 0,76 0,82 0,91 0,99

( Values in this table apply only to piping in plants. For steam tracing of pipe lines on piperacks or slee pe pewa ways ys ot othe herr ta ta ble ble f or or the the in inst staa llati ation o n of pip ipees on on pip pipeera rack ckss are are ap pl plie iedd.) CARBON STEEL STAINLESS STEEL Std Sch 40 XS Sch 80 Sch 1 60 60 XXS Sch 5S Sch 1 0S 0S S ch ch 40S Sch 80 S 0,60 0,61 0,63 0,66 0,62 0,63 0,65 0,67 0,63 0,65 0,69 0,72 0,65 0, 0,66 0,68 0,71 0, 0,69 0,72 0,77 0,82 0,68 0, 0,72 0,74 0,78 0, 0,75 0,80 0,85 0,95 0,73 0, 0,78 0,82 0,87 0, 0,80 0,86 0,93 1,04 0 ,76 0, 0,82 0,86 0 ,93 0,88 0,96 1,11 1,22 0 ,8 2 0, 0,88 0,95 1 ,04 1,04 1,15 1,29 1,52 0,91 0,98 1,13 1,25 1,17 1,32 1,56 1,82 0 ,9 8 0, 1,07 1,27 1 ,44

2 0,58 0,61 0,64 0,69 0,72 0,77 0,84 0,85 0,99 0,

  2,3 0,59 0,62 0,65 0,70 0,73 0,79 0,86 0,87 0,93 0,93

[Mhr [M hr/m /m]]

2    3  

Dn-mm   15   20   25   32   40   50   65   80

ø-Inch OD-mm 1/2” 21,3 3/4” 3/ 26,7 26 1” 33,4 1 1/4” 42,2 1 1/2” 48,3 2” 60,3 2 1/2” 76,1 3” 88,9

Dn-mm Dn-m m   15   20   25   32   40   50   65   65   80  

OD-mmt OD-m mt -Std|Ext 21,3 2\2 26,9 2\2,3 33,7 2\2,6 42,4 2\2,6 48,3 2,3\2,6 60,3 2,3\2,9 73 2,6\2,9 76,1 2,6\2,9 88,9 88 ,9 2, 2,9\ 9\3, 3,22

  Sch 10

CAR CA R BON BON STE TEEL EL - WA LL LL TH THIC ICKN KNES ESSS 2 - 7,1 mm 2,6 2,9 3,2 3,6 0,59 0,60 0,60 0,61 0,62 0,63 0,64 0,65 0,66 0,67 0,68 0,69 0, 0,71 0,73 0,74 0,76 0, 0,75 0,76 0,77 0,79 0, 0,81 0,82 0,84 0,86 0, 0,87 0,90 0,91 0,94 0, 0,89 0,91 0,93 0,96 0, 0,95 0, 95 0,98 0, 98 1,00 1, 00 1,03 1, 03

4 0,62 0,66 0,71 0,77 0,81 0,88 0,96 0,99 1,06 1,06 `

4,5 5 4, 5,6 6 ,3 0,63 0,63 0,67 0,68 0,69 0,70 0,72 0,73 0,75 0,77 0,79 0,80 0,83 0,85 0,83 0,85 0,88 0,90 0,91 0,93 0,97 1,00 0,99 1,03 1,07 1,11 1,02 1,05 1,09 1,13 1,10 1, 10 1, 1,13 13 1, 1,18 18 1, 1,23 23

7,1

0,79 0,93 1,04 1,16 1,18 1,29 1,29

STEAM TRACING ON PROCESS LINES (manho ur ur per meter of pr oc oces s line incl. steam supply and condensate return) ø number [Mhr/m] Dn tracer of tubes (proc.) to 3"  1/2” 1 0,80 4” ÷ 8” 3/4” 1 0,88 10” ÷ 16” 3/4” 2 1,30 18” ÷ 36” 3/4” 3 1,78 above 36 ” 3/4” 4 2,20

COPPER TUBES - DUCTILE OD-mm Mhr/m OD-mm 10 0,12 22 12 0,14 25 14 0,18 28 15 0,20 30 16 0,21 35 18 0,24 38 20 0,27 42

COPPER TUBES - STRONG : x 1,30

1.4 INSTRUMENT AND CONTROL PIPING

 All activityes on installation and supporting these lines, also sizes to 1/2", are included. Lines to 3 m ( 10 ft ) 5 [Mhr] totally Lines above 3 m ( 10 ft ) 1,30 [Mhr/m]

1.5 STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS FABRICATED FROM PIPES AND FITTINGS

1.5.1 STEAM DISTRIBUTORS Fabrication :7,50 [Mhr/ea] + 1,60 [Mhr/connect.]   Erection :12 [Mhr/ea] (supporting included) 1.5.2 CONDENSATE COLLECTORS   Fabrication :4,80 [Mhr/ea] + 2,40 [Mhr/ connect.]   Erection :10 [Mhr/ea] (supporting included)

Mhr/m x 0,3048 = Mhr/ft

[Mhr/m] 0,29 0,32 0,35 0,36 0,40 0,44 0,52

1.6 STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS FABRICATED FROM READY -MADE DISTRIBUTORS FOR 4 CONNECTIONS (ready-made distributors for 4, 8 or 12 connections)

1.6.1 STEAM DISTRIBUTORS Fabrication : 0,80 [Mhr] x number of connections Erection : 12 [Mhr/ea] (supporting included) 1.6.2 CONDENSATE COLLECTORS Fabrication: 1,40 [Mhr] x number of connections Erection: 10 [Mhr/ea] (supporting included)

 

2. FITTING (DIN ) 2.1 ELBOWS [Mhr/ea]

FOR PREFABRICATION : FOR INSTALLATION:

 

2   4  

Dn-mm   15   20   25   32   40   50   65   65   80   100   125   150   200   250   300   350   400   450   500   550   600   650   700   750   800   850   900

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

?Std|Ext 2\2 2\2,3 2\2,6 2\2,6 2,3\2,6 2,3\2,9 2,6\2,9 2,6\2,9 2,9\3,2 3,2\3,6 3,6\4 4\4,5 4,5\6,3 5\6,3 5,6\7,1 5,6\8 6,3\8,8 6,3\10 6,3\11 6,3\12,5 6,3\12,5 7,1\14,2 7,1 8 8 8,8 10

2.2 CAPS

2 1,28 1,43 1,61 1,86 2,03 2,32 2,66 2,72 3,05 3,56

2,3 1,29 1,44 1,62 1,87 2,04 2,34 2,68 2,74 3,07 3,58

2 ,6 1,29 1,45 1,63 1,88 2,05 2,35 2,70 2,76 3,09 3,61 4,11

2,9 1,29 1, 1,45 1,64 1,89 2,06 2,37 2,72 2,78 3,12 3,64 4,15 4,65

CARBON STEEL - WALL THICKNESS 2 - 12,5 mm 3,2 3,6 4 4,5 5 1,30 1,31 1,32 1,32 1,33 1,46 1,47 1,48 1,49 1,51 1,65 1,66 1,67 1,69 1,71 1,90 1,92 1,94 1,96 1,98 2,08 2,10 2,11 2,14 2,17 2,38 2,41 2,43 2,47 2,50 2,74 2,77 2,80 2,84 2,88 2,80 2,83 2,86 2,91 2,95 3,14 3,18 3,21 3,26 3,31 3,67 3,71 3,76 3,82 3,89 4,18 4,23 4,29 4,36 4,44 4,72 4,75 4,81 4,89 4,98 5,98 6,06 6,25 6,25 6,52 7,33 7,43 7,53 7,82 7,82 8,63 8,74 8,87 9,07 9,21 9,59 9,72 9,86 10,15 10,23 11,03 11,19 11,53 11,90 12,34 12,52 12,90 13,32 13,86 13,86 14,11 14,39 15,48 15,78 16,84 17,17 18,55 19,94

[Mhr/ea] x 0,50

5,6

6,3

7,1

22,72

1,52 1,73 2,01 2,20 2,54 2,93 3,01 3,38 3,97 4,53 5,09 6,52 8,00 9,43 10,47 11,90 13,32 15,19 16,73 17,60 19,01 20,44 21,86 23,29

25,48

26,13

1,54 1,76 2,05 2,25 2,60 3,00 3,07 3,46 4,07 4,66 5,23 6,70 8,24 9,75 10,83 12,30 13,77 15,19 16,73 18,13 19,58 21,06 22,53 24,00 25,47 26,93

8

8 ,8

10

11

12,5

2,35 2,74 3,17 3,26 3,67 4,34 4,98 5,61 7,30 8,86 10,46 12,03 13,69 15,33 16,38 17,97 19,57 21,95 23,60 25,26 26,92 28,58 29,09

2,40 2,81 3,26

2,49 2,91 3,39

2,56 3,01 3,51

2,67 3,16 3,69

3,78 4,48 5,14 5,80 7,46 9,19 10,84 12,03 14,29 16,30 16,99 18,65 20,31 22,95 24,60 26,26 26 27,92 29,58 29 30,22

3,95 4,70 5,40 6,11 7,97 9,70 11,62 13,38 15,16 17,08 17,98 20,70 21,50 23,88 24,99 2 8,00 28 28,51 3 0,78 30 32,01

4,10 4,89 5,63 6,38 8,47 10,16 12,01 13,88 15,76 17,78 18,85 21,70 24,48 25,38 26,23 2 9,08 29 30,00 3 2,78 32 33,61

4,32 5,18 6,00 6,80 8,87 10,98 13,00 14,41 16,42 18,42 20,44 22,46 24,78 26,46 28,48 30,50 30 32,51 34,53 34 36,52

1,79 2,29 2,66 3,08 3,16 3,56 4,19 4,80 5,41 7,10 8,52 10,05 11,15 12,68 14,20 15,73 17,25 18,78 20,29 21,82 23,35 24,88 26,40 27,91

  f  1,40÷1,60 1,20 1,00÷1,25

Materials:: Materials

- Cr-Mo alloy steel - Copper alloy - Killed C.S

85% 15%

- High temp. alloy steel - Alloy steel Ni - Aluminium alloy

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

1,00 ÷ 1,80 1,60 1,50

 

2. FITTINGS (DIN) 2.1 ELBOWS [Mhr/ea]

FOR PREFABRICATION : 85% FOR INSTALLATION : 15%

 

2    5  

Dn-mm OD-mm t - Std|Ext   15 21,3 2\2   20 26,9 2\2,3   25 33,7 2\2,6   32 42,4 2\2,6   40 48,3 2,3\2,6   50 60,3 2,3\2,9   65 73,1 2,6\2,9   65 76,1 2,6\2,9   80 88,9 2,9\3,2   100 114,3 3,2\3,6   125 139,7 3,6\4   150 168,3 4\4,5   20 2 00 219,1 4,5\6,3 4,   25 250 273 5\6,3   300 323,9 5,6\7,1   350 355,6 5,6\8   40 400 406,4 6,3\8,8   450 457 6,3\10   50 500 508 6,3\11   55 550 559 6,3\12,5   60 600 610 6,3\12,5

4,59 5,53 6,43 7,35 7, 9,49 11,76 14,00 15,44 17,61 19,86 21,94 24,12 24 26,42 26

           

28,44 30,61 30 32,79 34,96 37,14 37 39,28

66550 700 70 750 75 800 850 85 900 90

660 711 762 813 81 864 914 91 2.2 CAPS

77,,1\14,2 7,1 7, 8 8 8,8 8, 10

14,2

20

CARBON 14,232- 60 mm 36 22,2 STEEL 25 - WALL 28 THICKNESS 30

8,66 11,31 13,62 16,17 19,00 20,47 23,01 25,57 28,13 30,69

9,94 12,42 15,14 18,02 21,88 22,84 25,21 28,58 31,45 34,34

11,00 13,22 16,56 19,74 23,18 25,05 28,21 31,39 34,58 37,76

33,20 36,76 38,32 40,88 43,44 45,95

36,89 40,04 42,93 45,81 45 48,68 5 1,52 51

40,89

16

17,5

4,90 5,93

6,28

7,89 10,26 12,75 15,12 1 7,92 19,13 21,49 23,87 26,13 28,63 30,20 33,76 34,32 37,88 38,44 40,95

40

45

50

55

60

47,23 61,09 66,97 67,89 75,02

65,09 77,56 80,85 85,02

80,00 94,82 100,27

100,00 118,15

136,00

3,32 3,90

[Mhr/ea] x 0,50

16,33 18,74 22,39 24,45 28,03 31,60 35,20 38,79 42,39

18,00 21,04 25,20 28,24 34,97 37,32 40,45 44,59 49,24

29,58 31,24 36,97 42,07 46,45 50,63 50 53,24

32,00 35,45 41,89 45,07 50,45 55,63 60,22

38,00 44,89 52,31 55,74 60,89 69,22

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

50,44 56,75 Materials:: Materials

- Cr-Mo alloy steel - Copper alloy Killed C.S

  f  1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

Stainless steel High temp. alloy steel Alloy steel Ni Aluminium alloy

1,25 1,00 ÷ 1,80 1,60 1,50

 

2. FITTINGS (DIN) 2.3 TEES  [Mhr/ea] 2.3.1 STRAIGHT TEE

2    6  

Dn-mm   15   20   25   32   40   50   65   65   80

OD-mm t - Std|Ext 21,3 2\2 26,9 2\2,3 33,7 2\2,6 42,4 2\2,6 48,3 2,3\2,6 60,3 2,3\2,9 73,1 2,6\2,9 76,1 2,6\2,9 88,9 2,9\3,2

                                   

114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

100 125 150 200 250 300 350 400 450 500 550 55 600 60 650 7 00 70 7 50 75 8 00 80 850 9 00 90

3,2\3,6 3,6\4 4\4,5 4,5\6,3 5\6,3 5,6\7,1 5,6\8 6,3\8,8 6,3\10 6,3\11 6,3\12,5 6,3\12,5 7,1\14,2 7,1 8 8 8 ,8 10

  2 1,89 2,11 2,38 2,73 2,97 3,41 3,90 3,99 4,46

2,3 1,90 2,12 2,39 2,75 2,99 3,43 3,93 4,02 4,49

2 ,6 1,91 2,13 2,40 2,76 3,01 3,45 3,95 4,05 4,52

2,9 1,91 2,14 2,42 2,78 3,03 3,48 3,98 4,08 4,56

5,20

5,24

5,28 6,01

5,33 6,06 6,79

2.3.2 REDUCED TEE

CARBON STEEL - WALL THICKNESS 2 mm - 12,5 mm 3,2 3 ,6 4 4,5 5 5,6 1,92 1,93 1,94 1,96 1,97 2,15 2,17 2,18 2,20 2,23 2,25 2,43 2,45 2,47 2,49 2,52 2,56 2,80 2,83 2,85 2,89 2,93 2,97 3,05 3,08 3,11 3,15 3,19 3,25 3,50 3,54 3,58 3,62 3,68 3,75 4,01 4,06 4,11 4,17 4,23 4,31 4,11 4,15 4,20 4,27 4,33 4,42 4,60 4,65 4,71 4,78 4,86 4,96 5,37 6,12 6,90 8,74 10,70 12,59 13,97

5,44 6,20 6,94 8,86 10,85 12,77 14,16 16,08 17,98 20,20

5,51 6,28 7,04 9,15 11,01 12,96 14,37 16,31 18,25 20,20

[Mhr/ea] x 0,95

5,61 6,39 7,17 9,15 11,44 13,26 14,82 16,83 18,83 20,59 22,58 24,57

5,70 6,51 7,30 9,56 11,44 13,47 14,94 17,39 19,47 21,02 23,04 25,08 27,08 29,11 33,17

5,83 6,66 7,48 9,56 11,73 13,81 15,32 17,39 19,47 22,23 24,49 25,73 27,78 29,87 31,95 34,04

37,20

38,18

6 ,3 2,28 2,60 3,02 3,31 3,83 4,42 4,53 5,08 5,98 6,84 7,69 9,84 12,09 14,30 15,85 18,01 20,16 22,23 24,49 26,54 28,66 30,82 32,97 35,13 37,28 39,41

FOR PREFABRICATION : FOR INSTALLATION:

85% 15% 15

8

8 ,8

10

11

12,5

3,38 3,93 4,54 4,65 5,23

3,47 4,04 4,68 4,80 5,41

3,55 4,15 4,81

3,68 4,31 5,01

3,79 4,46 5,19

3,96 4,68 5,46

5,57

5,83

6,06

6,40

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9

6,17 7,07 7,95 10,20 12,52 14,76 16,35 18,59 20,81 23,06 25,29 27,54 29,74 31,98 34,22 36,46 38,70 40,91

6,40 7,33 8,26 10,60 13,04 13 15,38 17,69 20,13 22,55 22 24,05 24 26,39 28,73 32,27 34,71 36,15 39,59 42,03 42,72

6,61 7,59 8,56 10,99 13,54 15,97 18,69 21,13 23,55 24,99 27,43 29,87 33,27 33 35,71 38,15 39,59 44,03 44,43

6,94 7,98 9,03 11,77 14,32 17,16 19,75 22,38 25,22 26,49 30,56 31,68 35,99 36,83 40,45 42,02 46,92 47,17

7,23 8,33 9,44 12,25 15,02 17,75 20,75 23,38 26,22 27,83 32,56 36,23 37,99 38,72 41,45 44,19 48,92 49,61

7,69 8,89 10,09 13,15 16,28 19,26 21,32 24,30 27,27 30,26 33,24 37,23 39,17 42,16 45,14 48,13 51,12 54,06

114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 7 62 76 813 864 86 914

7,1

2,64

  f  1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

Materials:: Materials

- Cr-Mo alloy steel - Copper alloy - Killed C.S

- Stainless steel - High temp. alloy steel - Alloy steel Ni - Aluminium alloy

1,25 1,00 ÷ 1,80 1,60 1,50

 

2.3 TEES 2.3.1 STRAIGHT TEE

2   7  

  Dn-mm OD-mm t - Std|Ext 14 14,2 16   15 21,3 2\2   20 26,9 2\2,3   25 33,7 2\2,6   32 42,4 2\2,6   40 48,3 2,3\2,6   50 60,3 2,3\2,9 4,92   65 73,1 2,6\2,9 5,79   65 76,1 2,6\2,9   80 88,9 2,9\3,2 6,81 7,28   100 114,3 3,2\3,6 8,22 8,82   125 139,7 3,6\4 9,55   150 168,3 4\4,5 10,92 11,75   200 219,1 4,5\6,3 14,09 15,27   250 273 5\6,3 17,47 18,98   300 323,9 5,6\7,1 20,79 22,51 5,   350 355,6 5,6\8 22,90 25,69   400 406,4 6,3\8,8 26,12 28,44   450 457 6,3\10 29,47 31,96   500 508 6,3\11 32,55 35,50   550 559 6,3\12,5 35,78 38,90   600 610 6,3\12,5 39,20 42,58   650 6 60 66 7,1\14,2 42 42,19 45,47   700 711 7,1 45,42 49,28   750 762 8 48,64 52,09   800 813 8 51,87 54,91   850 864 8 ,8 55,10 60,72   900 914 10 58,27 63,47 2.3.2 REDUCED TEE

FOR PREFABRICA PREFABRICATION TION : 85% FOR INSTALLATION : 15%

[Mhr/ea]

17,5

20

CARBON STEEL - WALL THICKNESS 14,2 - 60 mm 22,2 25 28 30 32 36

40

45

50

55

60

71,37 92,45 101,35 112,65 11 118,73

100,00 1 17,52 11 122,46 12 128,73

117,52 143,80 152,02

130,00 150,00 179,35

190,00

9,36 12,92 16,87 20,31 24,11 28,69 30,49 34,28 38,09 41,90 45,72 49,47 53,28 57,09 60,91 64,72 68,47

14,88 18,57 22,64 26,94 31,74 34,11 38,22 42,69 46,99 51,30 55,21 59,83 59 64,14 6 8,44 68 72,74 72 76,97

[Mhr/ea] x 0,95

16,00 19,80 24,81 2 9,57 29 33,74 37,49 42,22 46,99 51,76 56,53 61,21

22,00 28,14 33,62 36,66 42,04 47,40 52,80 58,20 63,60

24,54 31,65 37,91 40,04 48,64 56,14 58,00 67,05 70,17

44,60 47,04 52,64 62,98 65,00 83,92 80,17

50,00 53,47 58,22 67,98 70,00 93,92 95,60

58,00 63,22 79,04 84,19 102,65 104,60

75,52 84,97 Materials:: Materials

- Cr-Mo alloy steel - Copper alloy - Killed C.S

  f  1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

- Stainless steel - High temp. alloy steel - Alloy steel Ni - Aluminium alloy

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914 1,25 1,00 ÷ 1,80 1,60 1,50

 

2. FITTINGS (DIN) 2.4 REDUCERS - CONCENTRIC

2    8  

Dn-mm   15   20   25   32   40   50   65   65   80   100   125   150   200   250   300   350   400   450   500   55 550   60 600   650   70 700   75 7 50   80 8 00   85 850   900

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914

t - Std|Ext 2\2 2\2,3 2\2,6 2\2,6 2,3\2,6 2,3\2,9 2,6\2,9 2,6\2,9 2,9\3,2 3,2\3,6 3,6\4 4\4,5 4,5\6,3 5\6,3 5,6\7,1 5,6\8 6,3\8,8 6,3\10 6,3\11 6,3\12,5 6,3\12,5 7,1\14,2 7,1 8 8 8,8 10

AND ECCENTRIC

FOR PREFABRICATION : 85% FOR INSTALLATION: 15%

[Mhr/ea]

  2

2,3

2,6

2,9

1,49 1,67 1,91 2,13 2,38 2,74 2,91 3,16 3,59

1,50 1,68 1,92 2,14 2,39 2,76 2,93 3,18 3,61

1,50 1,69 1,93 2,15 2,41 2,78 2,95 3,20 3,64 4,19

1,51 1,70 1,95 2,16 2,43 2,80 2,97 3,22 3,67 4,22 4,72

Man hour include next activities: - handling

- e  errection

- on-site transport - prefabrication

 weelding - w  prressure - p

CARBON STEEL - WALL THICKNESS 2 - 12,5 mm 3,2 3,6 4 4,5 5 5 ,6 1,52 1,71 1,96 2,18 2,44 2,82 3,00 3,25 3,69 4,26 4,78 5,94 7,39 8,77 10,02

1,53 1,72 1,97 2,20 2,46 2,85 3,03 3,29 3,74 4,31 4,82 6,02 7,44 8,87 10,09 11,31 12,79

1,54 1,73 1,99 2,22 2,49 2,88 3,06 3,32 3,78 4,36 4,88 6,15 7,54 9,00 10,23 11,47 11 12,89 14,31

1,55 1,75 2,01 2,25 2,52 2,92 3,11 3,37 3,84 4,44 4,95 6,18 7,80 9,16 10,46 11,73 13,19 14,55 16,01 17,62

1,56 1,77 2,04 2,27 2,56 2,96 3,16 3,43 3,91 4,52 5,04 6,38 7,80 9,40 10,62 12,10 13,61 14,92 16,32 17,81 19,28 20,95

1,58 1,79 2,07 2,31 2,60 3,01 3,22 3,49 3,99 4,61 5,14 6,42 8,06 9,52 10,83 12,14 13,81 15,59 17,00 18,21 19,72 21,23 22,75 24,57

  Materials Materials:: - Cr Mo Mo alloy steel - Copper alloy - Killed C.S.

testing

6,3

7,1

1,26 1,81 2,10 2,35 2,65 3,08 3,29 3,58 4,09 4,73 5,27 6,59 8,19 9,80 11,15 12,50 14,06 15,59 17,44 19,03 20,28 21,83 23,40 24,96 26,53 28,50

8

8 ,8

10

11

12,5

2,46 2,79 3,25 3,49 3,79 4,35 5,06 5,62 7,04 8,91 10,49 12,16 13,65 15,37 16,74 18,43 20,12 22,25 23,96 25,68 27,41 29,13 30,22

2,51 2,86 3,34 3,59 3,90 4,48 5,22 5,82 7,30 9,09 10,89 12,39 14,14 15,93 17,72 19,17 20,93 22,68 24,88 26,67 28,47 30,27 32,05

2,60 2,96 3,47 3,74 4,07 4,69 5,48 6,08 7,69 9,52 11,50 13,35 14,96 16,90 18,26 20,65 21,97 24,45 25,65 28,24 29,36 32,05 33,05

2,64 3,05 3,58 3,87 4,22 4,88 5,71 6,37 8,36 10,06 12,00 13,78 15,70 17,72 19,72 21,20 23,76 25,11 27,69 29,01 29 31,71 31 32,93 35,71

2,70 3,19 3,76 4,08 4,45 5,16 6,07 6,73 8,51 11,02 12,81 14,57 14 1 6,40 16 1 8,46 18 20,60 20 22,66 22 2 4,76 24 2 7,92 27 28,94 28 31,04 33,14 35,24 37,33

1,84 2,40 2,72 3,16 3,38 3,68 4,21 4,88 5,43 6,94 8,45 10,10 11,51 12,91 14,53 16,15 17,73 19,40 20,96 22,57 24,19 25,82 27,44 29,05

  f  1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

- Stainless steel - High temp. alloy steel - Alloy steel Ni - Aluminium alloy

OD O D-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 3 55,6 35 406,4 457 508 559 610 660 711 7 62 76 8 13 81 864 914

1,25 1,00 ÷ 1,80 1,60 1,50

 

2. FITTINGS (DIN) 2.4 REDUCERS - CONCENTRIC

 

2    9  

Dn-mm OD-mm t - Std|Ext   15 15 21,3 2\2   20 26,9 2\2,3   25 33,7 2\2,6   32 42,4 2\2,6   40 48,3 2,3\2,6   50 60,3 2,3\2,9   65 73,1 2,6\2,9   65 76,1 2,6\2,9   80 88,9 2,9\3,2   100 114,3 11 3,2\3,6 125 139,7 3,6\4   150 168,3 4\4,5 200 219,1 4,5\6,3 4,   250 273 5\6,3   300 323,9 5,6\7,1   350 355,6 5,6\8   400 406,4 6,3\8,8   450 457 6,3\10   500 508 6,3\11   550 559 6,3\12,5

4,73 5,50 6,50 7,22 9,09 11,45 13,82 15,70 17,64 19,96 22,18 24,47

  600   65 650   700   750   800   850   900

26,82 29,01 31,28 33,56 35,84 38,13 40,39

610 660 711 762 813 81 864 914 91

6,3\12,5 7,1\14,2 7, 7,1 8 8 8 ,8 8, 10

14,2

FOR PREFABRICATION : 85% FOR INSTALLATION : 15%

AND ECCENTRIC [Mhr/ea]

16

17,5

5,05 5,88 5,

6,23 6,

7,75 9,82 12,34 14,88 17,63 19,06 21,53 24,05 27,53

8,18 10,70 13,25 16,01 18,25 21,18 23,22 25,90 28,60

28,97 32,74 35,24 35 37,82 4 0,40 42,99 45,55

32,34 33,97 37,88 40,68 4 3,48 43 46,27 49,05

CARBON STEEL - WALL THICKNESS 14,2 -60 mm 22,2 25 28 30 32 36

40

8,89 1111,75 14,68 17,52 21,03 21 2 2,49 26,85 28,42 31,39

9,80 12,91 16,09 19,32 22,06 25,92 28,16 32,87 34,80

34,37 39,38 40,27 43,24 46,22 49,19 52,14

38,12 41,41

20

45

50

55

60

OD-mm 21,3 26,9 33,7 42,4 48,3 60,3 73,1 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 457 508 559

130,00

610 660 711 762 813 864 914

3,32 3,97

Man hour include next activities: - handling - on-site transport - prefabrication

- e  errection - w  weelding - p  prressure

testing

14,63 17,75 21,59 24,45 27,58 31,28 31 34,98 38,70

15,00 15 20,75 24,36 29,70 29 32,86 36,11 43,12 44,03

28,07 31,26 36,63 44,27 46,30 50,42

30,00 36,02 40,48 48,27 50,60 56,42

38,00 42,82 52,14 55,76 63,23

45,78 57,02 66,03 68,39

59,98 70,78 81,83

76,78 90,48

95,48

42,42

50,79

54,01

60,03

69,03

75,61

84,61

100,29

117,98

51,35 57,96   Materials Materials:: - Cr Mo alloy steel - Copper alloy - Killed C.S.

  f  1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

- Stainless steel - High temp. alloy steel - Alloy steel Ni - Aluminium alloy

1,25 1,00 ÷ 1,80 1,60 1,50

 

3. FLANGES 3.1 WELDING NECK

FOR PREFABRICA PREFABRICATION TION : 80% FOR INSTALLATION: 20%

[Mhr/ea]

 

 3    0  

CARBON STEEL

  Dn-mm ø-Inch   15 1/2”   20 3/4”   25 1”   32 1 1/4”   40 1 1/2”   50 2”   65 2 1/2”   80 3”   100 4”   125 5”   150 6”   200 8”   250 10”   300 12”   350 14”   400 16”   450 18”   500 20”   550 22”   600 24”   650 26”   700 28”   750 30”   800 32”   850 34”   900 36”

[kg] 0,5 0,7 1,1 1,5 1,8 2,7 4,4 5,2 7,5 9,2 1,0 18,3 25,0 39,0 51,0 60,0 71,0 88,0 103,5 119,0 136,0 143,0 168,0 197,0 211,0 236,0

  150#   PN6-16 [Mhr/ea] [kg/Mhr] 1,15 0,43 1,22 0,57 1,32 0,83 1,46 1,03 1,56 1,15 1,73 1,56 1,99 2,21 2,26 2,30 2,63 2,85 3,05 3,02 3,06 3,59 4,30 4,26 5,30 4,72 6,29 6,21 7,07 7,21 8,10 7,41 9,14 7,77 11,02 7,99 11,28 9,18 12,36 9,62 14,22 9,57 14,94 9,57 16,58 10,14 17,77 11,09 18,98 11,12 20,18 11,70

Man hour include next activities: - handling - on-site transport - prefabrication

  [kg] 0,8 1,3 1,7 2,2 3,2 3,6 5,4 7,4 11,9 16,0 20,0 31,0 44,0 64,0 88,0 113,0 134,0 171,0 204,5 238,0 304,0 367,0 422,0 465,0 545,0 590,0

- e  errection - w  weelding - p  prressure

300# 400# PN25-40 PN64 [Mhr/ea] [kg/Mhr]   [kg] [Mhr/ea] [Mhr/ea]  [kg/Mhr]  [kg] 1,29 0,62 0 ,9 1,29 0,70 0,9 1,37 0,95 1 ,5 1,37 1,09 1,5 1,48 1,15 1 ,9 1,48 1,28 1,9 1,63 1,35 2 ,6 1,63 1,60 2,6 1,73 1,85 3 ,3 1,73 1,91 3,3 1,91 1,88 4,7 1,91 2,46 4,7 2,19 2,47 6 ,5 2,16 3,01 6,5 2,48 2,98 8,7 2,48 3,51 8,7 2,87 4,15 14,0 2,87 4,88 18,1 3,32 4,82 19,0 3,32 5,72 30,0 3,74 5,35 26,0 3,74 6,95 36,0 4,98 6,23 40,0 4,98 8,04 50,0 6,40 6,87 54,0 6,40 8,44 90,0 7,67 8,35 78,0 7,90 9,87 110,0 8,64 10,18 105,0 105,0   9,17 11,45 150,0 9,91 11,40 131,0 11 11,18 11 11,72 190,0 11,20 11,97 159,0 12 12,63 12 12,59 240,0 12,51 13,67 190,0 14 14,11 13 13,47 295,0 13,83 14,78 232,5 15 15,60 1 4, 4,90 330,0 15,18 15,68 275,0 1 7, 7,11 16,07 365,0 16,53 18,39 340,0 18 1 8,62 1 8, 8,26 404,0 17,90 20,50 400,0 20 20,17 19 19,83 480,0 19,29 21,87 454,0 21 21,72 20 20,90 560,0 20,70 22,47 522,0 23 23,29 22 22,41 680,0 22,11 24,65 590,0 24 24,88 23 23,72 750,0 23,53 25,08 670,0 26 26,45 25 25,33 795,0

testing

  Materials Materials:: - Cr Mo Mo alloy steel - Copper alloy - Killed C.S.

600# PN100

900# PN160

1500# PN250

[Mhr/ea][kg/Mhr]   [kg] [Mhr/ea]  [kg/Mhr]   [kg] [Mhr/ea] [kg/Mhr]  [kg]

1,38 1,46 1,57 1,73 1,83 2,02 2,31 2,61 3,02 3,48 4,46 6,10 7,57 9,02 10,16 11,65 11 13,97 13 16,08 16 1 8, 8,33 21,33 2 3, 3,21 25,13 25 27,07 27 29,02 29 30,99 30 34,89 34

0,65 1 ,9 1,03 2 ,6 1,21 3 ,8 1,50 4 ,4 1,80 6 ,1 2,33 11,1 2,81 15,5 3,33 14,0 5,99 23,0 8,62 37,0 8,07 49,0 8,19 84,0 11,89 123,0 12,20 168,0 14,77 186,0 16,30 224,0 1 7, 7,17 300,0 1 8,34 373,0 18 18,01 526,5 17,12 680,0 17,41 715,0 19,10 840,0 20,69 975,0 23,43 1170,0 24,20 1375,0 22,78 1565,0

  f  1,40 ÷ 1,60 1,20 1,00 ÷ 1,25

1,64 1,73 1,86 2,03 2,16 2,39 2,75 3,08 3,51 3,94 4,96 6,75 9,08 11,75 13,25 15,24 17,25 19,29 21,36 23,46 25,56 27,70 29,86 32,04 34,24 38,39

1,16 1,50 2,04 2,17 2,82 4,64 5,64 4,55 6,55 9,39 9,88 12,45 13,55 14,30 14,03 14,70 17,40 19,34 24,65 28,99 27,98 30,33 32,65 36,52 40,16 40,77

- Stainless steel - High temp. alloy steel - Alloy steel Ni - Aluminium alloy

1,9 2,6 3,8 4,4 6,1 11,1 15,5 20,5 30,5 58,0 70,0 119,0 204,0 303,0 400,0 510,0 18”   20” 22” 24” 26” 28”   30” 32” 34” 36”  

1,97 2,07 2,21 2,40 2,55 2,80 3,19 3,61 4,19 4,87 6,90 8 ,9 ,96 11,18 11 14,68 14 16,98 19,56 19

0,96 3 ,6 1,26 4 ,0 1,72 6 ,0 1,83 9 ,0 2,39 13,0 3,96 19,0 4,86 24,0 5,68 43,0 7,28 66,0 11,91 11 111,0 10,15 17 172,0 13,28 22661,0 18,25 4 85 85,0 20,64 7 30 30,0 23,55 14”   26,08 16”  

2500# PN320 [Mhr/ea]   [kg/Mhr]  ø-Inch 2,39 1,51 1/2”   2,52 1,59 3/4”   2,68 2,24 1”   2,90 3,10 1 1/4”   3,10 4,19 1 1/2”   3,45 5,51 2”   3,90 6,15 2 1/2”   4,49 9,58 3”   5,12 12,89 4”   6,05 18,35 5”   8,44 20,38 6”   11,11 11 23,50 8”   15,10 15 32,12 10”   18,12 18 40,28 12”  

Notice: Unit weights in this table refer to welding neck flanges acc. to ANSI B 16-5.1977. for to 24”   and BS-3293-1960 (1) for26” ÷ 36”  

1,25 1,00 ÷ 1,80 1,60 1,50

kg x 0,4536 = lbs kg/Mhr x 2,2046 = lbs/Mhr

 

3. FLANGES 3.2 SLIP - ON 

 

 3   1  

Dn-mm ø-Inch  [kg] [kg]   15 15 1/2” 0,4   20 3/4” 0, 0,7   25 1” 0,8   32 1 1/4” 1,1   40 40 1 1/2” 1,4   50 2” 2 ,2   65 65 2 1/2” ,6   80 80 3” 4 ,1   100 4” 5 ,6   125 5” 6 ,3   150 6” 7,5   200 8” 12,6   250 10” 18 18,5   300 12” 28 28,0   35 0 1 4” 4” 36 36 ,0 ,0   40 4000 16”” 46, 16 46,00   45 4500 18”” 50, 18 50,00   50 5000 20”” 64, 20 64,00   55 5500 22”” 76 22 76,5 ,5   600   650   700   750   800   850   90 9000 3.3. 3.3. 3.4.. 3.4 3. 5. 5. 3.6.. 3.6

2 4” 4” 26” 28” 30” 3 2” 2” 34” 36”” 36

kg x 0.4536  = lbs kg/Mhr x 2,2046 = lbs/Mhr

[Mhr/ea]

89 ,0 ,0 106,0 126,0 12 140,0 1 68 68 ,0 ,0 179,0 205, 20 5,00

150# PN6-16

300# PN25-40

[Mhr/ea]  [kg/Mhr]  [kg]

CARB CA RBON ON 6ST STEE 00EEL #L

400# PN64

[Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr]  [kg

0,31 0,51 0,54 0,66 0,79 1,09 1,53 1,52 1,73 1,64 1,65 2,011 2,0 2,38 3,03 3,4 8 3,89 3, 89 3,75 3, 75 4,30 4, 30 4,66 4, 66

0,7 1,42 1 ,1 1,51 1 ,4 1,65 1 ,8 1,83 2 ,6 1,96 3 ,4 2,19 4 ,4 2,55 6 ,1 2,92 10,1 3,48 12,5 4,11 14,1 4,84 24,8 6,66 37,1 8,26 50,0 9,82 70,0 1 1, 1,01 97,0 97 ,0 12,6 12,622 123, 12 3,00 14, 14,25 25 133, 13 3,00 15, 15,90 90 170, 17 0,55 17,5 17,588

0,49 0 ,8 1,42 0,56 0,73 1,4 1,51 0,93 0,85 1 ,6 1,65 0,97 0,98 2 ,1 1,83 1,15 1,33 3 ,1 1,96 1,58 1,55 3,7 2,19 1,69 1,73 5,4 2,55 2,12 2,09 7,3 2,92 2,50 2,90 11,5 3,48 3,30 3,04 14,5 4,11 3,53 2,91 19 1 9,0 4,84 3,93 3,722 29,0 3,7 29,0 6,66 4,35 4,49 39,5 8,26 4,78 5,09 58,0 9,82 5,91 6,36 82 ,0 ,0 11 ,0 ,01 7,4 5 7,6 ,699 1105 05,0 ,0 12 12,6 ,622 8,32 8, 32 8,66 8, 126, 12 6,00 14, 14,25 25 8, 8,84 84 8,33 8, 152, 15 2,00 15, 15,90 90 9, 9,56 56 9,70 9, 70 185, 185,00 17 17,5 ,588 10,5 10,522

18,0 0 18 19,55 21,14 22,74 24,3 6 25,98 27,5 27 ,599

4,9 4 5,42 5,96 6,16 6,9 0 6,89 7,4 ,433

2 08 08,0 1 9, 9,2 7 255,0 2 00,,95 321,0 22,67 362,0 2 4, 4,41 3 98 98,0 2 6, 6,15 480,0 2 7, 7,91 540, 54 0,00 29,6 29,677

1 0, 0,79 2 18 18,0 19 ,2 ,27 12,17 2 9955,0 20,95 14,16 354,0 22 22,67 14,83 4 08 08,0 24,41 15 ,2 ,22 4 65 65,0 26 ,,115 17,20 5 22 22,0 27,91 18,2 18 ,200 601, 601,00 29 29,6 ,677

SOCKET SOCK ET WEL WELDI DING NG  LAP JOI JOINT NT + STU STUB B END END  BLIND   ORIFIC ORI FICE E COM COMPLE PLETE TE 

[Mhr/ea] x 0,60 [Mhr/ea] x 0,60 [Mhr/ea] x 0,30 [Mhr/ea] x 2,50

-

900# PN160 PN

PN100

1,27 1,36 1,49 1,66 1,78 2 ,01 2,35 2,70 3,24 3,84 4,54 6,28 6,28 7,78 7, 9,25 9, 10 ,3 ,33 11,8 11 ,833 13,3 13 ,344 14,,88 14 16,4 16 ,433

11,3 1 14,08 15,62 16,71 17,78 18,70 20,2 20 ,266

0,8 1,4 1,6 2,1 3,1 3,7 5,4 7,3 15,8 24,5 29,5 43,0 43,0 70,0 86,0 1 00 00,0 142,0 142,0 175,0 175,0 221,0 221,0 268, 26 8,00 31 5, 5,0 425,0 470,0 533,0 624 ,0 ,0 681,0 726, 72 6,00

[Mhr/ea] [kg/Mhr]  [kg]

[Mhr/ea] [kg/Mhr]  [kg]

1,51 0,53 1,60 0,88 1,74 0,92 1,93 1,09 2,06 1,50 2,30 1,61 2,67 2,02 3,05 2,39 3,63 4,35 4,27 5,74 5,02 5,88 6,899 6,8 6,244 6,2 8,55 8,19 10,17 8,46 11,42 11 8,76 13,1 13 ,100 10,8 10,844 14,,79 11,83 14 11,83 16,5 16 ,522 13 13,3 ,388 18,26 14 18,26 14,6 ,688

1,7 2,3 3,4 3,9 5,4 9,8 13,7 11,6 19,8 32,0 41,2 71,00 71, 100,0 133,0 152 ,0 ,0 184, 18 4,00 258, 25 8,00 3177,0 31 462, 46 2,55

1,75 1,86 2,00 2,20 2,35 2,60 3,00 3,42 4,03 4,72 5,52 7,54 7, 54 9,35 11,14 1 2, 2,5 7 14,4 14 ,433 16,3 16 ,322 18,2 18 ,244 20,1 20 ,199

0,97 1,24 1,70 1,77 2,30 3,77 4,57 3,39 4,91 6,78 7,46 9,42 10,70 11,94 11 12,0 9 12,75 12, 75 15,81 15, 81 17,3 17 ,388 22,91 22,91

1,7 2 ,3 2, 3,4 3,9 5,4 9,8 1 3,7 13 18,0 18 27,8 27 52,0 52 61,0 61 104,00 104, 175,0 264,0 30 8, 8,0 352, 35 2,00 18”  18 ”  20”  20 ”  22”” 22

2 0, 0,03 21,79 21 23,59 2 5, 5,40 2 7, 7,23 2 9, 9,08 30,911 30,9

608 ,0 ,0 692,0 817,0 942,0 113 5, 5,0 1339,0 1521 15 21,0 ,0

2 2, 2,1 6 24,14 26,16 28,20 3 0, 0,2 5 32,33 34,4 34 ,400

27,4 4 27 2288,67 31,23 3 3, 3,40 37,52 37 4 1, 1,42 44,222 44,2

24 ” 26” 28” 30” 32” 34” 36”  36 ” 

15 ,7 ,73 19,50 19,92 20,98 22,9 2 23,42 23,4 23 ,499

Man hour include next activities: - erection - welding - pressure t es est ing

handling on-site transport prefabrication

FOR PREFABRICA PREFABRICATION TION:  80% FOR INSTALLATION : 20%

  Materials Materials:: - Cr Mo Mo alloy steel - Copper alloy - Killed C.S.

1500# PN250 [Mhr/ea] [kg/Mhr] 2,08 0,82 2,19 1,05 2,35 1,45 2,57 1,52 2,73 1,98 3,01 3,26 3,45 3,97 3,91 4,60 4,57 6,08 5,33 9,76 6,19 9,85 8,40 12,38 8,40 12,38 10,42 16,79 12,44 21,22 14 ,1 ,10 2 1, 1,84 16,2 16 ,211 21 21,,71

2500# PN320 [kg] [Mhr/ea] 3,0 2,49 4,0 2,62 5,0 2,79 8,0 3,03 11,0 3,21 17,0 3,52 24,0 4,01 36,0 4,52 55,0 5,25 93,0 6,09 142,0 7,02 214,00 9,48 214, 9,48 407,0 11,76 573,0 14 14,06 14 ”   16”  16 ” 

[kg/Mhr]  ø-Inch

1,20 1,53 1,79 2,64 3,43 4,83 5,99 7,96 10,48 15,27 2 0,23 20 22,577 22,5 34,61 40,75 40

1/2”   3/4”   1”   1 1/4”   1 1/2”   2”   2 1/2”   3”   4”   5”   6”   8”  10”   12”  

Notice:

Uniit we Un weiig hts hts in th this is ta tabb le re reffe r to slip on flanges acc. to ANSI B 16-5. 1977. for to 24”   and BS-32 93 93-19 60 60 for 26” ÷ 36”  

  f  1,40 ÷ 1,60 1,20 1 ,0 ,00 ÷ 1,2 5

- Stainless steel 1,25 - High temp. alloy steel 1, 1,00 ÷ 1,80 - Alloy steel Ni 1,60 - Aluminium allo y 1 ,5 ,50

 

4. SMALL FITTINGS [Mhr/ea] 4.1 WELDOLETS, SOCKOLETS, NIPOLETS, etc. NIPOLETS, etc.

  114,3

CARBON STEEL 1 50 50 0# 0# 3 00 00 0# 0#   Std XS   1,39 1,44   1,56 1,63 1,92   1,8 2,28   2,12 2,53   2,33 3,02   2,72 3,85   3,42 4,67   4,05 6,02   4,99

6 00 00 0# 0#  XXS  1,57  1,84  2,24  2,80  3,21  4,04  5,46  7,00  9,64

  141,3   168,3   219,1

  6,05   7,07   9,96

12,78 16,89 23,28

  273

 13,47

  323,9

 16,23

  355,6

 17,97

  406,4

 20,50

  457

 23,03

  508

 25,58

  559   610

 28,12  30,67

  660   711

 33,18  35,75

  762

 38,27

4.2 HALF COUPLINGS FOR WELDING

ø-Inch OD-mm

 3   2  

1/2”   3/4”    1”  1 1/4”  1 1/2”  2”  2 1/2”   3”   4” 

  125   150 200   250

 5”   6”   8”  10” 

                   

12”  14”  16”  18”  20”  22”  24”  26”  28”  30” 

300 350 400 450 500 550 600 650 700 750

  21,3   26,7   33,4   42,2   48,3   60,3   73   88,9

7,50 9,42 13,83 17,30

85%

FOR INSTALLATION:

15%

  CARBON STEEL

 

  Dn-mm   15 15   20 20   25   32   40   50   65   80   100

FOR PREFABRICATIO N :

 3000#

Dn-mm   15   20   25   32   40   50   65   80   100

ø-Inch   1/2”    3/4”               

1”  1 1/4”  1 1/2”  2”  2 1/2”  3” 4”

OD-mm  21,3  26,7  33,4  42,2  48,3  60,3  73 88,9 114,3

6000#  XXS 1,31 1,53 1,82 2,16 2,47 3,17 3,90 5,03 6,17

  XS   1,27   1,44   1,69   2,00   2,23   2,66   3,38   4,10   5,27

4.4 THREADED FITTINGS  4.4.1 CARBON STEEL WITH ONE END

4.3 FITTINGS WITH SOCKET ENDS CARBON STEEL WITH ONE END Dn-mm   ø-Inch   1/2”    20   3/4”    25   1”    32   1 1/4”    40   1 1/2”  2”    50     65   2 1/2”  3”    80   4”   100  

20,61 22,83 26,12 29,41 32,72 36,02 39,34 42,59 45,93 49,21

  15

OD-mm  21,3  26,7  33,4  42,2  48,3  60,3   73  88,9 114,3

[Mhr/ea]   0,77     0,89     1,02   1,19   1,34   1,57   1,90   2,23   2,68

WITH 2 ENDS x 2 WITH 3 ENDS x 3

Dn-mm 15 20   25   32   40   50   65   80   100

ø-Inch

O DD- mm mm   21,3   3/4”    26,7   1”    33,4 1 1/4”     42,2 1 1/2”     48,3   2”    60,3 2 1/2”     73   3”    88,9   4”    114,3   1/2” 

[ Mhr Mhr/e /ea a]   0,17   0,18   0,20   0,23   0,27   0,32   0,42   0,53   0,70

Materials:

Man hour include next activities: - handling

- erection

(FOR WELDED FITTINGS ONLY) f 1,25 - Stainless steel

- on-site transport

- welding

- Cr Mo Mo alloy steel

- prefabrication

- pressure testing

- High temp. alloy steel

1,00 ÷ 1,80

- Copper alloy - Alloy steel Ni

1,20 1,60

- Killed C.S.

1,00 ÷ 1,25

- Aluminium alloy

1,50

4.4.2 NON-FERROUS METALS

 VALUES FOR CARBON STEEL x 0,50  

1,40 ÷ 1,60

4.4.3 "HERMETO" CO COUPL INGS VALUES IN TABLE 4.4.1 x 0,25

 

5. VALVES 5.1 VALVES WITH FLANGED ENDS 5.1.1 GATE, GL OBE, CHECK, SWING CHECK, BONNET,   BALL, BUTTERFLY, FILTER, etc [Mhr/ ea]

VF - Factor for installation of flanged valv es

fo r flanged valves                    3    3  

Dn-mm 15 20 25 32 40 50 65 80

 

ø-Inch

  1/2”   3/4”            

1” 1 1/4” 1 1/2” 2” 2 1/2” 3”

150# PN6-16 0,26 0,35 0,43 0,55 0,67 0,83 1,05 1,27

300# 25-40  0,28  0,37  0,45  0,58  0,71  0,87  1,11  1,33

400# PN64  0,34  0,44  0,55  0,70  0,86  1,06  1,35  1,62

600# PN100  0,35  0,45  0,56  0,72  0,88  1,08  1,38  1,66

900# PN160  0,35  0,46  0,57  0,73  0,89  1,10  1,39  1,68

1500# PN250  0,39  0,51  0,63  0,80  0,99  1,21  1,54  1,85

2500# PN320 0,40 0,52 0,65 0,83 1,02 1,25 1,59 1,91

D n to 100  

6 ÷ 16  PN  PN 25 ÷ 40  PN 64  PN 100  PN 160  PN 250  PN 320

  1,00   1,20   1,41   1,44   1,66   1,90   2,19

Dn 125 ÷ 200

ø 5” ÷ 8” 1,00 1,15 1,29 1,32 1,45 1,60 1,76

 

               

100 125 150 200 250 300 350 400

 

4” 5” 6” 8” 10” 12” 14” 16”

1,51 1,81 1,88 2,88 4,25 5,61 5,95 7,48

 1,60

 1,94

 1,98

 2,01

 2,21

 1,90

 2,12

 2,17

 2,38

 2,40

 2,16

 2,42

 2,48

 2,72

 2,74

 2,90

 3,23

 3,30

 3,63

 3,65

 4,68

 4,93

 5,14

 5,65

 6,21

 5,92  6,55

 5,92  6,90

 6,17  7,20

 6,78  7,91

 7,45  8,69

 7,89

 7,89

 8,23

 9,04

 9,93

5.1.2

CONTROL VALVES

[Mhr/ea] x 4,0

                   

450 500 550 600 650 700 750 800 850 900

  18”   20”   22”

7,65 9,35 9,85 10,20 11,05 11,90 12,75 13,60 14,45 15,30

 8,42  9,86

 8,87  9,86

 9,26 10,29

10,29 11,22 12,16 13,09 14,03 14,96 15,90 16,83

10,85 11,83 12,82 13,80 14,79 15,78 16,76 17,75

11,31 12,34 13,37 14,40 15,43 16,46 17,48 18,51

10,17 11,31 12,44 13,57 14,70 15,83 16,96 18,09 19,22 20,35

11,17 12,41 13,65 14,89

5.1.3 SAFETY VALVES 5.1.4 HYDRANTS HY 5.1.5 FLOW RATE METER 5.1.6 L EVEL GAUGES LE 5.1.7 CONDENSATE SEPARATORS CO 5.1.8 SIGHT GLASS SI 5.1.9 VENTURI TUBE VE 5.1.10 VALVES WITH E.M. DRIVE

[Mhr/ea] x 4,50 [Mhr/ea] x 2,0 [Mhr/ea] x 5,0 [Mhr/ea] x 2,70 [Mhr/ea] x 2,50 [Mhr/ea] x 1,80 [Mhr/ea] x 1,50 [Mhr/ea] x 3,0

             

  24”   26”   28”   30”   32”   34”   36”

2,28 2,64 3,02 4,03 6,84 8,21

150# 300# 400# 600# 900# 1500# 2500#

ø to 4”

(included in table)

Dn above 250 ø above 10”  1,00 1,10 1,16 1,21 1,33 1,46 1,61

 

5. VALVES 5.2 VALVES WITH WELDING ENDS  ENDS  [ Mhr/ea] 5.2.1 BUTT WELD

 3   4  

5.2.2 VALVES WITH SOCKET ENDS

  CARBON STEEL   Dn-mm ø-Inch  OD-mm   15 15 1/2”     21,3   20 20 3/4”     26,7   25   1”    33,4   32 1 1/4”    42,2   40 1 1/2”    48,3   50   2”    60,3   65 2 1/2”    73   80   3”    88,9   100   4”    114,3   125   5”    141,3   150   6”    168,3   200 8”     219,1   250  10”    273   300  12”    323,9   350  14”    355,6   400  16”    406,4   450  18”    457   500  20”    508   550  22”    559   600  24”    610   650  26”    660   700  28”    711   750  30”    762   800  32”    813

150# PN6-16   1,40   1,61   1,88   2,23   2,50   2,95   3,62   4,31   5,31   6,40   6,62   8,02  11,01  13,04  14,63  16,65  18,67  20,71  22,74  24,77  28,30  29,55  32,60  34,75

 

850

 34” 

  864

 

900

 36” 

  914

 800#

  300#  25-40

  400#  PN64

  600# PN100

  1,42   1,63

  1,48   1,71

 1,48  1,72

  1,90   2,26

  2,00   2,39

 2,01  2,40

  2,54   3,00

  2,69   3,19

 2,71  3,21

  3,68   4,38

  3,92   4,66

 3,95  4,70

  5,39

  5,74

 5,78

  6,50

  6,71

 6,76

  7,08

  7,38

 8,46

  8,61

  8,61

 12,26

 12,26

 14,65

 15,12

 16,40  18,69

 17,46  21,23

 20,97  23,27

 23,84  26,47

 25,56  27,86

 29,10  31,73

 30,13  32,42

 34,32  36,95

 34,72  37,01

 39,58  42,21

10,40 14,03 16,65 18,61 21,23 25,44 29,20 33,18 38,63 41,81 45,04 48,27 51,50

900# PN160  1,49  1,72  2,02  2,41  2,72  3,22  3,97  4,72  5,80  6,98  9,00 10,40 15,43 20,18 22,51 25,73 28,94 32,17 35,40 38,63 41,81 45,04 48,27 51,50

 36,91

 39,31

 44,83

54,73

54,73

Mo alloy steel - Cr Mo

 39,03

 41,57

 47,43

61,82

61,82

- Copper alloy

1,20

- Killed C.S.

1,00 ÷ 1,25

   0,71  0,83  0,98  1,16  1,33  1,59  1,94  2,30

1500# PN250  1,52  1,77  2,08  2,49  2,81  3,34  4,11  4,89  6,01  6,99 10,00 13,10 17,49 23,44 26,91 30,82 34,72 38,64 42,57 46,49

2500# PN320  1,54  1,79  2,10  2,51  2,84  3,37  4,16  4,95  6,08  7,24 11,42 15,23

Dn-mm   15   20   25   32   40   50   65   80   100

CARBON STEEL OD-m OD -mm m   21,3   3/4”    26,7   1”    33,4   1 1/4”    42,2   1 1/2”    48,3   2”    60,3   2 1/2”    73   3”    88,9   4”    114,3

5.3 VALVES WITH THREADED ENDS

 ø-Inch   1/2” 

5.4 PRESSURE GAUGES 5.5 THERMOMETERS

[Mhr/e [Mhr /ea] a]   0,96   1,12   1,32   1,59   1,81   2,15   2,65   3,16   3,87

ø-Inch

  1/2"   3/4” 

1”    1 1/4”    1 1/2”    2”    2 1/2”    3”    4”   

D- mm mm  O D  21,3   26,7   33,4   42,2   48,3   60,3   73   88,9   114,3

0,25 [Mhr/ea] 0,20 [Mhr/ea]

  Materials:

f  1,40 ÷ 1,60

- Stainless steel

1,25

- handling

- erection

ig h t em em p. p. al lo lo y s te tee l - H ig

1 ,0 ,00 ÷ 1 ,8 ,80

- on-site transport

- welding

- Alloy steel Ni

1,60

- prefabrication

- pressure testing

- Aluminium alloy

1,50

Man hour include next activities:

 

 

RATES FOR TENDER CALCULATIONS 1. MANHOUR ESTIMATE FOR INSTALLATION OF PIPING BASED ON DIAMETERS AND WEIGHTS (FOR CARBON STEEL ONLY) (Origin: Technical Technical Journal "3R International" of April 4, 1985) Productivity Efficiency Percentage (PEP) = 75%  

 3    5  

  Dn-mm   25   32   40   50   65   80   100   125   150   200   250   300   350   400   500   600   1000

ø-Inch

Type AS Ty AS

Ty pe AF AF

Type BS

Type BF

[Mhr/ton] [kg/Mhr] [Mhr /ton]   [kg [kg/M /Mhr] hr] [M [Mhr/ hr/ton ton]] [kg [kg/M /Mhr] hr] [M [Mhr/ hr/ton ton]]  [kg/Mhr]

  1”  1 1/4” 

  417   359

  2,40   2,80

  431   373

  2,32   2,68

  172   155

  5,81   6,45

  225   204

 

1 1/2”    2”  2 1/2”    3”    4”    5”    6”  8”   10”    12”    14”    16”    20”    24”    40” 

  330   286

  3,00   3,50

  344   299

  2,91   3,34

  146   131

  6,85   7,63

  193   176

 

  246   209

  4,10   4,80

  258   220

  3,88   4,55

  118   105

  8,47   9,52

  159   143

 

  165

  6,10

  175

  5,71

  88,5

  11,30

  122

 

  135

  7,40

  144

  6,94

  76,8

  13,02

  108

 

  111

  9,00

  119

  8,40

  66,7

  15,00

  94,7  

 

93,6 93, 6 

10,70 

9,90 

59,1 

 13,20

  82,2

  12,17

  50,8

  19,70

  73,8  

  63,2

 15,80

  68,7

  14,56

  44,5

  22,47

  65,5  

  59,5   50,6

 16,80  19,80

  64,8   55,3

  15,43   18,08

  42,7   38,0

  23,42   26,32

  43,8   38,9

 22,80  25,80

  48,1   42,9

  20,79   23,31

  34,2   31,5

  29,24   31,75

  63,0     56,7     61,5  

  20,8

 48,00

  23,3

  42,92

  20,1

  49,75

 site grading and facilities  si - decreas decrease e effec effectt of due to bad bad w weathe eatherr - scaffolding - radiographic inspection   - performance performance tests  

(calculate se separately) (add 5 - 7%) (add 2 - 4%) 4%) (calculate separately) (calculate separately) (calculate separately)

16,92 

 

  75,9

 Above standards do not not include: - st storing an and st store ha handling

101,0

 

84,7 

  47,7     31,6  

4,44 4,90 4, 90 5,18 5,68 5,6 8 6,29 7,00 7, 00 8,20 9,26 10,56 11,81 13,55 15,27 15,87 17,64 19,42 20,96 31,60

 Type AS Piping in the plant with prefabricated prefabricated weld joints Typ ype e AF Pipi Piping ng in the pl plan antt wi with th pr pref efab abri rica cate ted d   flanged joints Type BS Pip Piping ing outs outside ide the pla plant nt (pi (pipe pe ra racks, cks, sle sleepe eperr ways ways,, etc. etc.))   with prefabricated weld joints Type BF Pip Piping ing out outsid side e the the pla plant nt (pi (pipe pe ra racks cks,, slee sleeper per wa ways ys etc etc.) .)   with prefabricated flanged joints

Time allowance for - space obstruction  co o nn nn ec ec titi on on t o t he he ex is is titin g l in in es es - c - e  errection at higher elevations

(above 4 m)

kg/Mhr x 2,2046 = lbs/Mhr

to 15 % to 15 % 10 ÷ 20 %

[ Mhr Mhr/e /ea a]   0,52   0,63   0,75   0,92   1,11   1,35   1,73   2,13   2,63

 

(Use only if not possible acc. to man hours derived from basic estimate points)

2. EFFECT ASSESSMENT FOR QUICK CALCULATION 2.1 PIPING IN PROCESS PLANT Prefabrication and erection [kg/Mhr]

 3    6  

Dn-mm   ø-Inch   15   1/2”    20   3/4”    25   1”    32   1 1/4”    40   1 1/2”    50   2” 

OD-mm  21,3  26,7  33,4  42,2  48,3  60,3

  Sch 10

  65   80   100

  2 1/2” 

3”  4”

  125   150   200   250   300   350   400   450   500   550   600   650   700   750 > 800

   

5” 6” 8” 10”  12” 14” 16” 18”  20”  22”  24”  26”  28”  30”  32”

   

                       

>

Sch 20

Productivity efficiency percentage (PEP) = 75%

  1,44   1,92

 1,46  1,94

  1,67   2,03

  2,19   2,40

 2,21  2,43

  2,82   2,66

  2,67

 2,69

  2,90

 73,0

  3,35

 3,41

  3,56

 3,63

 3,92

 88,9

  4,35

 4,47

  4,80

 5,06

 5,60

114,3

  5,30

 5,67

  6,36

  7,46

 7,67

 7,89

141,3 168,3 219,1  273 323,9 355,6 406,4  457  508  559  610  660  711  762 > 813

  2,40

 2,43  7,58

  2,85   8,96

  3,84   11,27

 4,04 12,12

 4,01 12,29

 5”   6” 

16,85 20,09 20,55 21,51 24,01 25,68 30,74 32,88 33,43

16,94 20,30 20,90

 8”  10”  

  14,62   15,17   16,62   18,80   20,88   21,14   22,87   24,11   26,15  

28

 12,44  16,13  17,42  18,12  21,90  22,25  24,00  28,76  29,15  30,51  35,72

10,75 12,10 13,50 16,77 18,33 20,00 25,23 26,73 28,80 29,80 30,20 31,60 36,5

  Std  1,34

10,86 12,89 14,61 16,77 18,33 19,11 21,90 22,25 24,00 25,11 26,36 28,75   30

Sch 40

     15,60  17,64  20,64  22,40  27,14  29,49  30,80

Sch 60

11,15 15,30 16,10 18,20 20,90 23,00 27,70 29,70 31,00

60% 55%

 12,35  15,20

 Sch 80

 16,25

  16,50   17,22

 18,83  20,94

  19,56   21,22

 21,83  25,23

  23,73   28,26

 26,73  28,29

  30,14   31,98

Sch 100

Sch h 1 20 20  Sc

Sch Sc h 1 40 40

  14,00   17,50

  15,74   18,48

 16,10  19,00

  18,00   19,80

  18,93   20,07

 19,50  20,50

  22,00   24,00

  22,98   24,19

 23,20  25,00

  28,70   30,60

  29,69   31,13

 30,10  32,00

  32,10

  32,25

 33,00

XXS XX S

 3,06  3,18

 30,51  36,17

35,715

1/2”   3/4”    1”  1 1/4”  1 1/2”   2” 

 2,30  2,69

 28,16  29,15

 Included: pipes, fittings, flanges, valves and supports  Material: carbon steel  Ap  A pproximate div ision of hours for prefabrication and erection Prefabrication Erection to 11/2”  100% 2” ÷ 5” 6” ÷ 10”

  XS   1,50

ø-Inch

Sch 1 60 Sch 60  1,59  1,76  2,27  2,55  3,05  3,06

 10,67  11,46

Sch 30

 

2 1/2”   3”   4” 

12”   14”   16”   18”   20”   22”   24”   26” 28” 30” above 32” 

Piping between plants: ON PIPE RACKS [kg/Mhr] x 1,35 1,35

kg/Mhr x 2,2046 = lbs/Mhr

40% 45%

ON SLEEPER WAYS [kg/Mhr] WAYS [kg/Mhr] x 1,50

 

(Used only when such data provided in tendering documents ) [Mhr/m] [ kg/Mhr] Productivity Efficiency Percentage (PEP) = 75%

2. RATES FOR QUICK CALCULATION 2.2 PIPES  PIPES  (CARBON STEEL - NOT INSULATED)  ME  M EAN VALUE

FOR " TECHNIP" COMP . Sch 10   Sch 20   Std   Sch 40 XS   Sch 80   Sch 120   Sch 160 Average Dn-mm ø-Inch OD-mm [Mhr [Mhr/m] /m] [kg/M [kg/Mhr][Mhr hr][Mhr/m][kg/Mh /m][kg/Mhr][Mhr/m][ r][Mhr/m][kg/Mhr kg/Mhr][Mhr/m][k ][Mhr/m][kg/Mhr g/Mhr][Mhr/m][kg/M ][Mhr/m][kg/Mhr][Mhr/m] hr][Mhr/m] [kg/Mh [kg/Mhr] r] [Mhr/ [Mhr/m] m] [kg/Mh [kg/Mhr][Mhr/m][kg/Mhr] r][Mhr/m][kg/Mhr] diame diameter[i ter[inch] nch] Mhr/ Mhr/ ton*   15 118,40   1/2"   21,3   0,42   3,05   0,42   3,05   0,43   3,74   0,43   3,74   0,44   4,45   < 0,66   20 89,11   3/4"   26,7   0,43   2,99   0,44   3,91   0,44   3,91   0,46   4,81   0,46   4,81   0,48   6,06   0,67-0,87   25 56,35   1"   33,4   0,47   4,54   0,48   5,25   0,48   5,25   0,50   6,54   0,50   6,54   0,54   7,96   0,88-1,12   32 1 1/4”     42,2 43,15   0,50   5,44   0,53   6,51   0,53   6,51   0,56   8,11   0,56   8,11   0,60   9,48   1,13-1,37   40 1 1/2”     48,3 37,07   0,53   5,98   0,56   7,33   0,56   7,33   0,60   9,13   0,60   9,13   0,65   11,18   1,38-1,75   50 28,48   2”    60,3   0,57   7,03   0,61   8,98   0,61   8,98   0,67   11,19   0,67   11,19   0,77   14,42   1,76-2,25   65 2 1/2”     73 16,04   0,63   8,56   0,72   12,08   0,72   12,08   0,80   14,34   0,80   14,34   0,89   16,74   2,26-2,75   80 12,97   3"   88,9   0,69   9,58   0,81   14,04   0,81   14,04   0,92   16,61   0,92   16,61   1,08   19,81   2,76-3,50   100   4"   114,3   0,75   11,33   0,94   17,02   0,94   17,02   1,10   20,36   1,10   20,36   1,25   22,73   1,39   24,26   3,51-4,50  9,76   125   5"   141,3   0,85   13,73   1,09   20,09   1,09   20,09   1,30   23,86   1,30   23,86   1,52   26,51   1,74   28,36   4,51-5,50  7,60   150   6"   168,3   1,22   23,11   1,22   23,11   1,54   27,73   1,54   27,73   1,80   30,17   2,11   32,16   5,51-7,00  6,09   200   8"   219,1   1,43   23,50   1,63   26,22   1,63   26,22   2,11   30,69   2,11   30,69   2,68   33,81   3,15   35,24   7,01-9,00  4,66   250   10"   273   1,71   24,62   2,10   28,81   2,10   28,81   2,55   32,02   2,86   33,63   3,67   36,24   4,58   37,55   9,01-11,0  3,74   300   12"   323,9   1,98   25,37   2,46   29,92   2,59   30,79   2,90   32,55   3,71   35,63   4,92   38,05   5,86   38,55   11,01-13,0  3,51   350   14"   355,6   2,16   25,51   2,42   28,03   2,69   30,15   2,97   31,80   3,24   33,08   4,31   36,89   5,80   38,79   7,13   39,55   13,01-15,0  3,48   400   16"   406,4   2,42   26,13   2,72   28,58   3,02   30,79   3,65   33,70   3,65   33,70   5,34   38,01   7,22   39,75   9,07   40,26   15,01-17,0  3,41   450   18"   457   2,67   26,67   3,00   29,17   3,35   31,34   4,40   35,45   4,05   34,32   6,49   39,17   8,95   40,58   11,24   40,85   17,01-19,0  3,35   500   20"   508   2,93   27,03   3,68   31,79   3,68   31,79   5,04   36,54   4,46   34,77   7,76   40,10   10,71   41,27   13,72   41,17   19,01-21,0  3,30   550   22"   559   3,19   27,38   4,01   32,21   4,01   32,21   5,71   37,30   4,86   35,22   9,14   40,92   12,65   41,68   16,20   41,49   21,01-23,0  3,26   600   24"   610   3,44   27,67   4,33   32,56   4,33   32,56   6,65   38,50   5,25   35,62   10,66   41,48   15,22   41,98   19,39   41,62   23,01-25,0  3,23

 

 3   7  

  650   700   750   800   850   900   950  1000  1050  1100  1150  1200

  26"   28"   30"

  660   711   762

  4,15   4,22   4,72

  32"   34"

  813   864

  5,01   5,29

  36"

  914

  5,56

  38   40"

  30,60   5,65   35,96   32,46   6,04   36,26   31,14   6,43   36,55   31,37   6,82   36,80

  5,65   35,96   6,04   36,26   6,43   36,55

  25,01-27,0   27,01-29,0   29,01-31,0

  5,61   33,54   8,67   39,58   6,82   36,80   5,93   33,76   9,16   39,85   7,21   37,03   6,24   34,00   10,35   40,77   7,60   37,13

  31,01-33,0   33,01-35,0   35,01-37,0

 3,11  3,09

  966

  6,56   34,19

  7,98

  37,35

  37,01-39,0

 3,07

  1016

  6,87   34,38

  8,36

  37,56

 

>39,0

 3,06

  42"

  1066

  7,18

  34,54

  8,75

  37,74

  44"

  1118

  7,49

  34,71

  9,13

  37,90

  46"

  1168

  7,80

  34,81

  9,51

  38,07

  48"

  1219

  8,11   34,90

  9,89

8,24 4   3 8,2

  31,60   7,21   31,83   7,60

  37,03   37,13

  4,65   32,72   4,97   33,03   5,29   33,30

* Mhr Mhr/t /ton on f or or one one mi mill llim ime e tr tr e of a ve ve ra ra ge ge wa wa llll thi thick ckne ness ss

 3,21  3,18  3,15  3,13

     

Mhr/m x 0,3048 = Mhr/ft kg/Mhr x 2,2046 = lbs/Mhr

 

(Used only if such data provided in tendering documents)

2. EFFECT ASSESSMENT FOR QUICK CALCULATION   Productivity efficiency efficiency percentage (PEP) 75% 2.3 FITTINGS (CARBON STEEL) - MEAN VALUE VALUE [kg/Mhr]

FOR "TECHNIP" COMP.

  All types of fittings included.

 A   verage

  Dn-mm

ø-Inch 

15 20 25 32 40 50 65 80 100 125

1/2” 3/4”   1”  1 1/4” 1 1/2”   2”  2 1/2”    3”   4”     5”  

                 

 3    8  

OD-mm 21,3 26,7 33,4 42,2 48,3 60,3   73 88,9 114,3 141,3

Sch 10

Sch 20                    

Std 0,15 0,17 0,23 0,26 0,29 0,35 0,45 0,69 0,9 1,1

Sch 40 0,15 0,17 0,23 0,26 0,29 0,35 0,45 0,69 0,9 1,1

  XS

0,17 0,18 0,23 0,35 0,3 0,38 0,47 0,71 0,96 1,23

Sch 80   0,17   0,18   0,23   0,35   0,3   0,38   0,47   0,71   0,96   1,23

Sch 120

  1,07   1,47

Sch 160  0,17  0,18  0,24  0,27  0,33 0,36 36  0, 0,44 44  0, 0,68 68  0, 1,1 1   1, 1,37 37  1,

0,24 0,29 0,33 0,38 0, 38 0,48 0, 48 0,78 0, 78 1,14 1, 14 1,49 1, 49 2,25 2,25 3,33 3, 33

  150   200

  6”   8”  

168,3 219,1

  2,61

1,64 2,55

1,64 2,55

1,82 2,73

  1,82   2,73

  2,1   3,27

 2, 2,22 22 3,35 35  3,

  250

 10”

 3,98

  4,29

  4,73

 5,91

 16”  

  4,82

  5,48

 4,86

  450

 18”

  6,18

  5,3

 5,06

  500   550

 20”  22”

  6,17   6,11

  6,21   6,57

 6,93  7,38

  600   650

 24”  26”

  6,68

  7,14

 8,25

  700   750

 28”  30”

3,36 3,62 4,41 5,16 5,42 6,75 7,11 7,68 8,46 8,9 7,22

 4,05

 14”

3,12 3,47 4,23 5,25 5,72 7,97

  4,23

  400

3,12 3,38 4,07 4,65 4,8 5,94 6,08 6,65 7,56 7,62 7,95

  3,87

  350

2,67 2,84  3,9 4,32  4,5  6,0 5,91 6,62      

  3,98

 12”

273 323,9 355,6 406,4 457 508 559 610 660 711 762

  3,47

  300

  800

 32”

 

  850

 34”

  900   950

 36”  38”

  1000   1050

 40”    42”  

  1100   1150

 44”  46”

  1200

 48”  

8,21 8,69 9,87 14,28 14,84 16,52 17,42 18,26 19,38

4,29 4,82 5,4 6,75 6,98 7,52

813 864 914 966 1016 1066 1118 1168 1219 Note:

               

9,74

9,66 9,96 9,54 16,19 16,91 18,96 19,67 20,61 21,74

           

 

  "SOCKET"   0,23   0,31   0,36   0,42   0,62

XXS

Materials: Materials:

 

Stainless steel High temp. alloy steel Killed C.S Cr Mo alloy steel Alloy steel Ni Copper alloy Aluminium alloy

1,25 1,00 ÷ 1,80 1,00 ÷ 1,25 1,40 ÷ 1,60 1,60 1,20 1,50

f 

diameter [inch]  < 0,66

[Mhr/ton]*

0,67-0,87 0,88-1,12 1,13-1,37 1,38-1,75 1,76 1, 76-2 -2,2 ,25 5 2,26 2, 26-2 -2,7 ,75 5 2,76 2, 76-3 -3,5 ,50 0 3,51 3, 51-4 -4,5 ,50 0 4,51 4, 51-5 -5,5 ,50 0

2.087,00 1.760,00 1.178,00 893,30 739,10 698, 69 8,20 20 420, 42 0,50 50 256, 25 6,80 80 166, 16 6,10 10 119, 11 9,10 10

5,51-7 5,51 -7,0 ,00 0 7,0 ,011-9, 9,00 00

73,10 73,1 0 42,8 42 ,80 0

9,01-11,0 11,01-13,0 13,01-15,0 15,01-17,0 17,01-19,0 19,01-21,0 21,01-23,0 23,01-25,0  25,01-27,0  27,01-29,0  29,01-31,0

32,40 29,00 23,40 21,40 20,00 16,30 15,80 13,70 13,10 12,60 12,10

 31,01-33,0

11,80 11,20 10,80 6,93 6,62  5,90 5,67 5,36 5,15

 33,01-35,0  35,01-37,0  37,01-39,0  39,01-41,0  41,01-43,0  43,01-45,0  45,01-47,0   >47,0

Generally,, socket fittings to Ø 1 1/2" Generally kg/Mhr x 2,2046 =lbs/Mhr

are used in petrochemical plants. *[Mhr/ton] for one millimetre of average wall thickness

 

2.4 VALVES  VALVES  MEAN VALUE (ALL KINDS OF VALVES INCLUDED) Productivity Efficiency Percentage (PEP) = 75% 2.4.1. WITH FLANGED ENDS [Mhr/kg]

 3    9  

                                       

Dn-mm 15 20 25 32 40 50 65 80 100 150 200 250 300 350 400 450 500 550 600

2.4.2.

 

ø-Inch

  1/2”   3/4”  

1”

  1 1/4”   1 1/2”  

2”

 2 1/2”                      

3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24”

 150# NP6-16

300# NP25 0,222 0,216 0,195 0,150 0,134 0,089 0,085 0,079 0,064 0,049 0,046 0,044 0,041 0,037 0,033 0,029 0,027 0,022 0,019

0,266 0,259 0,234 0,180 0,161 0,107 0,102 0,077 0,077 0,056 0,052 0,049 0,045 0,040 0,036 0,031 0,029 0,024 0,020

WITH WELDING ENDS

2.4.2.1. BUTT WELDING: 2.4.2.2. SOCKET WELDING:

[Mhr/kg] x 3,0 [Mhr/kg] x 1,5

2.5 PIPE SUPPORTS Productivity Efficiency Percentage (PEP) = 80%

600# NP40 0,185 0,180 0,163 0,125 0,112 0,074 0,071 0,066 0,053 0,043 0,040 0,040 0,038 0,033 0,030 0,026 0,024 0,020 0,017

900# NP64 0,160 0,156 0,141 0,108 0,097 0,064 0,061 0,057 0,046 0,039 0,036 0,036 0,034 0,030 0,027 0,024 0,022 0,018 0,015

 

1500# 100-160 0,140 0,136 0,123 0,095 0,085 0,056 0,054 0,050 0,040 0,035 0,033 0,033 0,031 0,028 0,025 0,022 0,020 0,017 0,014

2.5. 2. 5.1. 1.

PART PA RTIC ICIP IPA ATI TION ON IN IN THE THE PIPI PIPING NG QUA QUANT NTIT ITY Y

2.5. 2. 5.2. 2.

to be estimated with 7 ÷ 9% FABRIC FABR ICA ATI TION ON AN AND D IN INST STAL ALLA LATI TION ON

2.5.2.1

DIVISION BASED ON THE UNIT WEIGHT OF SUPPORT Unit Fabrication Installation Fabrication+ installation   weight   [k g/Mhr] [kg/Mhr]   [kg/pc]   [kg/Mhr] 3,0 6,0   to 5   2,0   5 ÷ 20 7,0 10,0   4,12   20 ÷ 50 10,0 12,5   5,55   50 ÷ 75 12,0 14,0   6,46   75 ÷100 13,0 15,0   6,96 15,0 16,0 7,74  100÷150 16,0 20,0  above 150   8,90   Spring supports   10,0  

2.5.2.2

Fab abri rica cati tion on   DN   15 ÷ 50   65 ÷ 100

½” ÷2”  2 ½” ÷4” 

  125÷150   200÷350

5”÷6” 8”÷14”

[k g/Mhr]   2,80   5,75 8,25 14,10

Inst In stal alla lati tion on   [kg/Mhr]   5,1   6,25   8,15   9,10

Fab abri rica cati tion on+ + installation [k g/Mhr]   1,80   3,0   4,10   5,50

above 350 above 14”    16,0   11,50   6,70 2.5.2.3 2.5.2.3 EFFECT EFFEC T OF SUPPO SUPPORT RT FABRIC FABRICATIO ATION N AND AND INS INSTALL TALLATI ATION ON W WITH ITH ALREADY ALREADY KNOWN AVERAGE DIAMETER OF PIPING    

2.6 Mhr/kg x 0,4536 = Mhr/lbs kg/Mhr x 2,2046 = lbs/Mhr

DIVISION BASED ON THE PIPING DIAMETER

 The effect of the fabrication and installation installation [kg/Mhr] is equal to the average diameter in inches.

AVERAGE DIAMETER - Manner of Calculation  Average diameter of all pipings pipings in the plant or on the project shall be calculated in the following way: Sum of the multiplication product of the diameter and length of each pipe shall be divided by the sum of all pipe lengths. ( Dn Dn1 x l1) + ( Dn Dn2 x 2l ) + ( Dn Dn3 x 3l ) + ... ...   l + l + l + ...

1

2

3

 

3. RATES FOR INSTALLATION OF POLYETHYLENE PIPING

Productivity Efficiency Percentage Percentage (PEP) = 80% 3.1 PE Pipes DIN 8074 PN 6   Dn-mm   16   20   25   32   40   50

4    0  

                        

6735 90 110 140 160 180 200 225 250 280 315 355

t [mm]

PN 10 [kg/m]

t [mm]

[kg/m]

2,0 2,0 2,3 2,8

0,15 0,17 0,29 0,43

2,0 2,3 2,9 3,6 4,5

0,12 0,17 0,27 0,42 0,65

34,,63 5,1 6,2 7,9 9,1 10,2 11,4 12,8 14,2 15,9 17,9 20,1

00,,6987 1,38 2,04 3,60 4,33 5,45 6,77 8,55 10,50 13,20 16,70 21,10

56,,78 8,2 10,0 12,7 14,6 16,4 18,2 20,5 22,8 25,5 28,7 32,3

11,,0437 2,11 3,14 5,07 6,66 8,41 10,40 13,10 16,20 20,30 25,70 32,60

3.2 Rate Ratess for for insta installa llatio tionn of PE PE reinforce n forcemen mentt pads pads for for branc branchh conne connecti ction on            

PIPE Dn-mm 40 40 63 90 110 125

       

160 180 200 225

25

BRANCH 32 40

20 1,15 1,27 1,40 1,45 1,70

1,28 1,41 1,45 1,70

1,30 1,43 1,56 1,71

1,93

1,93

2,12

2,12

1,96 2,05 2,15 2,27

50

63

1,40 1,53 1,64

1,41 1,54 1,65 1,82

1,52 1,65 1,75 1,92

2,07 2,13 2, 2,23 2,35 2,

2,10 2,15 2,24 2,36

2,15 2,24 2,34 2,46

  PIPES Straight pipes Coils [Mhr/m] [Mhr/m] 0,24 0,12 0,24 0,12 0,28 0,14 0,29 0,15 0,32 0,16 0,45 0,20 00,,4572 0,54 0,58 0,69 0,73 0,77 0,83 0,89 0,95 1,02 1,11 1,21

00,,2258 0,30 0,40

FITTINGS AND VALVES Reducers Caps [Mhr/ea] [Mhr/ea]

Bends [Mhr/ea]

Tees [Mhr/ea]

1,05 1,05 1,11 1,27 1,29

1,58 1,58 1,67 1,92 1,95

1,05 1,08 1,19 1,28

0,51 0,51 0,54 0,64 0,65

11,,4694 1,78 1,90 2,11 2,46 2,64 2,81 3,02 3,30 3,77 3,98 4,27

22,,2486 2,67 2,82 3,21 3,72 4,02 4,23 4,56 4,98 5,67 6,00 6,45

11,,4518 1,71 1,96 2,07 2,31 2,58 2,75 2,93 3,18 3,55 3,89 4,15

00,,7862 0,89 1,02 1,07 1,24 1,34 1,41 1,52 1,66 1,89 2,00 2,15

Flanges [Mhr/ea] 0,62 0,62 0,62 0,66 0,77 0,78

Valves [Mhr/ea] 0,19 0,25 0,31 0,40 0,40 0,63

01,,9020 1,08 1,23 1,28 1,51 1,63 1,73 1,85 2,03 2,32 2,46 2,63

00,,8910 1,00 1,56 1,70 1,88 2,20 2,50 3,15 4,25 4,50 5,10 5,95

[Mhr/ea [Mhr /ea]]

mm x 0,03937 = inch kg/m x 0,672 = lbs/ft Mhr/m x 0,3048 = Mhr/ft

 

4. RATES FOR ERECTION OF PVC & FRP PIPING

5. CARBON STEEL PIPING (SCH 40) CEMENT LINED INSIDE

Productivity Efficiency Percentage (PEP) 80% Productivity Efficiency Percentage (PEP) 80% Pipes Socket Nozzle at Valves handling joint 90° and 90 PVC   reinforce housing ho   m ent me (handling) Dn-mm ø-Inch  [ Mhr Mhr/m /m]] [ Mhr Mhr/e /ea a ] [ Mhr Mhr/e /ea a ] [ Mhr Mhr/e /ea a]   15   1/2”    0,115   0,10   0,38   0,13   20   3/4”    0,120   0,11   0,39   0,16   25   1”    0,125   0,13   0,40   0,17   30 1 1/4”   0,130   0,14   0,43   0,20   40 1 1/2”   0,135   0,15   0,45   0,25   50   2”    0,150   0,17   0,50   0,35   65 2 1/2”   0,155   0,19   0,65   0,58   80   3”    0,165   0,23   0,80   0,85   100   4”    0,180   0,28   1,00   1,25   150   6”    0,185   0,35   1,30   1,60   200   8”    0,230   0,40   1,80   1,90   250   10”    0,280   0,50   2,30   2,50   300   12”    0,330   0,63   2,90   3,00   350   14”    0,400   0,78   3,60   400   16”    0,460   0,94   4,10   450   18”    0,520   1,08   4,80   500   20”    0,560   1,22   5,50   550   22”    0,620   1,36   6,20   600   24”    0,660   1,46   7,00 650   26”    0,720   1,57   700   28”    0,760   1,66   750   30”    0,800   1,74   800   32”    0,820   1,81 850   34”    0,850   1,87   900   36”    0,870   1,92   950   38”    0,890   1,98  1000   40”    0,920   2,05    

4   1  

SYNTHETIC MATERIAL S ABBREVIATIONS & INTERPRETATION

 FRP  PE  PVDF  PV PVC C PP  FP M -

EPDM DM  EP

 CR -

PTFE FE  PT PVC-C C PVC PB  POM  NBR  IIR  CSM  PEHD  PRFV -

FIBREGLASS RESIN POLYESTER   POLYETHYLENE POLYVINY POL YVINYLDENFL LDENFLUORID UORIDE E POL PO LYV YVIN INYL YLCH CHLO LORI RIDE DE,, HARD PO LY LY PR PR OP OP YL YL EN ENE (V IT ITON A ® ) FL UOR IN INDIAN RUBBER (KAUTSCHUK) (APT (A PTK) K) ETHYL ENE PROPYLENEINDIAN RUBBER   (NEOPRENE ®) CHL OROPRENE INDIAN RUBBER   (TEF (T EFLO LON N ®) ®) POLYTETRAFLUORETHYLENE POLYVINY POL YVINYLCHLO LCHLORIDE, RIDE, ADDITIONALLY CHL ORINATED POLYBUTENE POLYXYMETHYLENE NITRIL INDIAN RUBBER BUTYL INDIAN RUBBER (HYPALON ®) CHL ORSUL FONYLPOLYETHYLENE POLYETHY POL YETHYLENE LENE HIGH HIGH DENSITY  DENSITY  POLYESTE POL YESTER R RESIN FIBREGLAS FIBREGLASS S REINFORCED, REINFORCED, INTERNAL CORE OF PVC

Dn-mm

ø-Inch

  150   200

  6”    8” 

  250

  10” 

  300

  12” 

  350

  14” 

  400

  16” 

  500

  20” 

  600

  24” 

  700   800

  28”    32” 

  900   1000

  36”    40” 

  1100   1200

  44”    48” 

Pipes handling Pipe cutting

Butt weld

Sleeve joint with two f illet welds  fi

[Mhr/m]   0,66   0,82   1,08   1,30   1,58   2,05   2,30   2,88   3,63   3,95   4,20   4,45   4,65   4,80

[Mhr/ea] 2,00 2,60 3,10 4,10 5,00 6,60 8,60 9,40 13,30 14,90 16,40 17,90 19,30 20,60

[Mhr/joint]  3,30  4,60  5,70  6,90  7,90  9,20 10,40 12,40 15,50 17,35 19,15 20,85 22,45 24,00

[Mhr/cut.]] [Mhr/cut. 0,65 1,00 1,20 1,45 2,30 2,95 3,70 4,65 5,90 6,40 6,90 7,25 7,55 7,85

Nozzle att 90° a

Re R epair of   concrete lining on joints

[Mhr/ea] [Mhr/joint] 6,05 0,35 7,30 0,50 8,30 0,60 11,35 0,65 13,90 0,80 18,15 0,95 22,80 1,10 26,95 1,25 33,60 1,50 36,50 1,72 40,30 1,93 43,80 2,15 47,30 2,36 50,50 2,60

Note: 1. Piping of synthetic materials to be calculated acc. to the tables for PE or PVC piping 2. For diameters larger than 40” (1000 mm), to be calculated proportionally to 40”  

Mhr/m x 0,3048 = Mhr/ft  

 

6. PIPING MADE OF STEEL AND GREY CAST-IRON   I made an exception and included steel and grey cast piping in  the Chapter Piping Above Ground although they are in most cases laid underground.   According to these man hour rates only the pipes are determined according to the unit

6.2 FITTINGS  FITTINGS  (DIN: A, E, F, FF FF,, K, FFK, Q, MQ, MMQ, MMK, FFR, T, TT TT,, U, MMA, MMB, MMR, X, N) When calculating man hours for each fitting eac h

  of length whereas the man hour rates for all other fittings   sh shou ould ld be ca calc lcul ulat ated ed ac acc. c. to the typ type e an and d nu numb mber er of joi joint nts. s. Fo Forr ex exam ampl ple, e,  Tpiece with a flange at one end and a socket at two ends should be calculated as

end is calculated according to its type, except for the stra st raig ight ht en end. d.

1 x flanged end and 2 x socket end.     Pr Prod oduc ucti tivi vity ty ef effi fici cien ency cy pe perc rcen enta tage ge (P (PEP EP)) = 80 80% %

4   2  

6.1 CAST IRON PIPES     Nominal   diameter   DN   80 (3”)   100 (4”)   125 (5”)   150 (6”)   200 (8”)   250 (10”)   300 (12”)   350 (14”)          

400 450 500 600 700 800

Nominal diameter DN

Socket end [Mhr/ea]

Flanged end [Mhr/ea]

 0,6 0,75

  0,5 0,58

  0,79   1,15

0,8 0,86 1,05 1,28 1,85 2,67 3,42 4,02  4,8  6,0  7,2

  0,65   0,71

* Note:   According to John S. Page's manual each joint between the pipes is also added man hour for the socket joint. I do not agree with that. This could apply only if the fittings are not calculated separately. Just to mention that his man hour for a sock et joint is 1/3 lower than the man hour

80 (3”) 100 (4”) 125 (5”) 150 (6”) 200 (8”) 250 (10”) 300 (12”) 350 (14”) 400 (16”) 450 (18”) 500 (20”) 600 (24”) 700 (28”)

  1,48

in this table.

800 (32”)

 8,3

  4,32

 

Pipe length [m] 3; 4; 5 3; 4; 5 3; 4; 5 3; 4; 5 5 5 5 5

(16”) (18”) (20”) (24”) (28”) (32”)

 

[Mhr/m] *   0,25   0,295   0,33   0,36   0,46   0,56

5 5 5 5; 6 6 6

 

  0,92   1,15   1,4   1,64   1,9   2,18   2,46   3,05   3,67

  1,74   2,07   2 ,5 ,5 9  

3

  3,25

 /m x 0,3048 = Mhr/ft Mhr /m

6.3 VALVES Va lv lv es es to be e sti stima mate ted d by co cons nsid ide e rin ring g th the e h an an dl dli ng ng a s f or or t he he p ip ipi ng ng a bo bo ve ve g ro ro un un d a nd nd by ad di di ng ng 2 x Mhr/ea for a flanged end.

 

7. RATES FOR PIPING BASED ON INCHINCH -DIAMETER (ID)

CORRECTION FACTORS: - Different materials

Productivity efficiency percentage (PEP) 80% Some world companies ask in their call for t en ender for a price review according to inchdiameter (ID) and inclusion of all the operations and works involved in installation of piping.   Item 3.1 x F = Mhr D ID

 

Item 3.1 F D

4    3  

- E  Esstimate points

for butt joint of a relative diameter and

  wall thickness ( Chapter X. Pages 147 ÷ 201) - sum of factors for the activities required (see below) - diameter (or average diameter) of piping in inches  ACTIVITY FACTORS - p  prrefabrication - installation - prefabrication - i  innstallation - prefabrication - i  innstallation - i  innstallation - h  hyydrostatic - p  pnneumatic

- PIPES - PIPES - FITTINGS - FITTINGS - FLANGES - FLANGES - VALVES - PRESSURE TEST - PRESSURE TEST - ELEVATION IMPACT - IMPACT OF SPACE OBSTRUCTION

Sum

0,300 0,080 1,200 0,200 0,320 0,050 0,130 0,100 0,020 0,012 0,010 2,422

  Every company has its own way of listing the prices for each activity in its call for tenders. Therefore, only the factors for the activities that are required by tenderin documents are summed up.   Fabrication and installation of pipe supports is considered separately according to the tables on page 39..

CS Low alloy (0,5 Mo) 1 ,2 ,25 Cr 5 Cr 9 Cr Composite pipe Non-ferrous material Plastic resin CS p ip e lined inside (Lining CS):

1,00 1,10 1,3 0 1,40 1,50

3 ,5 N i SS 304 SS 3 16 16 SS 321 SS 347

- cement

1,60 1,25 1 ,2 ,25 1,25 1,25 0,75 2,00 0,60 1,20

- resin - g  gllass

1,15

1,10

- Place of installation:

 Above Ground Under Ground Pipe rack Bridge Around equipment Line pipe - Sleeper way

1,00 1,20 1,15 1,30 1,20 0,90

- Prefabrication

0,90

- Type of joint: Butt weld 90° Nozzle weld 90° Reinforced nozzle weld

1,00 1,60 3,00

Socket weld Seal weld Threaded joint Root pass Fillet weld Mitre weld

0,60 0,50 0,35 0,35 0,65 1,50

(Sockolet, weldolet, coupling, etc.)

1,60

 Tie-in to existing piping

4,00

 

OPERATION (BASED ON INCH-DIAMETER) 8. RATES FOR UNITS OF OPERATION (BASED Productivity efficiency percentage percentage (PEP) = 80% 1. Cuts, bevels and welds 1.1 Cuts and bevels - all materials 10 0,24 - Schedule

5S

0,35

[Mhr/ID]

- Schedule

20

0,29

[Mhr/ID]

- Schedule

10S

0,44

[Mhr/ID]

- Schedule

40

0,36

[Mhr/ID]

- Schedule

20

0,53

[Mhr/ID]

60

[Mhr/ID] [Mhr/ID]

- Schedule

- Schedule

0,29 0,61

- Schedule

40S 60

0,65 1,05

[Mhr/ID] [Mhr/ID]

- Schedule

80

0,75

[Mhr/ID]

- Schedule

80S

0,75

[Mhr/ID]

0,31

[Mhr/ID]

- Schedule

80

1,29

[Mhr/ID]

- Std

- XS - Schedule - Schedule

100 120

0,97 1,10

[Mhr/ID] [Mhr/ID]

- Schedule - Schedule

100 120

1,67 2,64

[Mhr/ID] [Mhr/ID]

- Schedule

160

1,23

[Mhr/ID]

- Schedule

160

3,54

[Mhr/ID]

0,61

[Mhr/ID]

- XXS 4   4  

1.2.2 Stainless steel - Schedule

[Mhr/ID]

- Shop fabrication

90%

- Shop fabrication

90%

- Field fabrication

125%

- Field fabrication

125%

1.2 Welding 1.2.1 Carbon Steel - Schedule - Schedule - Schedule

1.2.3 Alloy Steel - Schedule

10

0,29

[Mhr/ID]

20 40

0,35 0,60

[Mhr/ID] [Mhr/ID]

- Schedule

- Std

- Schedule

10

0,41

[Mhr/ID]

20 40

0,49 0,84

[Mhr/ID] [Mhr/ID]

0,25

[Mhr/ID]

- Std

0,35

[Mhr/ID]

- Schedule

60

0,70

[Mhr/ID]

- Schedule

60

0,98

[Mhr/ID]

- Schedule

80

0,86

[Mhr/ID]

- Schedule

80

1,20

[Mhr/ID]

0,30

[Mhr/ID]

- XS

0,43

[Mhr/ID]

- XS - Schedule

100

1,11

[Mhr/ID]

- Schedule

100

1,55

[Mhr/ID]

- Schedule

120

1,76

[Mhr/ID]

- Schedule

120

2,46

[Mhr/ID]

- Schedule

160

2,36

[Mhr/ID]

- Schedule

160

3,30

[Mhr/ID]

0,53

[Mhr/ID]

- XXS

0,85

[Mhr/ID]

- Shop fabrication

90%

- Shop fabrication

90%

- Field fabrication

125%

- Field fabrication

125%

- XXS

 

8. RATES FOR UNITS OF OPERATION (BASED ON INCH-DIAMETER)

2. Pipe - Handling Based on MID (meter-inch-diameter)

3. Miscellaneous 3.1 Temporary Items

- Schedule - Schedule

4    5  

10 20 - Schedule 40 - St d - Schedule 60 - Schedule 80 - XS - Schedule 100 - Schedule 120 - Schedule 160 - XXS

0,15 0,18 0,24 0,17 0,28 0,33 0,21 0,39 0,43 0,51 0,44

-

Shop fabrication 12%

-

Field fabrication 105%

[Mhr/MID] [Mhr/MID] [Mhr/MID] [Mhr/MID] [Mhr/MID] [Mhr/MID] [Mhr/MID] [Mhr/MID] [Mhr/MID] [Mhr/MID] [Mhr/MID]

-

Temporary Supports

0,17

[Mhr/kg]

-

Temporary Spacers

0,50

[Mhr/kg]

3.2 Tapering Wall Thickness for Fittings and Flanges

-

to 5 mm 5 ÷ 10 mm 10 ÷ 15 mm 15 ÷ 20 mm

0,25 0,45 0,68 0,90

[Mhr/ID] [Mhr/ID] [Mhr/ID] [Mhr/ID]

-

20 ÷ 25 mm

1,25

[Mhr/ID]

-

Shop fabrication 90%

-

Field fabrication 110%

3.3 Bending of pipe  /kg x 0,4536 = Mhr/ft Mhr /kg

-

Bending of pipe t o 1 1/ 1/ 2” 2”

1 ,0 ,0

[ Mh Mhr /b /bend]

 

9. RATES FOR PIPING WELDING - (Fitter's BUTT WELD (C. S.) - COMPLETE [Mhr/weld]

work not included)

Productivity efficiency percentage percentage (PEP) = 90%

4    6  

                 

ø-Inch 1/2” 3/4” 1” 1 1/4” 1 1/2” 2” 2 1/2” 3”

                                

46”” 8” 10” 12” 14” 16” 18” 20” 22” 24” 26” 2 8” 28 3 0” 30 3 2” 32 34” 34 36” 36

10

20

30

Std

40

60

XS

0,29 0,32 0,37 0,43 0,47 0,55 0,67 0,79

2,86 3,25 3,64 4,03 4,42 4,81 5,69 6,12 6,55 6,98 7,41 7,83

Factors for calculating the rates acc. to type of weld

1,82 2,23 2,62 3,13 3,56 3,98 4,87 5,35 5,83 7,68 8,27 8,85 9,44 10,03 10,60 1. 2. 3. 4. 5.

1,88 2,42 2,95 3,45 3,92 4,85 5,93 6,52 7,82 10,00 10,71 11,42 1 2,14 12 1 2,84 12

80

100

120

140

0,30 0,33 0,38 0,45 0,49 0,59 0,72 0,87

11,,0409 11,,1844 2,02 2,27 2,61 2,64 3,23 3,23 3,69 3,15 3,31 4,18 3,81 4,98 3,45 3,80 4,79 4,18 5,91 3,92 4,76 5,98 4,76 7,63 4,40 5,87 7,61 5,34 9,63 4,87 6,83 9,19 5,93 11,96 5,35 7,86 10,96 6 ,52 14,63 5,83 9,38 13,42 7, 7 ,10 17,65 6,30 7,68 6,77 8,27 7,25 8,85 7,73 12,51 9,44 8,20 13,29 10,03 8,67 15,35 10,60

Nozzle weld 90° No Nozzle weld 90° w. reinforcement N ozzle weld bevelled No Nozzle weld be bevelled w. w. reinforcement Weldolet, sockolet, nipolet, etc. We

2,97 4,37 6,05 7,45 9,51 12,27 15,47 18,69 23,51

1,50 2,50 1,90 3,00 2,00

12,,2290 3,50 5,08 7,26 8,85 11,56 15,11 18,87 23,17 29,30

6. 7. 8. 9. 10.

3,91 6,07 8,29 10,35 14,10 17,77 23,00 27,93 34,90

Fillet weld Fillet weld Fillet weld Fillet weld Fi Mitre weld

160 0,31 0,34 0,40 0,47 0,53 0,67 0,81 1,03

XXS 0,32 0,36 0,43 0,52 0,59 0,73 0,97 1,24

ø-Inch 1/2”   3/4” 1” 1 1/4” 1 1/2”   2”   2 1/2” 3” 3”

12,,4668 4,35 6,91 9,89 11,89 16,06 21,00 26,87 33,05 41,45

13,,7125 4,20 6,07 7,26

46””   8”   10”   12”   14”   16”   18”   20”   22”   24”   26”   28”   30”   32”   34”   36”  

"socket weld" "dummy" 90° "dummy" on elbow closing dummy cl

Factors for different kinds of materials

1. Carbon steel 2. Stainless steel

1,00 1,50

3. Chromium-Molibden steel

1,40

0,60 0,90 1,35 0,30 1,30

 

10. MAN HOURS FOR WELDING OF PIPING   BUTT WELD - ROOT PASS AND FILLER PASSE

 

4   7  

ø-Inch   1/2”   3/4”   1” 1”   1 1/4”   1 1/2”   2” 2”   2 1/2”   3” 3”   4”   6”   8” 8”   10 10”   12”   14”   16”   18”                  

20” 22” 24” 26” 28” 30” 32” 34” 36”

Root pass - GTAW [Mhr/weld] 0,10 0,12 0,15 0,17 0,19 0,21 0,26 0,29 0,33 0,42 0,55 0,70 0,83 0,91 1,03 1,16 1,28 1,40 1,53 1,65 1,78 1,90 2,03 2,15 2,28

10

20

30

1,95 2,22 2,48

1,27 1,53 1,79 2,22 2,53 2,82

1,33 1,72 2,12 2,54 2,89 2, 3,69 3,

2,75 3,02 3,28 4,04 4,34 4,65 4,75 5,26 5,55

3,59 3,95 4,30 6,03 6,49 6,95 7,41 7,88 8,32

4,65 4, 5,12 6,29 8,22 8,81 9,39 10,09 10,56

FILLER AND COVER PASSES - SMAW [ Mhr/weld] St d 40 60 XS 80 0,19 0,20 0,20 0,21 0,22 0,23 0,26 0,28 0,28 0,30 0,34 0,38 0,41 0,46 0,50 0,58 0,67 0,81 1,07 1,42 1,47 2,27 2,06 1,94 3,23 2,53 2,99 2,32 2,48 4,18 2,98 4,15 2,54 2,89 4,79 3,27 5 ,00 5, 2,89 3,73 5,98 5, 3,73 6,60 3,24 4,71 7,61 7, 4,18 8,47 3,59 3,95 4,30 4,65 4,99 5,35 5,70 6,05 6,39

5,55 6,46 7,85

10,48 11,14 13,07

9,19 9, 10,96 13,42

4,65 5,12 5,57 6,03 6,49 6,95 7,41 7,88 8,32

10,68 13,23 16,12

100

120

140

2,42 3,67 5,22 6,54 8,48 11,11 11

0,96 1,78 2,95 4,38 6,43 7,94 10,53 13,95

3,36 5,37 7,46 9,44 13,07 16,61

160 0,21 0,22 0,25 0,30 0,34 0,46 0,55 0,74 1,13 2,26 3,80 6,21 9,06 10,98 15,03 15 19,84 19

14,19 17,29 21,98

17,59 21,77 27,77

21,72 26,53 33,37

25,59 25 31,65 39,92

XXS 0,22 0,24 0,28 0,35 0,40 0,52 0,71 0,95 1,39 2,73 3,65 5,37 6,43

ø-Inch 1/2”   3/4”   1”   1 1/4”   1 1/2”   2”   2 1/2”   3”   4”   6”   8”   10”   12”   14”   16”   18”   20”   22”   24”   26”   28”   30”   32”   34”   36”  

 

 

4    8  

 

12. INSTALLATION OF PIPING ABOVE - GROUND Unit standards as per integral elements Prefabrication and installation breakdown (Technical (T echnical calculation manual, year 2003.) 1. 1.1.

Pipes Pipes in the plant

1.2.

Pipes on pipe rack Pi

2. Fittings 2. 1. Elbows 2.1.1. Elbows and mitre mitre   bends prefabricated to 2.2.2. Mitre bends bends to be manufactured 2.2.

Tee - pieces to

to 1 1/2" 2"- 48" above 48"

Prefabrication _ 8% _ _

  Installation 100% 92% 100% 100%

to 1 1/2" 2" - 48"

_ 85%

100% 15%

to 48" above48" to 1 1/2"

85% 50% _

15% 50% 100%

2"- 48" to1 1/2" 2"- 36"

2.3.

Reducing pieces completed

2.4. 2.5.

Caps - all bores O' lets, half - couplings and the like

3. 3.1. 3. 1.

Flanges Flan Fl ange gess - for for wel weldi ding ng all all  ty  t ypes and bores, Blind flanges, orifice plates, spectacle blind and the like

3.2.

4.

 Valves -a -all kinds, types pad bores

5.

Pipe supports

 

to 2" 3" - 6" 8"- 14" 16" and above

6. Miscellaneous 6. 1. All branch welds 6. 1. Stiffener rings and reinforcing pads 7.

85% _ 85% 100% 85%

15% 100% 15% _   15%

80% _

20% 100%

_

100%

65% 55% 50% 45%

35% 45% 50% 55%

100% 100%

_   _  

Bolts and gaskets - not - not to be taken into account

49

 

II. PIPELINES - Basis for calculation of man hours Productivity efficiency percentage (PEP) = 75%

Contents:

1. 2. 3. 4. 5. 6. 6.1 6.2 7. 8.

PIPE TRANSPORT STRINGING BENDING JOINTING WELDING WRAPPING MACHINE WRAPPING HAND WRAPPING LAYING IN TRENCHES SPECIAL POINTS

8.1 8.2 8.3 8.4 8.5 8.6 9. 10. 10.1 10.2

BORING UNDER ROADS OR RAILROADS BREAK OUT OF ROADS CONNECTING PIPELINE SECTIONS CROSSING WATERCOURSES INSTALLATION OF CLEANING STATIONS PUTTING UP PIPELINE MARKERS PRESSURE TESTS PRELIMINARY & FINISHING WORKS PRELIMINARY WORKS FINISHING WORKS

To make an estimate for laying a pipeline is a very “sensitive” operation, particularly for estimators lacking experience theempirical laying andrates i nstallation installation such pipelines. Worldand recognized companies specializing in this kind of work in have based onofdiameter and length, on “inch-meter” “i nch-meter” respectively respectively. .A widely recognized manual for that purpose is John S. Page's Page's Cost Estimating Manual for Pipelines and Marine Structures. The impact of climate, ground grou nd and the state is quantified quanti fied empirically. empirically. Since our company does not specialize only in pipelines, we developed rates and elements el ements for calculation of the time needed. However, 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, Similarly, he can change them depending on the case. 1.

PIPE TRANSPORT

Basic rate for pipe transport is..............................0,8

[Mhr/ton]

The basic rate changes with the conditions by adding or deducting the following rates:

 

   

 Distance:

for each kilometre more than 5 km.............. plus 0,06

[Mhr/ton]

 Roads:

- c  ciity roads+............................................ plus 0,20 [Mhr/ton] - a  assphalt roads to 50 %............... not co considered - a  assphalt roads above 50 %.............. plus 0,15 [Mhr/ton]

 Means of   t trransport:

- t  trrailer truck lo l ong vehicle......................... not considered ÿ- t trrailer with HIAB................................... minus 0,10 [Mhr/ton] - t  trracktor with a trailer............................... plus 0,20 [Mhr/ton]

 Loading:

- s  sppecial crane for loading.......................... not considered - l lo oading by HIAB......................................plus 0,15 [Mhr/ton] - c  crrane used also for loading.......................plus 0,20 [Mhr/ton]

 Unloading:

- unloading by a special crane to - a temporary pipe storage.........................minus 0,20 - unloading with pipe stringing along the right-of-w right-of-way ay

[Mhr/ton]

  by a special crane.................................. not considered - u  unnloading and pipe stringing by HIAB......... plus 0,20 [Mhr/ton]

50

 

 Pipe Diameter:

to 4” 4”....................................plus 0,30 [Mhr/ton]  6 6”” ÷ 8”....................................not considered 10” 14” 18” 26”

 Piipe Type:  P

÷ 12”..................................minus ÷ 16”..................................minus ÷ 24”..................................minus and above............................minus

0,15 0,30 0,40 0,50

[Mhr/ton] [Mhr/ton] [Mhr/ton] [Mhr/ton]

- not wrapped..................................not considered - wrapped....................................plus 0,10 [Mhr/ton]

 Co  C ontinuity of continuous transport:..................................minus 0, 0,15 [Mhr/ton] - wit ith h occasio ion nal sto top ppages..........not con onssidered - acc. to circumstances.................plus 0,15 [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 0,21 [Mhr/pc]

  to 4”...........................plus   6” 6” ÷ to 8”............................plus 10” ÷ to 14 14”..............................plus 16” ÷ to 20”.............................plus 22” and above..............................plus

0,25 0,29 0,34 0 ,38 0, 0,41

[Mhr/ [Mhr/ [Mhr/ [Mhr/ [Mhr/

pc] pc] pc] pc] pc]

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”.................................4,5   4”..................................5,6   6” 6” ÷ 8”.............................. ....6,5 10” ÷ 14”....................................7,5 16” ÷ 20”.....................................9 22” and above.............................12,5

[Mhr/bending] [Mhr/bending] [Mhr/bending] [Mhr/bending] [Mhr/bending] [M [Mhr/bending]

- Shop bending: contractors - Bending for special points is not calculated according to this rate but is included under special points.

51

 

4.

PIPE JOINTING

It includes pipefitter works for joining of pipes. Welding is not included. - Basic rates:  3””....................0,75  3  4””....................1,25  4  6””....................1,75  6  8””....................2,25  8 10”...................2,75 12”...................3,25

[Mhr/joint] [Mhr/joint] [Mhr/joint] [Mhr/joint] [Mhr/joint] [Mhr/joint]

14”.....................3,75 16”.....................4,25 18”.....................4,75 20”.....................5,25 22”.....................5,75 24”.....................6,25

[Mhr/joint] [Mhr/joint] [Mhr/joint] [Mhr/joint] [Mhr/joint] [Mhr/joint]

 The rate for pipe joining is calculated by increasing or decreasing the basic rate by the following percentages:

a. Place of jointing: - ne near ar tre trenc nch h on te temp mp.. tim timbe berr su supp ppor orts ts - above trench - in trench

0% +10% +25%

b. Type Type of pipe: pip e: - iron pipes - prewrapped pipes

0% +10%

c. Right-of-way quality: - city street - along a road - dry rocky right-of-way - possible mud

+20% -10% 0% +15%

d. Means of production: - crane - pipe laying machine

+5% 0%

e. Average pipe length: - shorter than 8 m - longer than 8 m Example: - a. - b. - c. - d. - e.

0% +10%

pipe Ø 6" basic rate is 1,75 [Mhr/joint] + 10% + 10% - 10 10% + 5% 5% + 0% 0%

 Total  T otal   + 15%  The final manhour rate is a sum of the basic rate 1,75 [Mhr/joint] + 15% = 2,01[Mhr/joint]

52

 

5.

WELDING

  SMAW SMAW SMA W

ertical up (conventional): vver verica icall dow down n (F (Fall allnah naht): t): Mhr/weld= Mhr/we Mhr /weld= ld= XX xx Ø Ø xx tt // 440 7355 73

X = values from below table; Ø = pipe diameter in inches; t - wall thickness in mm  X-value  X-v alue table tab le

6.

 

Ø

             

2” 3” 4” 6” 8” 10” 12”

 

X 54 42 36 27 24 21 20,60

Ø 14” 16” 18” 20” 22” 24” above 24”

  X 20,30 20,05 19,80 19,60 19,40 19,20 19,00

10” 0,82 30”

14” 1,05 34”

WRAPPING

6.1 MACHINE WRAPPING (acc. t John S. Page)

 

Ø

  [Mhr/m]

 

Ø

to 2” 0,23 20”

3” 4” 0,30 0,39 22” 24”

6” 0,52 26”

8” 0,66 28”

12” 0,92 32”

16” 18”   1,21 1,35 36”  

  [Mhr/m]

1,48

1,64 1,77

1,94

2,07

2,23

2,40

2,56

2,69

I find above values overestimated, which is based on my monitoring the wrapping works.  Therefore, I suggest that the following percentages of the above values are considered.

  Diameter

%

  2"-8"   10"-16"   18 18"-24"   26"-36"

36% 40% 45% 50%

Mhr/m2

Mhr/sqft

0,37 0,40 0,43 0,47

0,0344 0,0372 0,04 0,044

6.2 HAND WRAPPING  Single-layer wrapping:  Doubl  Dou blee-la laye yerr wrap wrappi ping ng::  We  W eld wrapping:

7.

Machine wrapping x 2 Machi Ma chine ne wra wrapp pping ing x 2,5 2,5 Mhr/weld= Mhr/m for hand wrapping

Mhr /m  /m x 0,3048 0,3048 = Mhr/ft

LAYING IN TRENCH

 This kind of laying is considered only when the pipeline is hand wrapped near a trench or above a trench. Man hours include also collection and transport of timber supports and possible installation of concrete weights in case of an underwater pipeline.

  6” 6” 10” 14” 18”

  to 4”......................................................0,12 ÷ 8”......................................................0,13 ÷ 12”......................................................0,15 ÷ 16”......................................................0,17 ÷ 24”......................................................0,18 above 24”......................................................0,20

[Mhr/m] [Mhr/m] [Mhr/m] [Mhr/m] [Mhr/m] [Mhr/m]

53

 

8.

SPECIAL POINTS

“specialpoints points”aremeans works pipelines cannot the workThe andterm the special left forthelater on. on This requireswhere speciala point teamscrew for executing suchdo works. The special points are: 8.1 BORING UNDER ROADS AND RAILROADS Generally, the erection company does not perform the boring. The erection company performs the Generally, following activities:  Supply of the material needed for protection and header pipe  Cutting of protection conduit to the length dictated dict ated by a boring team  Protection conduit welding Protection conduit wrapping  Header pipe assembling and wrapping Header pipe leak test  Installation of spacers and pulling in the main pipe  Installation of "Z" seals (sleeve)  Construction of air vents on both sides of the road/railroad  Putting up necessary signs for the road/railroad works

  6” 10” 14” 18”

  ÷ ÷ ÷ ÷

to

4”......................................................100 8”......................................................130 12”......................................................160 16”......................................................190 24”......................................................220

[Mhr] [Mhr] [M [Mhr] [Mhr] [Mhr]

  above 24”......................................................250  Connection to the header is included.

[Mhr]

8.2 BREAK OUT OF ROADS  These special points can be performed without stopping the road traffic or by bypassing the traffic.  This rate does not include the excavation and repair of the right-of-wa right-of-way y. w/o protection pipe   to 4”...............................16   6” ÷ 8”...............................25 10” ÷ 12”...............................30 14” ÷ 16”...............................40 18” ÷ 24”...............................50   above 24”...............................60

w/o traffic [Mhr]...............................30 [Mhr]...............................35 [M [Mhr]...............................40 [Mhr]...............................50 [Mhr]...............................60 [Mhr]...............................70

with traffic [Mhr] [Mhr] [Mhr] [Mhr] [Mhr] [Mhr]

with protection pipe   to 4”...............................32   6” ÷ 8”...............................50 10” ÷ 12”..............................60 14” ÷ 16”..............................80 18” ÷ 24”.............................100   above 24”.............................120

w/o traffic [Mhr]...............................40 [Mhr]...............................60 [Mhr]...............................75 [Mhr]..............................100 [Mhr]..............................120 [Mhr]..............................140

with traffic [Mhr] [Mhr] [Mhr] [Mhr] [M [Mhr] [Mhr]

 The connection to the header is included. 8.3 CONNECTING PIPELINE SECTIONS  This item includes the works on interconnecting two pipeline sections.   to 4”.....................................................10   6” ÷ 8”.....................................................12 10” ÷ 12”.....................................................15 14” ÷ 16”.....................................................18 18” ÷ 24”.....................................................20   above 24”.....................................................25

[Mhr] [Mhr] [Mhr] [Mhr] [Mhr] [Mhr]

54

 

8.4

CROSSING WATERCOURSES

 The watercourses are rivers, streams and canals with or without wit hout water, water, etc. Generally Generally,, specialist firms undertake the works on river crossings whereas crossings under streams and canals are executed by erection companies, which undertake also the straight sections. The following operations are included under this item. -

Bending Conn Co nnec ecti ting ng & we weld ldin ing g of se sect ctio ions ns Leak test of sections Wrapping

- Laying in trench - In Inst stal alla lati tion on of co conc ncre rete te we weig ight htss - Backfilling (Other works are the responsibility of a civil contractor)

  Canal Canal Stream   w/o water with water with water   to 4”.............................70 [Mhr]......................130 [Mhr]....................150 [Mhr]   6” ÷ 8”...............................90 [Mhr]......................155 [Mhr]....................175 [Mhr]  10  1 0” ÷ 12”............................110 [Mhr]......................180 [Mhr]....................220 [M [Mhr]  14  1 4” ÷ 16”............................130 [Mhr]......................205 [Mhr]....................260 [Mhr]  18  1 8” ÷ 24”............................150 [Mhr]......................230 [Mhr]....................300 [M [Mhr] above 24”............................160 [Mhr]......................250 [Mhr]....................320 [M [Mhr] - Connecting to the header: header: - one side included - the other side according according to the rate rate for “Connecting Pipeline Sections” 

8.5 8. 5

INST IN STAL ALL LATI TION ON OF CL CLEA EANI NING NG ST STA ATI TION ONS S

 This item includes the installation of pipes coming out of the ground and installation of a pig launcher and a pig trap. The construction of the station is i s not included but it can be rated as prefabrication:   to 4”...........................................20 [Mhr/station]   6” 6”÷ 8”...........................................27 [Mhr/station] 10”÷ 12”..........................................33 [Mhr/station] 14”÷ 16”..........................................40 [Mhr/station] 18”÷ 24”..........................................46 [Mhr/station] above 24”.........................................55 [Mhr/station]

8.6

PUTTING UP PIPELINE MARKERS

 This item covers all the operations relating to putting up the pipeline markers. Their fabrication is not included.   Each marker = 2,50 [Mhr]

8.7

OTHER SPECIAL POINTS - Make-on of branches on a pipeline - Installation of measuring and control stations - Installation of reducing stations - Installation of condensate drain stations - Bridge crossings - Watercourse crossings

Man hours for these special points are calculated according to the manhour rates for fabrication and installation of the piping in plants. pl ants.

55

 

9.

PRESSURE TESTS

Generally,, the pressure tests on the pipelines are performed by teams specialized for this kind of Generally work. The team must be provided with all necessary equipment.  The pipelines are constructed in sections, which start and end at a stream that is at a place with sufficient water to wash and test the pipeline washing and testing. The section length depends on the pipeline right-of-way configuration. This rate determines the time needed to test a 5 km (3 miles) long section. The following time allowances to be considered for longer sections: - Pipeline section to 5 km or 3 miles......................................= 150 [Mhr] - Each kilometre longer than 5 km or 3 miles.......................plus 20 [Mhr/km] or [Mhr/mile]

10.. 10

PRE PR ELI LIMI MINA NARY RY AND FI FIN NIS ISHI HING NG WO WORK RKS S

10.1

PRELIMIN INA ARY WORKS

 They include: - Setting up a camp - Setting up offices - Setting up warehouses and stores - Setting up workshops - Erection of necessary fences - Preparation of machinery - Construction of auxiliary devices

 The rate for the preliminary works is 4% of 4% of the total man hours for the works from 1 through 9.

10.2

FINISHING WORKS

 The finishing works include: -Cleaning the right-of-way from residual material, pipes, timber supports, construction material, and other debris - Dismantling temporary works - Loading the equipment and material - Other finishing works  The rate for the finishing works is 50% of 50% of manhours for preliminary works.

56  

III. STEEL STRUCTURE ERECTION (Acc. to MONTMONTAŽA Co. 1980)   Kind of Work Sorti So rting n g the the struc structu ture re and and prepa prepara rati tion on for erection and pre-erection

[Productivity efficiency percentage (PEP)=75%]

0,05

0,1

0,15

0 ,2

0,25

Unit weight of elements in [t] and man hours [Mhr/ton] 0,35 0,5 0,8 1 2 3 4 5

6,6

5,5

5,0

4 ,4

3 ,8

3,7

3,3

3,1

2,9

2,6

2,4

2 ,2

1 ,1

-

-

   -

   -

   -

   -

   -

   -

   -

6,6 5,5 7,04

5,8 4,7 6,17

5,5 4,47 4,95

5,41 4,41 4 ,4

4,93 3,63 4,09

-

  -

  -

  -

  -

  -

  -

  -

11,0 10,5

10,6 9,43

10,3 8,87

9,58 7,98

-

  5,72  -

  5 ,5  -

  4,84  -

  4,4  -

  4,18  -

  3,85  -

2,44  -

-

  5,83  -

1,1

2,12 2,86  1,1

1,93 2,12  1 ,1

-

    -

    -

   14,9

   13,2

   12,6

 6,05  12,1

 3 ,5  11,6

4,23 5,33 11,0 10,5

3,74 4,78 9,9 9,9

2,84 3,52 8 ,8

-

   25,4 15,9 20,1

   19,9 15,4 19,8

   16,9 14,3 18,7

   12,8 13,2 17,6

   12,1 12,6 16,5

   -

    -

4,95 4,62 7,81   -

12,1

   33,0

   26,4

   22,4

   18,9

   16,7

   -

1. BASIC MAN HOURS - UNIT

  1.11 1.   1.22 1.           1.3       1.4 1.55 1.  5   7  

                                 

PrePr e-er erec ecti tion on of str struc uctu ture re a) by crane: 1.2.1. a Columns 1.2.2. a Beams and columns 1.2.3. a Lattice beams b) by hand: 1.2.1. b Columns and beams 1.2.2. b Lattice beams Tran ranspo sport rt of stru structu cture re to ere erecti ction on pla place ce 1.3.1. Columns and beams 1.3.2. Lattice beam 1.3.3. Small structure Installation of of an anchor bo bolts an and br break in in Stru St ruct ctur uree e re re cti ction on (hoisting and putting up the structure) a) by crane: 1.5.1.a Columns 1.5.2.a Beams 1.5.3.a Lattice beam 1.5.4 .a .a Different diagonal small it em ems b) by el. winches: 1.5.1.b Columns by supporting arms 1.5.2.b Beams " " " " 1.5.3.b Lattice supports by masts 1.5.4.b Binding joists 1.5.5.b Longitudinal beams 1.5.6.b Floor grids and chequered sheets c) By hand operated winches or haulage cranes: 1.5.1.c Columns by supporting arms 1.5.2.c Beams " " " " 1 .5 .5.3 .c .c Trusses support s by sup. ar ms ms 1.5.4.c Binding joists 1.5.5.c Longitudinal beams

-

5,94

-

34,4 15,9 22,0

-

4 ,0

-

12,6 15,4

-

    -

8

10

12

15

20 20

 -

 -

 -

 -

4,27 3,02 3,76

3,66 2,95 3,19

3,3 2,64 2,56

2,92 2,39 2,86

2,88 1,82

9,09 5,08

7,63 6,87

6,92 6,05

6,87 5 ,8

6,38 5,44

3,74

1 ,6 2,05  1,32

1,57 1,99  1,32

1,52 1,81  1,32

1,03 1,76

0,92 1,72

0,69

 1,65

 1,65

0,82 1,55  1,65

1,96 2,23 4,95  -

1,47 1,63 4,4  -

1,33 1,57 3,85

1,29 1,6 3,3

-

2,35 2,94 6 ,6  -

 -

 -

1,14 1,46 2,75  -

0,96 1,33 2,8  -

4,34 3,75 5,72    -

3,96 3,47 5,28    -

3,74 3,26 4,95    -

3,63 2,92 4,4    -

  -

  -

-

4,62 4,18 6,7    -

3,85       -

   -

8,8 7,7 14,3  -

6,6 6,0 12,1  -

5,05 5 ,5 9,9  -

5,5 5,06 9,35  -

4,95 4,4 8,8  -

4,4 3,85 8,25  -

-

2,87 2,75 4,18

   -

-

-

  -

7,7  -

 -

-

    -

-

-

-

 -

-

    -

     

1.5.6.c Floor grids and chequered sheets 1.5.7.c Wall windows 1.5.8.c Misc. construct, diagonals & small items pcs. 1.5.9.c Staircase treads [Mhr/ea]

24,2 44,0 -

23,1 36,0

20,9 30,0

19,8 25,0

18,7 -

17,6  -

16,5  -

13,2  -

 -

 -

  -

  -

  -

23,1  -

22,0  -

20,9  -

 -

0 ,8

-

-

   -

   -

   -

   -

   -

   -

   -

   -

   -

  -

  -

  -

  -

  -

  -

  -

  -

  -

 

1.6

INSTALL INST ALLAATION OF LOST FORMW FORMWORK ORK Trape rapezoidal zoidal sheets for concret concretee slabs

- Bolting of binding beams is performed by the manufacture - Sheets are fastened by nails driven in by pistols.

the structure supplier. supplier.

1.6.1 Type "HOLORIB" or "MONTANA" "MONTANA" (length c. 4 m, width 620 mm)   to 10 1000 m2   weight   [kg/m2] t = 0,75 mm t = 0,88 mm t = 1,0 mm

11,4 13,5 15,3

to 1000 sqft 0,13 Mhr/m2 0,14 Mhr/m2 0,15 Mhr/m2

1000 ÷ 50 10 5000 5000 ÷ 10 50 1000 00 m2 m2 1000 ÷ 5000 5000 ÷ 10 000 sqft sqft 0,12 Mhr/m 2 0,11 Mhr/m2 0,13 Mhr/m 2 0,12 Mhr/m2 0,14 Mhr/m 2 0,13 Mhr/m2

1000 10 00 ÷ 10 1000 0000 m2 10000 ÷ 100 000 sqft 0, 105 M h r /m2 0,11 Mhr/m2 0,12 Mhr/m2

1000 10 0000 ÷ 50 5000 0000 abo bovve m2 50000 m2 100 000 ÷ above 500 000 5 00 00 000 sqft sqft 0,10 Mhr/m2 0,09 Mh M hr/m 2 2 0,105 Mhr/m 0,10 Mh Mhr/m2 0,11 Mhr/m2 0,105 Mhr/m2

1.6.2 Type Type "KRUPP HÖSCH" (length 3,6 ÷ 5,8 m, width 700 700 ÷ 800 mm)   to to 100 m2

t = 1,0 mm

12,8

0,23 Mhr/m2

100 ÷ 500 500 ÷ 1000 1000 ÷ 10000 10000 ÷ 50000 above m2 m2 m2 m2 50000 m2 1000 ÷ 5000 5000 ÷ 10 000 10000 ÷ 100 000 ÷ above 500 000 sqft sqft 100 000 sqft 500 000 sqft sqft 0,22 Mhr/m2 0,21 Mhr/m2 0,20 Mhr/m2 0,19 Mhr/m2 0,18 Mhr/m2

t = 1,25 mm t = 1,50 mm

16,0 19,2

0,24 Mhr/m2 0,25 Mhr/m2

0,23 Mhr/m2 0,22 Mhr/m2 0,24 Mhr/m2 0,23 Mhr/m2

  weight   [kg/m2]

to 1000 sqft

0,21 Mhr/m2 0,22 Mhr/m2

0,20 Mhr/m2 0,21 Mhr/m2

0,19 Mhr/m2 0,20 Mhr/m2

Note: 1. Steel brackets for trapezoidal plates (Stahlknagge) are generally generally shop welded. If site welded, the rate of 5 ÷ 6 % is added. 2. Above rates rates include also placement of Z sections and seal caps.

1.77 1.

INST IN STAL ALLA LATIO TION N OF OF WIR WIREE ROPE ROPE CL CLAM AMPS PS

  ø   to 20 mm  21 ÷ 25 mm

1.8

Mhr/ea 8,0 9,0

ø Mhr/ea ø Mhr/ea ø Mhr/ea ø Mhr/ea 26 ÷ 30 mm 11,0 36 ÷ 40 mm 16,0 46 ÷ 50 mm 24,0 56 ÷ 60 mm 32,0 31 ÷ 35 mm 14,0 41 ÷ 45 mm 20,0 51 ÷ 55 mm 28,0 > 60 mm 40,0

REAMING OF HOLES

M 20 M 22 M 24 M 27 M 30 M 36 M 42 M 48 M 56 M 64   a) by pn. or el. drilling machine from scaffold - manhour/hole   0, 0,1 0,11 0,12 0,13 0,14 0,15 0,16 0,18 0,19 0,2   b) by a reamer - man hour/hole 0,44 0,49 0,5 0,52 0,57 0,61 0,66 0,76 0,78 0,79 1.99 1.

BOLLTIN BO TING G FRO FROM M SCA SCAFF FFOL OLDI DING NG - MAN MANHO HOUR UR PE PER R 100 100 PI PIEC ECES ES

M 20   16,5

M 22 M 24 M 27 M 30 M 36 M 42 M 48 M 56 M 64 18,1 18,7 19,2 20,3 23,1 26,6 30,8 33 37,4

mm x 0,03937 = inch m x 3,28 = ft Mhr/m2 x0,0 x0,0929 929 = Mhr/sqf Mhr/sqftt kg/m2 x 0,2048 0,2048 = lbs/sqft lbs/sqft

When tightening the bolts by a torque wrench, manhours are multiplied by 1,5 factor. factor. Note: The above manhours manhours do not include include scaffolding. scaffolding.

58

 

2. ERECTION OF MISCELLANEOUS STEEL STRUCTURES 2.1 2. 1

(PEP = 75%)

BASI BA SIC C MAN MANHO HOUR UR RA RATE TES S - TO TOTAL

2.1.1 BUILDINGS AND CANOPY FRAMING   Cubic   weight   [kg/m3]   2       

Rate [Mhr/ton] 18,1

Cubic weight [kg/m3] 12

Rate [Mhr/ton] 16,7

Cubic weight [kg/m3] 22

Rate [Mhr/ton] 15,7

Cubic weight [kg/m3] 35

Rate [Mhr/ton] 14,6

1 17 7,,8 5 17,3 17,0

1 14 6 18 20

1 16 6,,5 3 16,1 15,9

2 24 6 28 30

1 15 5,,5 3 15,1 14,9

4 40 5 50 55

1 14 3,,2 9 13,5 13,2

4 6 8 10

Cubic weight [kg /m3] =

Structure weight [kg]  

 

Width [m] x Length [m] x Height [m]

Type of structure 2.1.2 Equipment & bridging supports 2.1.3 Towers for transmission lines 2.1.4 Stairs structure 2.1.5 Tower structure for chimney or similar

Light 17,5 12 20 44

2 asea cp hp eo s rt 2..1 1..6 7A Sn inte gn lenm mnbdetrosru 2.1.8 Bridging between the buildings 2.1.9 Conveyor bridges 2.1.10 Crane tracks outside buildings 2.1.11 Bridge crane 2.1.12 Portal crane 2.1.13 Port crane 2.1.14 Construction crane 2.1.15 Stationary crane 2.1.16 Piping bridges (outside oil refinieres)

476 32 25 28 60 55 36 35

Mhr/ton Medium 15,5 9 40

   

-6 30 33,6 18 22 25 55 -

Heavy 13,2 6   4-,5     16 20     -

Structure: light to 30 kg/m; medium-weight medium-weight 30 ÷ 60 kg/m; heavy above 60 kg/m 3. CORRECTION FACTORS  The rate for calculation is computed by multiplying the basic rate by a medium correction factor. factor.  The medium correction factor is computed by adding up all selected factors and dividing them by 10. K1   Weather impact K1 Month : K1 :

I 1,2

  II 1,,15 1

  III 1,05

  IV 1,0

 V 1,0

  VI 1,0

  VII 1,0

  VIII   IX   X   XI XII   1,0 1,03 1,06 1,09 1,0

K2   Abnormal impact of temperature K2 temperature   Average temp. :   K2 :

  below - 10° C   1,6

(-10)° C ÷ (- 5)° C 1,3

(- 5)° C ÷ 30° C 1,0

above 30° C   1,15

kg /m x 0,672 0,672 = lbs/ft kg/m3 x 2,2046 2,2046 = lbs/m lbs/m3

59

 

K3   Impact of elevation elevation at which the works are executed K3 Heght in [m] to:  15  1 K3 :

  25

  35

  45

  60

  75

1,06

1,12

1,18

1,24

1,35

  80  1,5

K4   Impact of the job site ground K4 - hard and flat ground

0,9

- 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

0,95 1,0 1,05 1,1 1,15

K5   Impact of the structure engineering level K5 - documentation fully developed - only erection process with written instruction - documentation not developed

1,0 1,05 1,1

K6   Impact of installation joint type K6 - min. 90 % bolted joints - min. 90 % welded joints - min. 90 % riveted joints

1,0 1,33 1,5

K7   Impact of pre-assembling practicability K7 - pre-erection possible - smooth - pre-erection possible - restricted - pre-erection not possible

0,75 1,00 1,20

K8   Impact of the structure design K8 - very simple - simple - normal - complex - very complex

0,85 0,95 1,00 1,05 1,15

K9   Impact of the structure complexity K9 - welded plate structure - rolled sections structure - pipe structure

1,30 1,00 1,20

K10   Impact of the component bulking K10 - delivery in bulk - basic assembling - assembled for normal transport - assembled for special transport

1,60 1,25 1,00 0,90

100 1,65

60

 

4. STEEL STRUCTURES IN OIL REFINERIES AND PETROCHEMICAL PLANTS 4.1 LIGHT STRUCTURE (to 30 kg/m) 4.1.1 Ladders and step irons 4.1.2 Floors - treads 4.1. 1.3 3 Light platform rmss and landin ing gs 4.1.4 Railing - straight Railing - round

40,0 50,0 35,,0 35 80,0 100,0

[Mhr/ton] [Mhr/ton] or 0,56 [Mhr/ea] [Mhr/ton] [Mhr/ton] or 1,6 [Mhr/m] [Mhr/ton] or 2,0 [Mhr/m]

4.2 MEDIUM-WEIGHT MEDIUM-WEIGHT STRUCTURE (31 ÷ 60 kg/m) 4.2.1 Ai Air coolers 18,5 4.2.2 Medium platforms and landings 14,5 4.2.3 Structure on towers 20,0 4.2.4 Staircases 22,0 4.2.5 Torch structure 14,0 4.2.6 Pipe supports, trestles, supports on prepared foundations 25,0

4.3 HEAVY STRUCTURE (above 60kg/m) 4.3. 3.1 1 Pip ipe e racks 4.3.2 Ki K iln structure 4.3.3 Reactor and regenerator structure 4.3.4

-Large spanworkshops to 10 m - 10 ÷ 20 m - above 20 m

[Mhr/ton]

8,5 8,5 12,0

[Mhr hr//ton] [Mhr/ton]

11,0

[Mhr/ton]

12,0 14,0 15,0

[Mhr/ton] [Mhr/ton] [Mhr/ton]

4.4 MISCELLANEOUS STRUCTURES 4.4.1 Floor grids 1,2 4.4.2 Chequered plate flooring - fabrication 1,2 - installation 1,0 4.4.3 Lining of large workshops and hangars - corrugated sheets 0,4 - sandwich elements - roof 1,0 - sandwich elements - fasade 1,2

4.5 PIPE HANGERS AND SUPPORTS 4.5.1 Fabrication 4.5.2 Erection 4.5.3 Spring supports  erection

[Mhr/ton] [Mhr/ton] [Mhr/ton] [Mhr/ton] [Mhr/ton]

[Mhr/m2] [Mhr/m2] [Mhr/m2] [Mhr/m2] [Mhr/m2] [Mhr/m2]

7,0 10,0

[kg/Mhr] [kg/Mhr]

12,0

[kg/Mhr]

(Classification of steel structures acc. to UHDE Dortmund)

(PEP = 75%)

61

 

5. ERECTION AND DISMANTLING OF MISCELLANEOUS STEEL STRUCTURES (PEP = 75%) 5.1 ERECTION OF STEEL STRUCTURES - ACC. TO TO THE WEIGHT

  20 ÷ 50 tons

  5,0

  50 ÷ 100 tons

  4,0

  100 ÷ 250 tons

 3,50

  250 ÷ 500 tons

  3,0

  500 ÷ 750 tons

 2,90

 750 ÷ 1000 tons

 2,80

1000 ÷ 1500 tons

 2,60

Bulking, raising, positioning and Structure fastening temporary bolting [Mhr/ton] [Mhr/ton]   9,50 welding of    6,0 bolted joint 5,0   9,0 welding of 5,30 bolted joint 4,50   8,50 welding of 4,50 bolted joint 4,0   8,0 welding of 4,30 bolted joint 3,70   7,50 welding of 4,10 bolted joint 3,40   7,30 welding of 3,80 bolted joint 2,90   7,0 welding of 3,50 bolted joint 2,50   6,60 welding of 3,20

1500 ÷ 3000 tons

 2,40

  6,30

3000 ÷ 5000 tons

 2,20

  6,0

above 5000 tons

  2,0

  5,50

  Structure weight      

to 20 tons

Unloading and on-site hauling [Mhr/ton]  5,50

bolted joint welding of bolted joint welding of bolted joint welding of   bolted joint

2,0 2,80 1,80 2,40 1,50  2,0 1,0

 Above man hours do not include painting and scaffolding. scaffolding.

5.22 5.

MISC MI SCEL ELLLAN ANEO EOUS US ST STRU RUCT CTUR URES ES

5.2.1 STRAN STEEL FRAMING - stud system - rafter system - jois joistt sys system tem

0,16 [Mhr/m2] 0,39 [Mhr/m2] 0,22 0,2 2 [Mh [Mhr/m r/m2]

Man hours do not include covering, painting and scaffolding. 5.2.2 STEEL OVERHEAD PIPE, BRIDGES, ETC. - unloading - bul bulki king ng,, hois hoistin ting, g, po posi sitio tionin ning g and and te temp mpor orar ary y bol boltin ting g  fastening: - welded design - bolted design  Total:  T otal: -welded design - bolted design

2,33 [Mhr/ton] 11,2 11 ,20 0 [M [Mhr/ hr/to ton] n] 2,33 [Mhr/ton] 1,87 [Mhr/ton] 15,86 [Mhr/ton] 15,40 [M [Mhr/ton]

Man hours do not include covering, painting and scaffolding.

TOTAL

[Mhr/ton] 19,60 18,66 18,0 17,26 15,86 15,40 14,75 14,18 13,72 13,06 13,06 12,22 12,40 11,48 11,57 10,45 10,73 9,80 9,90 9,05 8,86 7,93

62

 

5.2.3 DOCK AND CANOPY FRAMING - unloading - rai aisi sing ng,, pos osit itio ioni ning ng an and d te tem mpo pora rary ry bo bolt ltin ing g - fastening: - welded design - bolted design  Total:  T otal:

1,87 7,00

[Mhr/ton] [Mhr [M hr//to ton] n]

1,96 [Mhr/ton] 1,40 [Mhr/ton]

- welded design - bolted design

10,83 10,27

[Mhr/ton] [Mhr/ton]

Man hours do not include covering, painting and scaffolding. 5.2.4 PLATFORMS AND FLOORS - unloading - erection: - platform framing - catwalk framing - chequered floor plate

25 [kg/Mhr]

or

3,0

[Mhr/ton]

37,5 35,5 40,0

[Mhr/ton] [Mhr/ton] [Mhr/ton]

Man hours do not include painting and scaffolding. 5.2.5 BAR JOISTS, PARTITION FRAMING, MONORAILS MONORAILS AND EQUIPMENT SUPPORTS a) bar joists - unloading

2,80 [M [Mhr/ton]

- erection and fastening  Total:  T otal: b) partition framing - unloading - fabrication cutting out - erection and fastening

[Mhr/ton]

14,00

[Mhr/ton]

5,12 [[M Mhr/ton] 41,00 [Mhr/ton] 25,62 [Mhr/ton]  Total:  T otal:

c) monorails - unloading - erection and fastening

71,74

[Mhr/ton]

5,12 [[M Mhr/ton] 25,62 [Mhr/ton]  Total:  T otal:

d) equipment supports - unloading - fabrication cutting out - erection and fastening  

11,20

30,74

[Mhr/ton]

5,12 [[M Mhr/ton] 51,24 [Mhr/ton] 56,37 [Mhr/ton] Total:

112 12,,73 [Mhr/ r/to ton n]

Man hours do not include erection of equipment, painting and scaffolding. 5.2.6 STAIRS & LADDERS - un unlo loa adi ding ng mi misc sce ell llan aneo eous us st stee eell ite items 2,80 2,80 a) stairs: - fabrication of all sizes 71,74 - fi fiel eld d er erec ecti tion on 915 mm (3 915 (3'' 0” 0”)) wi wide de 2, 2,00 00 - field erection - fi fiel eld d er erec ecti tion on - landing fabrication

1067 mm (3' 6”) wide 2,30 1220 12 20 mm (4 (4'' 0” 0”)) wi wide de 123, 123,0 0 41,00

[Mhr [M hr//to ton] n] [Mhr/ton] [Mhr [M hr/t /ton on]] [Mhr/ton] [Mhr [M hr/t /ton on]] [Mhr/ton]

63

 

b) ladders - fabrication of straight ladders - fabrication of ships ladders - fabrication of safety cages - erection of straight ladders - erection of ships ladders - erection of safety cages - r  ruung erection ø 19 mm (3/4”)

123,0 102,5 123,0 0,92 0,76 0,92

0,47

[Mhr/ton] [Mhr/ton] [Mhr/ton] [Mhr/ton] [Mhr/ton] [Mhr/ton]

[Mhr/ton]

Man hours do not include painting and scaffolding.

5.2.7 HANDRAILS a) Standard Pipe Handrails - 1067 mm (3' 6”) High -

fabricatio ion n 1 1/4” & 1 1/2” - str tra aight run unss fabricatio ion n 1 1/4” & 1 1/2” - angle led d runs erection 1 1/4” pipe - straight free standing erection 1 1/4” pipe - angled free standing erection 1 1/2” pipe - straight free standing erection 1 1/2” pipe - angled free standing

3,3 3,3 2,7 2, 76

[kg/Mhr] or [kg/Mhr] or

303, 3,0 0 [Mhr/to ton n] 362, 2,0 0 [Mhr/to ton n] 0,49 [Mhr/m]* 0,58 [Mhr/m]* 0,61 [Mhr/m]* 0,73 [Mhr/m]*

[kg/Mhr] or

1,3367,0 0 0,49 0,50

Mh hrr//m to]n*] [[M [Mhr/m]* [Mhr/ea]

[kg/Mhr] or [kg/Mhr] or

719,0 862,0 0,61 0,7 0,73 0,86

[Mhr/ton] [Mhr/ton] [Mhr/m]* [Mhr/m]* [Mhr/m]* [Mhr/m]*

b) Single Pipe Handrail - Wall Attached: --

fearb ercitcia otnion 1 1/14”1/4&” 1pi1p/e2” pipe erection 1 1/2” pipe erection of wall brackets

7,35

c) Standard Angled Iron Handrail - 1067 mm (3' 6”) High -

fabrication - straight runs 1,39 fabrication- angled runs 1,16 erection 50x50x6 mm - straight free standing erection 50x50x6 mm - angled free standing erection 50x50x6 mm - straight free standing erection 50x50x6 mm - angled free standing

d) STANDARD TOE OR KICK PLATES  3,5 mm x 150 (6”)  4,76 mm x 150 (6”)  6,35 mm x 150 (6”)

0,46 [Mhr/m] 0,61 [Mhr/m] 0,76 [Mhr/m]

[Mhr/m]* refers to the length of handrail and not the length of a pipe or a section. o - Straight runs are those with all connecting members at 90 angles. - Angles   Angles runs are those with all connecting members at an angle larger or smaller than 90o. - 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.

kg /Mhr x 2,2046 2,2046 = lbs/Mhr Mhr/m x 0,3048 = Mhr/ft

5.2.8 DOOR, LOUVER AND DUCT FRAMES a) Door Frames - unloading - fabrication - installation

195,0 [kg/Mhr] 21,0 [kg/Mhr] 21,60 [kg/Mhr]

or or or

5,13 47,62 46,30

[Mhr/ton] [Mhr/ton] [Mhr/ton]

64

 

b) Louver Frames - unloading - fabrication - erection

195,0 21,60 24,30

c) Duct Frames - unloading - fabrication - erection

194,15 [kg/Mhr] 21,57 [kg/Mhr] 27,73 [kg/Mhr]

[[k kg/Mhr] [kg/Mhr] [kg/Mhr]

or or or

5,13 [Mhr/ton] 46,30 [Mhr/ton] 41,10 [Mhr/ton]

or or or

5,15 [Mhr/ton] 46,36 [Mhr/ton] 36,00 [Mhr/ton]

Man hours do not include painting and scaffolding.

kg /Mhr x 2,2046 = lbs /Mhr  /Mhr

5.2.9 MISCALLANEOUS IRON & STEEL a) Bins & Hoppers - unloading - fabrication - erection

194,15 [kg/Mhr] 32,35 [kg/Mhr] 80,90 [kg/Mhr]

or or or

5,15 [Mhr/ton] 30,91 [Mhr/ton] 12,40 [Mhr/ton]

b) Miscallaneous Hangers - fabrications - erection

19,41 16,18

[kg/Mhr] [kg/Mhr]

or or

51,52 61,80

c) Metal Thresholds - Installation

1,40

[Mhr/ea]

d) Wheel Guards - installation

0,47

[Mhr/ea]

or or or

5,15 [Mhr/ton] 46,36 [Mhr/ton] 36,06 [Mhr/ton]

e) Trench Framing - Unloading - Fabrication - Installation f) Trench Covers - Plates in installation - Grating in i nstallation

194,15 [kg/Mhr] 21,57 [kg/Mhr] 27,73 [kg/Mhr]

[Mhr/ton] [Mhr/ton]

1,0 1,40

[Mhr/m2] [Mhr/m2]

g) Curb Angles - unloading - fabrication - installation

324,0 20,25 15,0

[kg/Mhr] [kg/Mhr] [kg/Mhr]

or or or

3,0 49,40 66,60

h) Steel Curbing - unloading - fabrication - installation

195,0 19,50 27,0

[kg/Mhr] [kg/Mhr] [kg/Mhr]

or or or

5,12 [Mhr/ton] 51,30 [Mhr/ton] 37,00 [Mhr/ton]

i) Pipe Sleeves - fabrication - installation

16,20 8,0

[kg/Mhr] [kg/Mhr]

or or

61,70 [Mhr/ton] 125,00 [Mhr/ton]

 j) Anchor Bolts - fabrication - installation

24,30 15,0

[kg/Mhr] [kg/Mhr]

or or

41,15 66,60

k) Ledger Angles - unloading - fabrication - installation

195,0 24,30 16,20

[kg/Mhr] [kg/Mhr] [kg/Mhr]

or or or

5,13 [Mhr/ton] 41,15 [Mhr/ton] 61,70 [Mhr/ton]

[Mhr/ton] [Mhr/ton] [Mhr/ton]

[Mhr/ton] [Mhr/ton]

Man hours do not include painting and scaffolding.

65

 

5.2.10 STEEL GRA GRATING TING

- Installation of floor grids Grating Bar Size Weight [kg/m2] 19,05 x 4,76 mm 28,80 25,04 x 3,18 mm 25,39 25,04 x 4,76 mm 37,11 31,3 x 3,18 mm 30,76 31,3 x 4,76 mm 44,92 38,1 x 3,18 mm 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 - st stra raig ight ht an and d di diag agon onal al ba band ndin ing g - circular banding - welding of curb angles - rounding of curbs by grinding

[Mhr/m2] 1,1 1,0 1,4 1,2 1,7 1,4 1,8 1,9 2,0 2,2 2,4 0,30 0,45 0,36 0, 36 0,60 0,76 1,07

[Mhr/m] [Mhr/m] [Mhr [M hr/m /m]] [Mhr/m] [Mhr/m] [Mhr/m]

0,40 0,42 0,71 0,82

[Mhr/m2] [Mhr/m2] [Mhr/m2] [Mhr/m2]

Man hours do not include painting and scaffolding. 5.2.11 SIDING - sectioOF n shLARGE eets WORKSHOPS AND HANGARS - 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 MISCELLANEOUS ITEMS - Steel structure - Miscellaneous steel items - Machinery: light heavy - Pipes (C.S.)   to 2”   3” ÷ 6”   8” ÷ 12” 14” ÷ 16” 18” ÷ 24” 26” ÷ 36” - Railroads:  Ties and tracks  Turnouts  T urnouts - Miscellaneous Fence of three strand barbed wire Fence of five strand barbed wire Chain link fence Guard rail

8,65 [Mhr/ton] 15,15 [Mhr/ton] 14,90 12,40

[Mhr/ton] [Mhr/ton] [M

0,48 0,86 1,84 3,19 4,60 5,50

[Mhr/m] [Mhr/m] [Mhr/m] [Mhr/m] [Mhr/m] [Mhr/m]

0,95 30,0

[Mhr/m] [Mhr/ea]

0,24 0,28 0,46 0,77

[Mhr/m] [Mhr/m] [Mhr/m] [Mhr/m]

Man hours do not include loading, transport and unloading and scaffolding. kg /m2 x 0,2048 = lbs/ft Mhr/m2 x 0,0929 0,0929 = Mhr/sqft Mhr/sqft Mhr/m x 0,3048 = Mhr/ft

kg/Mhr x 2,2046 = lbs/ft

66

 

IV. ERECTION OF EQUIPMENT IN PETROCHEMICAL INDUSTRY  Productivity Efficiency Percentage (PEP) (PEP) = 75% 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). 1.

Man hours include: - Unloading - Hauling from storage to the place of erection - Hoisting by usual hoisting means - Putting up to the design elevation - Positioning of connection points - Position inspection

 TIME ALLOWANCE ALLOWANCE FOR ERECTION ERECTION OF EQUIPMENT AT AT ELEVATION ELEVATION  All stated below, man man hours for erection of equipment are applicable when the equipment base is at an elevation of up to 2 m above the site zero level.  Apply the following factors for higher elevations:

 

Elevation Factor   0 ÷ 2 m..............................................1,00   2 ÷ 4 m..............................................1,10   4 ÷ 6 m..............................................1,20   6 ÷ 10 m..............................................1,25 above 10 m..............................................1,30

1.1 All Equipment to 0,5 ton

10[Mhr/ea] or 25,0[kg/Mhr]

1.2 Towers above 0,5 ton

25 [Mhr/ea] + 3 [Mhr/ton]

1.3 Towers consisting of more pieces:   Joint:

50 [Mhr/ea] + 3 [Mhr/ton] + joint 60 [Mhr/m] of joint circumference

1.4 Package Unit to 10 tons :   above 10 tons :

30 [Mhr/ea] + 5 [Mhr/ton] 50 [Mhr/ea] + 5 [Mhr/ton]

1.5 Other Equipment   0,5 ÷ 2 tons :   2,1 ÷ 10 tons : 10,1 ÷ 20 tons :   above 20 tons : 1.6 Bridge Cranes - Erection of crane track (rails) - Erection of crane with a trolley and a drive 1.7 Lifts 25 [Mhr/m2] shaft + 15 Mhr Mhr per meter meter of elevation elevation

12 [Mhr/ea] + 3 [Mhr/ton] 15 [Mhr/ea] + 4 [Mhr/ton] 20 [Mhr/ea] + 5 [Mhr/ton] 10 [Mhr/ea] + 5 [Mhr/ton] 2,50 [Mhr/m] 25,0 [Mhr/m] span

67

 

1.8 Electrostatic Precipitators Wei eigh ghtt [t [ton on]]   to 100 ton/unit   100 ÷ 250 ton/unit   above 250 ton/unit

Efffect [k Ef [kg/ g/M Mhr hr]] 25,0 30,0 35,0

1.9 Marine loading arms (acc. to John S. Page)

- assembling and erection [Mhr/ea]   Load. arm   diam.   inch   4”   6”   8”   10”   12”   14”   16”   18”   20”  

24”

to 6 40 50 70 91 115 128 150 163 187 224

Total length of loading arm (meters) 6÷9 9 ÷ 12 12 ÷ 15 15 ÷ 18 51 62 79 100 63 78 97 120 88 108 132 163 114 134 159 171 144 167 194 217 161 183 208 283 186 206 228 301 205 223 240 313 237 256 276 356 281

295

308

386

18 ÷ 21 125 150 200 224 315 321 333 341 386

21 ÷ 24 156 188 244 265 370 381 396 405 422

24 ÷ 27 186 235 296 315 434 447 472 482 502

27 - 30 235 294 356 375 509 523 563 575 598

419

457

536

628

NOTE: I find above man hours for loading arms too stringent, so I suggest they are increased by 20 ÷ 25 %.

2. ROTARY EQUIPMENT (pumps, EQUIPMENT (pumps, compressors, fans, blowers, bl owers, 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

m x 3,281 = ft kg /Mhr x 2,2046 2,2046 = lbs/Mhr Mhr/m x 0,3048 = Mhr/ft

2.1 CENTRIFUGAL PUMPS 2.1.1 MAN HOURS BASED ON POWER [kW] Power [kW]   to 10 kW   10 ÷ 50 kW   50 ÷ 100 kW 100 ÷ 150 kW 150 ÷ 200 kW 200 ÷ 250 kW   above 250 kW

[Mhr/kW] 2,00 + 1,60 + 1,30 + 1,20 1,00 0,90 0,75

[Mhr/ea] 5 10 20

Minimum hours 5 26 90 150 180 200 225

68

 

-  Pumps supplied with a coupling on one pedestal -  Pumps and drive motors supplied separately drive mo motors an and re reduction ge gears su supplied se separately -  Pumps, dr -  Vertical pumps -  Fans -  Blowers -  Gear pumps -  Mixers -  Compressors to 200 kW

x 1,00 x 1,20 x 1, 1,40 x 0,80 x 1,25 x 0,85 x 0,70 x 0,75 x 1,00

2.1.2 MAN HOURS BASED ON WEIGHT [kg]

             

 

  Weight [kg]   to 100   101 ÷ 200   201 ÷ 300 301 ÷ 400 401 ÷ 500 501 ÷ 600 601 ÷ 700 701 ÷ 800 801 ÷ 900 901 ÷ 1000 1001 ÷ 1250

Effect [kg/Mhr] 11,0 12,0 14,0 16,0 18,0 20,0 22,0 24,0 26,0 280 30,0

1 12 55 01 1÷ ÷ 1 25 00 00 0 2001 ÷ 2500 above 2500

3 0 32 4,,0 36,0 38,0

-  vertical pumps -  fans -  blowers -  gear pumps -  mixers -  compressors

Min. [Mhr/ea] 5 9 17 21 25 28 30 32 34 35 36 4 42 7 56 70

[kg/Mhr] x 1,0 [kg/Mhr] x 1,0 [kg/Mhr] x 1,0 [kg/Mhr] x 1,0 [kg/Mhr] x 1,0 [kg/Mhr] x 1,0

kg x 0,4536 = lbs kg/Mhr x 2,2046 = lbs/Mhr

NOTE: If the data on power and weight are available, perform the calculation on both bases and take the mean value. 3

2.1.3 MAN HOURS BASED BASED ON THE CAPACIT CAPACITY Y [m /hr] (FOR LIQUID LIQUI D MEDIA ONLY)  

3

[m /hr] to 10   10,1 ÷ 20   20,1 ÷ 30   30,1 ÷ 40   40 40,1 ÷ 50   50 50,1 ÷ 60   60 60,1 ÷ 70   70 70,1 ÷ 80   80 80,1 ÷ 90   90,1 ÷ 100 100,1 ÷ 110 110,1 ÷ 120 120,1 ÷ 130 130,1 ÷ 140 140,1 ÷ 150

3

Mhr x [m /hr] 1,06 0,96 0,87 0,78 0,71 0,65 0,59 0,54 0,50 0,46 0,42 0,39 0,36 0,34 0,32

3

[m /hr] 160,1 ÷ 170 170,1 ÷ 180 180,1 ÷ 190 190,1 ÷ 200 200,1 ÷ 210 210,1 ÷ 220 220,1 ÷ 230 230,1 ÷ 240 240,1 ÷250 250,1 ÷260 260,1 ÷270 270,1 ÷280 280,1 ÷290 290,1 ÷300 300,1 ÷750

3

Mhr x [m /hr] 0,28 0,27 0,26 0,24 0,23 0,39 0,21 0,20 0,19 0,185 0,18 0,175 0,17 0,165 0,16

150,1

÷ 160

0,30

above 750

0,15

69

 

Conversion of Units l/s x 3,6 = m3 /h /hr

l/min x 0,06 = m3 /h /hr

US gallons per minute:

US gpm x 0,227 = m3/hr

Cubic feet per minute:

cfpm x 1,7 = m3/hr

Cubic feet per hour:

cfphr x 0,283 = m3/h / hr

2.2

COMPRESSORS

2.2.1 2.2. 1

COMPR CO MPRESS ESSORS ORS DRI DRIVEN VEN BY ELE ELECTR CTRIC IC MO MOTO TOR  R    to 200  201 ÷ 30 300  301 ÷ 50 500  501 ÷ 75 750  751÷ 1000 1001 ÷ 1500 1501 ÷ 2250 2251 ÷ 3000 3001 ÷ 4000 4001 ÷ 5000

kW k W kW kW kW kW kW kW kW kW kW kW kW kW kW

  above 5000 kW 2.2. 2. 2.2 2

Acc. to Table 2.1.1 1,30 [Mhr/kW] 1,19 [Mhr/kW] 0,88 [Mhr/kW] 0,70 [Mhr/kW] 0,55 [Mhr/kW] 0,44 [Mhr/kW] 0,41 [Mhr/kW] 0,35 [Mhr/kW] 0,30 [Mhr/kW]

(min. (min. (min. (min. (min. (min. (min. (min. (min.

220 Mhr) 390 Mhr) 595 Mhr) 660 Mhr) 700 Mhr) 825 Mhr) 990 Mhr) 1230 Mhr) 1400 Mhr)

0,25

(min.

1500 Mhr)

(min. (min. (min. (min. (min. (min. (min. (min. (min. (min. (min. (min. (min. (min. (min.

250 Mhr) 400 Mhr) 530 Mhr) 600 Mhr) 700 Mhr) 785 Mhr) 870 Mhr) 975 Mhr) 1090 Mhr) 1230 Mhr) 1400 Mhr) 1540 Mhr) 1825 Mhr) 2070 Mhr) 2500 Mhr)

[Mhr/kW]

COMP CO MPRE RESSO SSORS RS DRI DRIVE VEN N BY GA GAS S TURB TURBIN INE E   to 250   251 ÷ 350   351 ÷ 450   451 ÷ 600   601 ÷ 750   751 ÷ 900   90 901 ÷ 1100 1101 ÷ 1300 1301 ÷ 1500 1501 ÷ 1750 1751 ÷ 2000 2001 ÷ 2500 2501 ÷ 3000 3001 ÷ 4000   above 4000

kW kW kW kW kW kW kW kW kW kW kW kW kW kW kW

1,62 1,52 1,34 1,18 1,05 0,97 0,89 0,84 0,82 0,80 0,77 0,73 0,69 0,64 0,50

[Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW] [Mhr/kW]

70

 

3. TOWERS & VESSELS - INSTALLATION OF INTERIOR COMPONENTS & EQUIPMENT 3.1

INST INS TALL ALLA ATIO TION N OF TRA TRAYS YS AND AND DEM DEMISTE ISTERIN RING G PADS PADS

2

 Tower Diameter  Tower   [mm]   to 1000

1. 9,2

2. 10,0

  1001 ÷ 1200   1201 ÷ 1400   1401 ÷ 1600   16 1601 ÷ 1800   18 1801 ÷ 2000   20 2001 ÷ 2250   22 2251 ÷ 2500   25 2501 ÷ 2750   27 2751 ÷ 3000   30 3001 ÷ 3250   32 3251 ÷ 3500   above 3500

8,3 7,8 7,4 6,8 6,5 6,3 6,15 5,75 5,5 5,3 5,2 5,0

9,9 9,3 8,8 8,2 7,8 7,5 7,3 6,9 6,6 6,3 6,2 6,0

[Mhr/m ] 3. 4. 11,2 12,3

5. 7,7

6. * 30,0

[kg/Mhr] 6. 3,30

10,7 10,2 10,0 9,4 8,7 8,4 8,0 7,7 7,5 7,2 6,75 6,4

6,4 5,6 4,8 4,1 3,7 3,4 3,3 3,2 3,1 3,0 2,9 2,8

23,0 20,0 18,0 15,5 13,8 12,5 11,0 10,3 9,4 9,0 8,5 8,0

3,97 4,18 4,70 5,34 5,63 6,16 6,45 6,72 7,06 7,38 7,70 8,00

11,8 11,2 11,0 10,3 9,5 9,2 8,8 8,5 8,2 7,9 7,4 7,0

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 t rays 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 25%. 3.2 VESSELS & TOWER PACKING Packing the vessels and towers with different solid packings in bulk condition: 3

 to towe wers rs :  ves  v esssel elss :

20,0 [M 20,0 [Mhr hr/e /ea] a] + 3, 3,0 0 [M [Mhr hr/m /m3] 10,0 10 ,0 [M [Mhr hr/e /ea] a] + 2,5 2,5 [M [Mhr hr/m /m ]

or or

12,0 [[M Mhr/ton] 10,0 [M [Mhr/ton]

3.3 OPENING AND CLOSING OF MANHOLES ON VESSELS AND TOWERS Manhole Size

[Mhr/ea]

 

to 14” 16” 18” 20” 24” 28”

10,0 12,0 13,0 16,0 18,0 20,0

30” 32” 36”

21,0 22,0 24,0

Class : 150# x 1,0 300# x 1,15 600# x 1,30

Mhr /m  /m2 x 0,0929 = Mhr/sqft Mhr/m3 x 0,02831 0,02831 = Mhr/cuft Mhr/cuft

40 42”

kg/Mhr x 2,2046 = lbs/Mhr

26,0 28,0

71

 

3.4 ERECTION OF PLA PLATFORMS, TFORMS, LADDERS AND FLOOR GRIDS ON VESSELS AND TOWERS (PREDRESSING) 3.4.1 Erection Erection average effect : 60,0 [kg/Mhr] 3.4.2 Estim Estimate ate of quantity quantity of platform platforms, s, ladders ladders and floor floor grids 2 It is calculated per [m ] of the shell shell surface area (without bottom and roof). 2

 

 

Elevation to 10 m 10,1 ÷ 15 m 15,1 ÷ 20 m 20,1 ÷ 25 m 25,1 ÷ 30 m 30,1 ÷ 35 m 35,1 ÷ 40 m 40,1 ÷ 45 m 45,1 ÷ 50 m 50,1 ÷ 55 m 55,1 ÷ 60 m above 60 m

2

[kg/m ]* 37,00 33,50 31,00 28,00 25,00 22,00 20,00 18,00 16,00 14,00 13,50 13,20

[Mhr/m ]* 0,62 0,56 0,52 0,47 0,42 0,37 0,33 0,30 0,27 0,23 0,22 0,21

* These data should be regularly monitored and occasionally revised.

4. EQUIPMENT SCAFFOLDING 4.1 Tubular scaffold (for each piece of equipment separately)   to 10 m

3

3

10 ÷ 50 m

50 ÷ 100 m

0,60

0,58

0, 0,30 0,90

3

3

3

100 ÷ 500 m

500 ÷ 1000 m

above 1000 m

0,55

0,52

0,50

0,47

0,27

0,25

0.23

0,20

0,18

0.85

0,80

0,75

0,70

0,65

Scaffold erection 3

[Mhr/m ] or 2

[M [Mhr hr/m /m ] Scaffold dismantling 3

[Mhr/m ] or 2

[M [Mhr hr/m /m ]

Total

 

Elevation factor at which the scaffold is erected or dismantled:   0   5  10  15

÷ 5m ÷ 10 m ÷ 15 m ÷ 20 m

1,00 1,25 1,35 1,40

2,2046 = lbs/Mhr kg /Mhr x 2,2046

 20 ÷ 25 m  25 ÷ 30 m above 30 m

1,65 2,00 2,50

Mhr/m x 0,0929 0,0929 = Mhr/s Mhr/sqft qft Mhr/m3 x 0,0283 0,02831 1 = Mhr/cuft Mhr/cuft m3 x 35,32 35,32 = cuft cuft

kg/m2 x 0,2048 0,2048 = lbs/ lbs/sqft sqft 2

3

72

 

4.2 Patent Scaffolding Sections: Length : Width : Height :

Length

One to Two Sections Long  Three to Five Sections Long Six and More  Sections Long

7 feet; 2,1 m 5 feet; 1,5 m 5 feet; 1,5 m

  Manhours per section One or Two Sections   High Erection Dismantling Total Erection

More Than Two Sections High Dismantling

Total

1,40

1,00

2,40

1,70

1,20

2,90

0,90

0,60

1,50

1,00

0,70

1,70

0,70

0,40

1,10

0,90

0,50

1,40

73  

 VII. CORROSION PROTECTION 1. SAND BLASTING AND PAINTING OF PIPING

1    0    3  

Dn-mm   15   20   25   32   40   50   65   80   100   125   150   200   250   300   350   400   450   500   550   600   650   700   750   800   850   900   950   1000   1050   1100   1150   1200   1350   1500

ø-Inch 1/2” 3/4” 1” 1 1/4” 1 1/2” 2” 2 1/2” 3” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24” 26” 28” 30” 32” 34” 36” 38” 40” 42” 44” 46” 48” 54” 60”

OD-mm 21,3 26,7 33,4 42,2 48,3 60,3 73 88,9 114,3 141,3 168,3 219,1 273 323,9 355,6 406,4 457 508 559 610 660 711 762 813 864 914 965 1016 1067 1118 1168 1219 1372 1524

Productivity Efficiency Efficiency Percentage (PEP) = 80%

SURFACE AREA OF PIPING ELEMENTS Pipe Elbow TEE Reducer Flange 1m r=1,5d [m2 ] [m2 ] [m 2 ] [m2 ] [m2 ] 0,067 0,003 0,003 0,002 0,012 0,083 0,005 0,004 0,003 0,017 0,105 0,008 0,007 0,005 0,020 0,132 0,013 0,011 0,006 0,023 0,151 0,017 0,015 0,009 0,030 0,19 0,027 0,023 0,013 0,035 0,24 0,039 0,035 0,019 0,046 0,28 0,058 0,050 0,022 0,056 0,36 0,097 0,082 0,033 0,080 0,44 0,120 0,124 0,050 0,096 0,53 0,210 0,178 0,067 0,120 0,69 0,472 0,302 0,094 0,170 0,86 0,552 0,470 0,138 0,230 1,02 0,776 0,661 0,186 0,260 1,12 0,936 0,797 0,333 0,300 1,28 1,222 1,040 0,410 0,350 1,43 1,545 1,307 0,490 0,390 1,60 1,910 1,626 0,732 0,420 1,75 2,312 1,957 0,800 0,460 1,92 2,754 2,342 0,878 0,490 2,07 3,223 2,732 1,136 0,520 2,24 3,741 3,185 1,230 0,560 2,39 4,297 3,642 1,312 0,600 2,56 4,891 4,163 1,405 0,630 2,71 5,524 4,683 1,488 0,670 2,88 6,182 5,265 1,581 0,700 3,03 6,891 5,848 1,663 0,740 3,20 7,639 6,502 1,757 0,780 3,35 7,639 7,149 2,144 0,800 3,52 8,425 7,871 2,252 0,840 3,66 10,095 8,550 2,342 0,980 3,83 10,996 9,338 2,451 0,920 4,31 13,930 11,827 2,758 2, 1,020 4,79 17,187 14,600 3,065 3, 1,120

Valve [m2 ] 0,030 0,036 0,043 0,054 0,065 0,147 0,185 0,173 0,297 0,390 0,460 0,660 0,890 1,190 1,570 1,790 2,220 2,520 3,220 3,920 3,800 3,850 4,330 4,820 5,320 5,820 6,450 7,100

RATES FOR PIPES Blast and Two Middle First Coat Coats [Mhr/m2 ] [Mhr/m2 ] 0,60 0,45 0,60 0,40 0,57 0,38 0,55 0,38 0,53 0,33 0,47 0,32 0,42 0,29 0,39 0,29 0,36 0,28 0,34 0,25 0,34 0,25 0,33 0,25 0,33 0,23 0,32 0,23 0,31 0,22 0,31 0,22 0,31 0,22 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20 0,30 0,20

above table [Mhr/m2] x 1,4 [Mhr/m2] x 1,3

- Reducers: - Flanges: - Valves:

[Mhr/m2] x 1,1 [Mhr/m2] x 1,5 [Mhr/m2] x 1,6

2

m x 10764 10764 = sq sq ft 2 Mhr/m x 0,0929 0,0929 = Mhr/sq Mhr/sq ft Mhr/m x 0,3048 = Mhr/ft

 

2.

SAND SA ND BL BLAS ASTI TING NG AN AND D PA PAIN INTI TING NG OF ST STEE EEL L ST STRU RUCT CTUR URES ES

2.1 2. 1

Sand Sa nd bl blas asti ting ng an and d pri prime mer: r: 0, 0,33 33 [M [Mhr hr/m /m2] + 0, 0,08 08 [M [Mhr hr/m /m2] = 0,4 0,41 1 [Mh [Mhr/ r/m m2] Material Consumption:  — siliceous sand for the purity puri ty grade SA 2 1/2   — 2 15 ÷ 25 25 [kg/m [kg/m ]

  or:

 — corrund (Al2O3) for the purity purity grade grade SA 2 1/2 1/2

  5 ÷ 9 [kg [kg/m /m2]

2.2

ø-Inch ø-In ch 1/2”   3/4”   1”   1 1/4”   1 1/2”   2”   2 1/2”   3”   4”   5”   6”   8”   10”   12”   14”   16”   18”   20”   22”   24”   26”   28”   30”   32”   34”   36”   38”   40”   42”   44”   46”   48”   54”   60”  

1.2 MATERIAL CONSUMPTION - acc. to Item 2 (page 104)

1.1 RATES FOR PIPING ELEMENTS

- Pipes: - Elbows: - Tees:

TOTAL  TOT Covering  TOTAL AL Four Coats Four Coats Coat [Mhr/m2 ] [M [Mhr hr/m /m2] [M [Mhr hr/m /m]] 0,30  1,34   0,09 0,30  1,30   0,11  1,24 0,29   0,13  1,18 0,25   0,16  1,11 0,25   0,17 0,21  1,00   0,19 0,21  0,92   0,22 0,20  0,88   0,25  0,84 0,20   0,30  0,79 0,20   0,35 0,19  0,78   0,41 0,17  0,75   0,52  0,72 0,16   0,62  0,70 0,16   0,72  0,69 0,16   0,77  0,69 0,16   0,89 0,16  0,69   0,99 0,15  0,65   1,04 0,15  0,65   1,14  0,65 0,15   1,25  0,65 0,15   1,35 0,15  0,65   1,46 0,15  0,65   1,55 0,15  0,65   1,66  0,65 0,15   1,76  0,65 0,15   1,87 0,15  0,65   1,97 0,15  0,65   2,08 0,15  0,65   2,18 0,15  0,65   2,29  0,65 0,15   2,38  0,65 0,15   2,49 0,15  0,65   2,80 0,15  0,65   3,11

or:

 — ground dross for the purity grade SA 2 1/2 15 ÷ 20 20 [kg/m [kg/m2]

or:

 — hot (metal sand) 1,5 ÷ 2,0 [kg/m2]

Next Coats 2

2.2.1

2.2.2

Up to 100 microns:

by brush  byy spray gun  b

0,25 [Mhr/m ] 0,10 [Mhr/m2]

Material consumption:

colour

0,30 [kg/m2]

Above 100 microns:

by brush  byy spray gun  b

0,33 [Mhr/m2] 0,15 [Mhr/m2] 0,40 [kg/m2]

Material consumption:

NOTE: 1. Consumption of the abrasive material depends on the corrosion pitting of the structure, wind, space and the possibility of regeneration r egeneration of the abrasive used. 2. Paint consumption depends on the corrosion pitting, coat thickness, wind, and the manufacturer's instructions. 2.3

Time Ti me al allo lowa wanc nces es for jo job b con condi diti tion onss

2.3 .3..1

Wor orkk at at elev elevat atio ions ns to

  2.3.2

2m

2 ÷ 10 4m 4÷ m above 10 m

no allowances

 —   —   —   — 

+ + 10 20 % % + 30 %

Work in inside - with ventilation - no ventilation

2.3.3 2.3 .3

+ 10 % + 50 %

Work in in lumber lumbered ed room roomss (spac (space e obstr obstruct uction) ion) + 20 %

104

 

2.4

MEASUR MEA SUREME EMENT NT AND AND CA CALC LCUL ULA ATIO TION N OF QUA QUANTI NTITIE TIES S FOR FOR CORR CORROSI OSION ON PRO PROTEC TECTIO TION N

2.4. 2. 4.1 1

Mach Ma chine ines, s, mot motors ors,, pumps pumps,, conve conveyo yors rs  A surface area of parallelopiped parallelopiped shape x 1,5

2.4 .4.2 .2

2.4.3

Stee St eell St Stru ruct ctur ure e  - Heavy structure  - Medium-weight structure  - Light structure

(above 60 kg/m): (31 ÷ 60 kg/m): (to 30 kg/m):

 - Floor grids:  - Ladders and step iron:  - Mesh railings:  - Flat sheets:  - Corrugated sheets:

length x width x 5 length x width length x height x 3 actual painting area actual painting area x 2

Pipe Supports  - for piping

to 4”

40 [m2/ton]

15 ÷ 20 [m2/ton] 25 ÷ 30 [m2/ton] 35 ÷ 40 [m2/ton]

 - for piping

30 [m2/ton]

above 4”

3.

SAN SA ND BL BLAS AST TIN ING G AN AND PAI PAIN NTIN ING G OF OF ST STORAG AGE E TAN TANKS KS

3.1

Outer su surfaces of of st storage ta tank   - Sand blasting SA 2 ½ :  - First coat 75 µ :  - Second coat 40 µ :  - Third coat 125 µ :    - Fourth finishing coat 50 µ :  Total  T otal = 290 µ :

0,33 [Mhr/m2] 0,07 [Mhr/m2] 0,05 [Mhr/m2] 0,09 [Mhr/m2] 0,06 [Mhr/m2] 0,60 [Mhr/m2]

Inne nerr sur surffaces of of sto storrage ta tank   - Sand blasting SA 2 ½: 40 µ :  - First coat  - II + III + IV coat 400 µ :  Total  T otal = 440 µ :

0,35 [Mhr/m2] 0,05 [Mhr/m2] 0,30 [Mhr/m2] 0,70 [Mhr/m2]

3.2

NOTE: These man hours refer to the climate conditions prevailing in the Central Europe.

105

 

 VIII. THERMAL INSULATION  Productivit Productivity y 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. 1.1 Pipe insulatio insulation n Manhours per linear linear metre [Mhr/m] Piping  ND Ø  25 1”  32  3 2 1 1/4”

30 0,53 0,57

40 0,54 0,59

50 0,56 0,60

Insulation Thickness [mm] 60 80 100 0,59 0,60 0,64 0,62 0,67 0,67

120 0,68 0,71

150  0,71 0,74

 

 40  40  50  65  80 100 125 150 200

1 1/2 2” 2 1/2” 3” 4” 5” 6” 8”

0,60 0,65 0,66 0,68 0,73 0,75 0,80 0,92

0,62 0,66 0,68 0,70 0,75 0,79 0,83 0,96

0,65 0,68 0,69 0,73 0,77 0,81 0,85 0,98

0,67 0,69 0,71 0,75 0,78 0,83 0,89 1,01

0,68 0,71 0,74 0,77 0,83 0,86 0,92 1,05

0,71 0,73 0,76 0,80 0,85 0,90 0,98 1,11

0,74 0,76 0,79 0,83 0,89 0,95 1,03 1,15

0,77 0,79 0,83 0,86 0,93 1,01 1,09 1,22

250 300 350 400 450 500 600 700 800 900 1000

10” 12” 14” 16” 18” 20” 24” 28” 32” 36” 40”

1,01 1,13 1,20 1,31 1,47 1,52 1,76 1,95 2,18 2,40 2,63

1,05 1,14 1,26 1,35 1,50 1,58 1,80 2,03 2,25 2,48 2,70

1,10 1,20 1,29 1,41 1,56 1,62 1,88 2,10 2,34 2,57 2,97

1,13 1,24 1,35 1,46 1,59 1,69 1,95 2,18 2,44 2,64 2,89

1,19 1,29 1,43 1,54 1,70 1,78 2,04 2,29 2,55 2,81 3,08

1,23 1,37 1,50 1,62 1,79 1,88 2,16 2,42 2,70 3,00 3,23

1,28 1,44 1,58 1,73 1,88 1,97 2,25 2,55 2,85 3,15 3,41

1,37 1,54 1,74 1,84 1,97 2,12 2,44 2,76 3,08 3,38 3,68

- Insulation of pipes and fittings, except for pipe bends is included. - Insulation of valves not included. - Scaffolding not included.

mm x 0,03937 = inch Mhr/m x 0,3048 = Mhr/ft

106

 

1.2

Insulation of pipe bends [Mhr / ea]   Piping  ND Ø  25 1”  32  3 2 1 1/4”  40  4 0 1 1/2”  50 2”  65  6 5 2 1/2”  80 3” 100 4” 125 5” 150 6” 200 8” 250 10”

  30 0,58 0,63 0,68 0,75 0,84 0,91 1,07 1,22 1,36 1,67 1,99

40 0,59 0,65 0,71 0,79 0,88 0,95 1,13 1,28 1,43 1,73 2,06

300 350 400 450 500 600

2,33 2,63 2,93 3,24 3,56 4,16

2,40 2,70 3,04 3,38 3,71 4,31

12” 14” 16” 18” 20” 24”

50 0,60 0,68 0,74 0,83 0,90 0,98 1,16 1,31 1,49 1,80 2,14

Insulation Thickness [mm] 60 80 100 120 0,62 0,68 0,71 0,75 0,71 0,75 0,79 0,83 0,75 0,81 0,84 0,89 0,84 0,89 0,93 0,98 0,93 0,98 1,05 1,10 1,02 1,08 1,13 1,20 1,20 1,28 1,35 1,43 1,35 1,43 1,50 1,59 1,52 1,61 1,70 1,80 1,92 1,95 2,06 2,18 2,21 2,33 2,48 2,59

150 0,83 0,89 0,94 1,05 1,16 1,28 1,50 1,69 1,91 2,33 2,78

2,48 2,81 3,15 3,49 3,83 4,43

2,55 2,90 3,23 3,60 4,01 4,58

3,23 3,68 4,13 4,58 5,03 5,85

2,70 3,08 3,45 3,83 4,20 4,88

2,85 3,26 3,64 4,05 4,43 5,14

3,00 3,49 3,83 4,28 4,69 5,40

 

700 800 900 1000

28 32” 36” 4 0” 40

1.3

Valve Insulation

4,80 5,40 6,00 6,68

4,99 5,59 6,23 6,90

5,14 5,78 6,45 7,16

5,29 5,96 6,64 7,39

5,63 6,34 7,09 7,88

ND

Ø

 [Mhr/ea]

ND

Ø

[Mhr/ea]

25 32 40 50 65 80 100 125 150 200 250

1” 1 1/4” 1 1/2” 2” 2 1/2” 3” 4” 5” 6” 8” 10”

0,71 0,74 0,77 0,80 0,83 0,86 0,93 1,01 1,09 1,22 1,37

300 350 400 450 500 600 700 800 900 1000

12” 14” 16” 18” 20” 24” 28” 32” 36” 40”

1,54 1,67 1,84 1,97 2,12 2,44 2,76 3,08 3,38 3,68

1.4 1. 4

Pipi Pi ping ng in insu sula lati tion on ba base sed d on th the e su surf rfac ace e are area a

1.4 1. 4.1

Surf Su rfac ace e are area a cal calcu cula lati tion on

5,96 9,71 7,50 8,33

6,29 7,09 7,95 8,78

6,75 7,65 8,55 9,45

Factors acc. to Insulation Thickness 30 mm x 0,91 40 mm x 0,95 50 mm x 1,0 60 mm x 1,02 80 mm x 1,07 100 mm x 1,13 120 mm x 1,18 150 mm x 1,25

 The pipe surface area is calculated by adding adding two insulation thicknesses to the pipe diameter. diameter.   ( do + 2t ) x 3 3,14 ,14  A =  [m2]   1000

do = pipe OD t = insulation thickness

[mm] [mm]

107

 

 - Pipe bend surface area 2

 A = ( d + 2t ) ( 2d + t ) x 4,93 [m ] o

o

do = pip pipe e OD [m] t = insulation thickness [m] - Valve surface area Surface area of 1 m pipe x 1,5 1.4 1. 4.2

Manh Ma nhou ourr rat ates es [M [Mhr hr/m /m2]

Insulation Thickness [mm]

30

40

50

60

80

100

120

150

[Mhr /m2]

1,15

1,13

1,11

1,10

1,07

1,05

1,04

1,00

Included:

- pipes - all fittings - valves - insulation holders - sc scaf affo fold ldin ing g

Nott in No incl clud udes es::

1.4. 1. 4.3 3

Divi Di visi sion on ba base sed d on on the the ope opera rati tions ons - Insulation holders

30 %

- Mineral wool and al. foil - Sheets

25 % 45 %

- Prefabrication - Erection

60 % 40 %

- Prefabrication - Erection

30 % 70 %

2.

THER TH ERM MAL INS NSUL ULAT ATIO ION N OF VE VESS SSE ELS AND AND KI KILN LNS S

2.1

Insulation Insulat ion with with mine mineral ral woo wool, l, smooth smooth alu alumin minium ium shee sheets, ts, dura durable ble ela elasti sticc sealin sealing g includ including ing substructure   Insulation Thickness   80 80 mm 100 mm 120 mm 150 mm 180 mm

2.2

[Mhr/m2] 0,92 0,94 0,99 1,01 1,09

Insulation Insulat ion with min miner eral al wool, wool, tra trapez pezoida oidall galv galvani anised sed E 40 she sheets ets,, 1-mm 1-mm thick thicknes ness, s, both side painting, durable elastic sealing substructure included.   Insulation thickness   80 80 mm 100 mm 120 mm 150 mm 180 mm

[Mhr/m2] 0,78 0,80 0,84 0,88 0,96 mm x 0,03937 = inch m x 3,281 = ft m2 x 10,76 10,764 4 = sq ft ft Mhr/m2 x 0,0929 0,0929 = Mhr/s Mhr/sq q ft

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 but in i n 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 - hanging scaffolds b) Scaffold Dismantling

[m3 ] [m3]

- cantilever scaffolds - platform floors [m2]

[m3 ]

- same categorization as for erection c) Rental - same categorization per week and month  The price of erection and dismantling of scaffolding varies by its height every 5 ÷ 10 m. When estimating the scaffolding quantity, quantity, the quantity for erection in [m3] and an average erection erection height are determined. 1.1

PIPING IN PLANTS - Quantit ityy: - Type :

1.2

65 ÷ 80 % 10 ÷ 15 % 5 ÷ 15 % 10 ÷ 15 %

PIPING ON PIPERACKS - Quantity:

1.3

2,5 ÷ 3, 3,0 [m3/t] piping weight standing scaffolds hanging scaffolds cantilever scaffolds platforms landings

- Type :

Option I Pipe rack surface area = [m2] scaffold Option II 2 [m3/t] piping weight standing scaffold 10 % hanging scaffold 10 - 15 % cantilevel scaffold 0÷ 5%

- Height : - Rental :

platforms floors 4÷6m average 2 ÷ 3 months

75 ÷ 85 %

STEEL STRUCTURES - Quantity: - Type :

- Height : - Rental:

1,5 ÷ 2,0 [m3/t / t] structure weight standing 60 ÷ 70 % hanging 10 ÷ 20 % cantilever 5 ÷ 10 % platforms fl floors 5 ÷ 10 % average 10 m average 1 ÷ 2 weeks

m3 x 35,3 35,32 2 = cu cu ft 2 m x 1076 10764 4 = sq ft

109

 

1.4

EQU QUIP IPME MENT NT IN PET ETRO ROC CHE HEMI MIC CAL PLANT NTS S

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 o f towers, but it is 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 th e equipment erection only, it could be calculated in the following way: - Quantity: 0,75 ÷ 1,0 [m3/ton] equipment weight - Type: standing 90 % platform floors 10 % - Height: 10 ÷ 20 m - Rental: 1 month

2.

ESTI ES TIMA MATE TE OF SCA SCAFF FFOL OLDI DING NG WH WHEN EN DO DONE NE BY AN AN ERE ERECT CTIO ION N COM COMPA PAN NY 

 This kind of scaffolding 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

PIPING IN PLANTS:

2,50 ÷ 3,0 [m3/ton] piping quantity

2.2 2. 2

PIPI PI PING NG ON PI PIPE PERA RACK CKS: S: Opti Option on I Pi Pipe pe ra rack ck su surf rfac ace e ar area ea = [m2] sc scaf affo fold ld 3   Option II 2,0 [m /t /ton] piping quantity

2.3

STEEL STRUCTURES:

1,5 ÷ 2,0 [m3 /t /ton] structure quantity

2.4 2. 4

EQUI EQ UIPM PMEN ENT T IN IN PET PETRO ROCH CHEM EMIC ICAL AL IN INDU DUST STRY RY::

0,75 0, 75÷1 ÷1,0 ,0 [m3/t /ton on]] equ equip ipme ment nt qu quan anti tity ty

(If used for the equipment erection only) When the scaffolding quantity quantity is calculated in [m3] or [m2], which is more or less the same we should estimate the material needed for tubular or patent scaffolding. 2.5

TUBULAR SC SCAFFOLDING

 There are sets of tubular scaffolding scaffolding with a list of material needed such as as tubes and clamps for 500 m (Iron Works Sisak). If it is expected that the scaffolding scaffolding will be erected and dismantled several several times during the works execution, the following calculations should be considered: 3

2.5. 2. 5.1 1

Tub ubula ularr sc scaf affo fold ld mater materia iall    Total  T otal scaffolding:

[m3] + [m2]  

= 

m3  or  m2

5

 The scaffolding quantity to round up to hundred (100).

m3 x 35,3 35,32 2 = cu cu ft 2 m x 1076 10764 4 = sq sq ft ft

110

 

2.5. 2 2.5.2

Plan Pl anki king ng top topss for sc scaf affo fold lding ing Scaffold quantity / 100 = m3 planking tops

2.6

SCAFFOLDING LA LABOUR

Determine the number of scaffolding hours by calculating: Erection + dismantling = 0,90 [Mhr/m3] or m2 x elevation factor factor (for average average elevation)

(See "Equipment Scaffolding", page 72 - 73)  After that, determine the labour needed for scaffolding and the means of transport.

111

 

2. ESTIMATE OF WELDING ROD CONSUMPTION AND ADDITIONAL WELDING WELDING MATERIAL 1. PIPING

1.1

WELD DEPOSIT [kg/weld]

  ø

  Sch   10 0,009 0,011 0,017

           

2” 3” 4” 6” 8” 10”

            

1 12 4”” 16” 18” 20” 22” 24”

0,263 0,3 0,337 0,376 0,413 0,45

Sch 20

Sch 30

0,161 0,186

0,39 0,493

Std 0,026 0,057 0,086 0,303 0,39 0,45

0 0,,2 33 99 3 0,449 0,505 0,907 0,992 1,089

0 0,,5 67 26 5 0,726 1,501 1,67 1,84 2,255

0 0,,5 67 36 5 0,726 0,807 0,907 0,998 1,089

Sch 40 0,026 0,057 0,086 0,303 0,39 0,45

Sch 60

0,717 0,83

XS 0,043 0,085 0,208 0,558 0,717 0,83

11,0 ,1671 1,34 1,5 1,22 1,412 3,42

11,7,5169 2,935 3,28 4,042 5,2 7,2

11,0 ,1671 1,338 1,5 1,67 1,84 2,0

Sch 80 0,043 0,085 0,208 0,558 0,717 1,215 2,35,504 3,783 5,4 9,743 10,72 12,67

Sch 120

0,383 0,821 1,565 2,345

Sch 160 0,104 0,255 0,562 1,215 2,576 3,674

3 5,,8 11 9 5,92 9,58 12,52 15,94 21,42

68,7 ,7776 11,59 17,0 19,61 24,56 31,33

XXS 0,213 0,375 0,835 1,58 2,03 3,27 3,81

           

26” 28” 30” 32” 34” 36”

0,73 1,27 1,36 1,459 1,542 1,633

2,172 2,336 2,506 2,671 2,84 3,003

3,43 3,674 3,92 4,164 4,409

1,18 1,27 1,36 1,45 1,54 1,633

2,172 2,336 2,504 2,671 2,84 3,003

4,563 4,844 6,554

kg /weld x 2,2046 = lbs/weld

1.2

PIPING IN PLANTS

 The most difficult job for installation of this type of piping piping is to estimate welding rod consumption with regard to the piping weight. Since this estimate is not used for the welding rod procurement but for calculation of price only,, higher departures than the actual needs are allowed. only 1.2.1 1.2. 1

If the number number of of welds is known known then they they are calcul calculated ated accordin according g to the Table 1.1 1.1 with a final increase of 25 ÷ 35 % (for smaller modifications, repairs, losses, etc.).

1.2.2 1.2. 2

If numberr of numbe weldsbeisdone welds not known kn and it cannot cannot be determ determined ined within within a reason reasonable able time, time, then then thethe calculation should asown follows:

Welding rod weight = 0,6 ÷ 1,0 % piping weight or 6,0 ÷ 10,0 [kg/ton] (Higher percentage is inversely proportionate to the pipe weight in relation to the total tot al weight of piping). 1.2. 1. 2.3 3

Piping Pipi ng qua quanti ntity ty per per inch inchdi diam amet eter er (ID (ID)) Welding rod weight = 0,06 [kg/ID]

112

 

1.3 1.3

PIPI PI PING NG BE BETW TWEE EEN N PLAN PLANTS TS AND AND PI PIPI PING NG ON PI PIPE PERA RACK CKS S

1.3.1

If the piping piping quantiti quantities es are listed accor according ding to their diamete diameters rs then the weld weld is assumed assumed to come come on average every 6 meters of the piping length. The number of joints joi nts estimated to be multiplied by the t he values from Table Table 1.1 and increased in creased by 20 %.

1.3. 1. 3.2 2

If onl onlyy the the tota totall pipi piping ng weig weight ht is is know known: n:

Welding rod weight = 0,5 % of the piping weight or

1.4

5,0 [kg/ton]

PIPING (C (C.S.) - TO TOWN NE NETWORKS

- The best way is to estimate the number of joints join ts and to use the Table 1.1 for the quantity of welding rod, and to apply the increase in crease of 15 ÷ 25 %. 1.5

PIPELINES

- For this type of pipelines the number of joints on the header line should always be calculated. The calculation will be done with the weights from Table Table 1.1 increased by 20 %.

1.6

PIPE SUPPORTS

1.6. 1. 6.1 1

Supp Su ppor ortt Fab abri rica cati tion on

Welding rod weight = 0,8 ÷ 1,0 % support weight or 8,0 ÷ 12,0 [kg/ton] [kg/ton] 1.6. 1. 6.2 2

Supp Su ppor ortt In Inst stal alla lati tion on

Welding rod weight = 0,3 0,3 ÷ 0,5 % support support weight or 3,0 ÷ 5,0 [kg/ton]

2.

STEEL STRUCTURES

Fabrication  

- Heavy structure - M ed edium-weight structure - Light structure

3.

Erection

0,6 % or 6,0 [kg/ton] 0,75 % or 7,5 [kg/ton] 0,9 % or 9,0 [kg/ton]

0,2 % or 2,0 [kg/ton] 0,25 % or 2,50 [k [ kg/ton] 0,3 % or 3,0 [kg/ton]

CYLINDRICAL STORAGE TA TANKS

Welding rod weight = 0,75 ÷ 1,0 % storage tank weight

4.

EQUIPMENT IN IN PE PETROCHEMICAL IN INDUSTRY  kg/ton x 2,2046 = lbs/ton

Welding rod weight = 0,1 ÷ 0,3 % equipment weight

113

 

3. ESTIMATE OF CONSUMPTION OF TECHNICAL GAS AND GRINDING PLATES

  P I P I N G

In plants

Oxygen  Acetylene  Argon (2.*) Grinding & cutting plates

[kg/ton] [kg/ton] [kg/ton] [pc/ton]

6÷8 4÷5 10 ÷ 15 4÷6

 Piping  between  plants  an  a nd town  networks

3÷5 2÷3 0÷4 3÷4

Pipelines

2÷3 1,5 ÷ 2   2÷3

Pipe supports

12 ÷ 15 7 ÷ 11   5÷8

Erection of steel structures

3÷5 2÷3   2÷3

Equipment in petrochemical plants

0,7 ÷ 1,0 0,5 ÷ 0,7 0,3 ÷ 0,5 0,25 ÷ 0,33

Cylindr. storage tanks

2÷3 1,5 ÷ 2   4÷6

1. Theitquantities other technical gas their such quantities as hydrogen, nitrogen, and C CO O2 are negligible and I leave up to the of estimator to estimate or not. 2.* The quantity of argon depends on the welding method and use of different types of materials. The above data of 10 ÷ 15 kg/t is taken into account when there is some 10 % 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 17,0 ÷ 22,0 kg/ton.

3. Technic Technical al Gas Data: - Oxygen 40 l bottle, 150 bar = 50 l bottle, 200 bar =

6 m3 = 1 0 m3 =

8,4 kg 13,27 kg

= =

6,5 m3 = 8,1 m3 =

6,3 10

- Argon

40 l bottle, 150 bar = 40 l bottle, 200 bar = 50 l bottle, 200 bar =

6,4 m3 = 8,8 m3 = 1 0 m3 =

10,8 kg 14,4 kg 18 kg

- CO2

40 l bottle, 60 bar

- Propane

small bottle (27,2 l) large bottle (79 l)

= =

11,5 kg (max.) 33,5 kg (max.)

- Butane

small bottle (27,2 l) large bottle (79 l)

= =

13,3 kg (max.) 38,7 kg (max.)

- Nitrogen

40 l bottle, 150 bar = 50 l bottle, 200 bar =

- Acetylene 40 l bottle, 15 bar 50 l bottle, 15 bar

=

6m3 =

6 m3 = 1 0 m3 =

kg kg

30 kg

7,55 kg 12,6 kg

114

 

4.

Calcul Cal culati ating ng the the qua quantit ntities ies of nitro nitrogen gen or air air requ required ired fo forr pres pressur sure e test testing ing  The quantity of nitrogen or air is calculated by the following formula:   (p2 - p1 ) x V x 100 100.0 .000 00 m= [kg]   T x R    where:

kg x 2,2046 = lbs

m = gas weight [kg] p2 = final pressure [bar] p1 = starting starting pressure pressure [bar]  V = system volume (to be tested) [m3]  T = temperature [K] ( = °C + 273,15) R = gas constant [J/kgK] [J/kgK] Rair = 287 287,0 ,0 [J/ [J/kgK kgK]] Rnitrogen = 29 2 96,7 [J/kgK]

EXAMPLE: A 50 m3 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

we need?   (10- 6 ) x 50 x 100.000 m=     290 x 296,7

= 232,44 kg

the number of 40 l bottles, 150 bar : 232,44 / 7,55 7,55 = 31 bottles

4.

EST ES TIM IMAT ATE E OF EL ELEC ECTR TRIICI CITY TY CONS NSUM UMPT PTIO ION N

 The client often requires an estimate of electricity consumption it has to provide and the estimator estimator must fulfil that request. If he finds that the contractor will use its own power sources from generators and genera gen eratin ting g set sets, s, the then n he wil willl est estima imate te only the par partt of ele electri ctricit cityy cons consump umption tion fro from m the pow power er grid grid.. The total power requirements should be calculated on the basis of an estimate of the welding rods needed. 1. Piping 1.1 In plants 1.2 Piping between plants

7,5 [kWh/kg] welding rod quantity 5,0 [kWh/kg] welding rod quantity

1.3 Pipelines

3,5 [kWh/kg] welding rod quantity

2. Erection of steel structure 3. Equipment erection 4. Storage tank erection

4,0 [kWh/kg] welding rod quantity 9,2 [kWh/kg] welding rod quantity 7,0 [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 machinery.. Such data can be used only if the motor operates continuously under the load foreseen by the manufacturer. manufacturer. However, 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 1. Power Plant 125 kW 2. Diesel Welding Set 400 A 3. Diesel Compressor 7 m3/min 4. Pipe Laying Machine 5. Tractor 53 kW (72 HP) 6. Tractor 88 kW

Fuel

Consumption

% use

l/day

l/month

360

9.000

Diesel oil

30 l/h

50 %

Diesel oil

6 l/h

5 ÷ 60 %

3 ÷ 36

75 ÷ 900

Diesel oil Diesel oil

8 l/h 40 l/h

5 ÷ 50 % 20 %

4 ÷ 40 80

100 ÷ 1.000 2.000

Diesel oil

8 l/h

20 %

16

400

(120 HP) 7. Fork Lift 3 t 8. Fork Lift 5 t 9. Tank truck 10. Truck 7,5 t 11. Truck 10 t 12. Trailer truck 13. Pickup 14. Passenger van 8 + 1 seat 15. Passenger car  

Diesel oil Diesel oil Diesel oil Diesel oil Diesel oil Diesel oil Diesel oil Gasoline

12 l/h 12 l/h 18 l/h 20 l/100 km 20 l/100 km 22 l/100 km 26 l/100 km 15 l/100 km

20 % 10 % 10 % 15 ÷ 75 km/day 25 ÷ 150 km/day 30 ÷ 150 km/day 75 - 160 km/day 50 ÷ 150 km/day

24 12 18 3 ÷ 15 5 ÷ 30 6 ÷ 33 20 ÷ 40 7,5 ÷ 22,5

600 300 450 75 ÷ 375 125 ÷ 750 150 ÷ 825 500 ÷ 1.000 188 ÷ 560

Gasoline

16 l/100 km

60 ÷ 150 km/day

10 ÷ 24

250 ÷ 600

Gasoline

10 l/100 km

75 ÷ 150 km/day

7,5 ÷ 15

225 ÷ 450

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 10% of the fuel prices.

l x 0,2642 = U.S. gal

116

 

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 th e job site. 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 (or sold). For that reason, the cost of tools should be calculated in the following way:  Type of job  Type 1. Piping......................................................................[US$/h] in 2002 1.1 in plants........................................................... plants................................................................0,25 .....0,25 1.2 piping between plants..............................................0,2 plants..............................................0,20 0 1.3 pipeline........................................................... pipeline..................................................................0,15 .......0,15 2. Erection of steel structure.......................................... 0,15 3. Equipment erection...................................................0,1 erection...................................................0,18 8 4. Storage tank erection *............................................ *..............................................0,15 ..0,15 *There are more tools and devices used at erection of storage tanks that are not included in this table.

7. ESTIMATE OF SAFETY AT WORK MEANS

 The means for safety at work are:

1. For For pe pers rson onal al pr prot ote ect ctio ion n - protective clothing - protective shoes - protective gloves - protective goggles - raincoats or overalls - protective helmets

2. For For pr prot otec ecti tion on at di difffe ferren entt job jobss - protection masks - welding aprons - welding masks - welding gloves - glass - welding clothes - goggles - belts - rubber boots - waistcoats - etc.

 The estimator should evaluate the yearly costs per each labourer for maximum number of labourers. Costs per labourer/year: - climate similar to Cr Croatia - climate colder than in Croatia - climate warmer than in Croatia

250,- US$ 300,- US$ 200,- US$

8. ESTIMATE OF ERECTION TIME

When the erection time is not mentioned in the th e call for tenders, the estimator should estimate it. In the magazine "3 R" of April 1985, there is a formula for calculating the time required for erection of piping: D = tm0,3 where

D = erection time in weeks (50 hour week)   tm = hours requir required ed acc. to the calcul calculation ation

My opinion is that this formula should be used to calculate the erection time only for the works up to 10.000 hours . For the works above 10.000 hours the erection time should be increased by c. 20% in the following way: D = tm0,3 x 1,2

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  Ma  M anhours   1.000   1.500   2.500   4.000   6. 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

Erection time Weeks Months 8 1,9 9 2,1 10 2,3 12 2,8 14 3,25 17 4 21,5 5 25 6 29 6,75 33,5 7,8 38,5 9 43 50,5 57,5 66 75,6

10 11,75 13,4 15,3 17,6

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 Some maketake estimates based on and consider crane should liftshould between 150 andestimates. 300 kg/hour. kg/hour . Others into account theweight number ofthey labourers andthat saya that one crane 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 OF CRANE

10 t

BUILDING CRANES 4  TOWER  PORTAL 1 CRANES MOBILE CRANE 3  PROJECTION MOBILE CRANE 2  trussed boom CATERPILLAR   —  trussed boom

CAPACITY  CAPACITY  45 t 60 t

20 t

30 t

80 t

100 t 150 t > 150 t

4

5

5

 —

—

—

—

— 

1

1

1

1

 —

—

—

— 

3

2

3

3

2

2÷3

2

3

2

4

4

4

3

2÷3

3

2

— 

 3

2

2

1

1

1

1

(They are grouped according to "Montage Gerätebuch", Issue 1985) 1985)

118

 

 The most suitable trucks for up to 2-ton cargo are those with a hydraulic hydraulic jack. Forklifts are very suitable for the cargoes from 2 to 8 tons.  To make  To make an optimum selection of the cranes, cranes, it is important to fully familiarize 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. organi zation. Before selecting the cranes, an average number of production labourers should be determined. 9.1

SELLEC SE ECTI TIO ON OF TH THE E LARG RGE EST CRA RAN NE

 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 t he crane, access roads, rental possibilities, lifting lift ing technology, technology, working time, etc.  The time for using the largest crane should be estimated by lifting the heaviest pieces of equipment (above 20 tons if possible). In this case the next largest crane that will stay longer at the job site could coul d be of smaller capacity (c. 60 ÷ 80 tons) and as a result thereof its monthly rental fee would be lower as well. 9.2

PIPING IN PLANTS

9.2 .2.1 .1

PRE PR EFABR BRIC ICA ATI TION ON

 The use of a crane is not important during the piping prefabrication. The use of one forklift of 3 ÷ 5 tons could be considered. From time to time, a smaller crane of 8 to 10 tons and HIAB truck tr uck could be used of which 1/3 for prefabrication and 2/3 for erection.  Twenty  T wenty five labourers should be allocated to one piece of lifting 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  T wenty labourers per crane. One truck with HIAB for 35 ÷ 40 labourers but only its it s 2/3. Crane capacity to be determined as follows: 70 % to 20 t 20 % to 35 t 10 % to 60 t 9.2. 9. 2.3 3

PREF PR EFAB ABRI RICA CATI TION ON AND AND ER EREC ECTIO TION N

Forapplies technical calculations, bothenough prefabrication and erection consideredwhich together together. . This type of of calculation when there are not data or time to make are a calculation, is the most often case.  The means for hoisting should be determined in the following way: - forklift 3 ÷ 5 t 65 labourers per forklift - truck with "HIAB" 60 labourers per truck   - mobile crane 20 labourers per crane of which 75 % - to 20 t capacity 15 % - to 35 t " 10 % - to 60 t "

119

 

9.3

PIPI PI PING NG BE BETW TWE EEN PL PLAN ANTS TS

Lower capacity cranes will mostly satisfy the requirements for erection of this kind of piping. The scope of prefabrication is smaller, smaller, and therefore the calculation calculatio n should be made as follows: - truck with "HIAB" 45 labourers per truck   - car crane 32 labourers per crane of which 90 % -t -to o 20 t capa capaci city ty 10 % - to 40 40 t capa capaci city ty 9.4

PIPELINES

 At pipeline laying special cranes are used for unloading, loading, pipe stringing and performance of special points. Generally, Generally, car crane renting should be avoided whenever a continuous continu ous work is not possible.  This refers refers particularly particularly to the works on right-of-ways right-of-ways where the pipe layers and trucks with HIAB are used. used. Consequently,, estimator can rely on crane for some activities only, which should be elaborated separately. Consequently  All manuals for calculations of pipeline erection provide for special elaboration of each activity from pipe transport to pressure testing.

9.5 9. 5

EREC ER ECTI TION ON OF ST STEE EELL STRU STRUCT CTUR URES ES

Erection of steel structures is not actually actuall y 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 t he tower building

cranes for their very high efficiency and outreach.  The cranes should be calculated as follows: - heavy steel structure - medium-weight steel structure - light steel structure

9.6 9. 6

6÷ 7 10 ÷ 12 16 ÷ 18

labourers per crane labourers per crane labourers per crane

INST IN STAL ALLA LATI TION ON OF OF PROC PROCES ESS S EQUI EQUIPM PMEN ENT T

 At installation of process equipment firstly we should identify the largest crane (item 9.1.) 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 calculated as follows: 1 crane on 12 ÷ 13 labourers of which: 60 % - for the second largest crane (c. 40 ÷ 80 t) 20 % - for for 30 t cran cranes es 20 % - for for 20 20 t cra crane ness 9.7 9. 7

EREC ER ECTI TION ON OF OF CYLI CYLIND NDRI RICA CALL STOR STORAG AGE E TAN TANKS KS Special attention should be paid to the selection of a crane for erection of cylindrical storage tanks.

 This type, height, of crane cann ot be selected cannot according to the number of labourers but according to the th e type, diameter, diameter arrangement, and the number of storage tanks, etc.  A mobile crane with a truss boom of maximum 20-ton capacity is the most adequate when we install one storage tank. If there is a group or a series of storage tanks, we should consider using tower cranes of sufficient reach and on tracks, if possible and necessary. necessary. If there are several storage tanks, we shall need another smaller crane for loading and unloading the plates and getting them closer closer.. Generally, Generally, an adequate erection concept is required and each activity should be supported with an adequate crane. On average, 18 ÷ 25 labourers should be allocated per one crane. When erecting spherical storage tanks (balls) the same measures for crane selection apply. 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. 213.))

10.1

10.2

MATE TER RIAL FO FOR PI PIPIN ING G - Unloading: - Handling and sorting: Piping in plants Piping between plants Pipeline STEEL ST STRUCTURE - Unloading: - Handling and sorting: Heavy structure Medium-weight structure

0,70 [Mhr/ton] 60 % 60 % 60 %

and above and above and above

1,20 [Mhr/ton] 0,80 [Mhr/ton] 0,50 [Mhr/ton]

0,85 [Mhr/ton] (above 60 kg/m) (31 ÷ 60 kg/m)

1,10 [Mhr/ton] 1,50 [Mhr/ton]

Light structure 10.3

PROCESS EQ EQUIP IPM MENT - Unloading: Bulk material (packings) Equipment Equipment Equipment - Handling and sorting: Bulk material (packings) Equipment Equipment Equipment - Sorting near foundation Equipment - Sorting at store

10.4 10 .4

CYLIND CYLI NDRI RICA CALL ST STOR ORAG AGE E TAN ANKS KS - Unloading: - Handling and sorting: - Handling and sorting:

(to 30 kg/m)

2,0 [Mhr/ton]

to 5 [t/pc] 5 ÷ 10 [t/pc] above 10 [t/pc]

1,20 [Mhr/ton] 1,10 [Mhr/ton] 1,0 [Mhr/ton] 0,80 [Mhr/ton]

to 5 [t/pc] 5 ÷ 10 [t/pc] above 10 [t/pc] above 10 [t/pc]

0,60 [Mhr/ton] 0,80 [Mhr/ton] 1,0 [Mhr/ton] 0,30 [Mhr/ton] 0,90 [Mhr/ton]

near foundation in store

0,85 [Mhr/ton] 0,40 [Mhr/ton] 0,80 [Mhr/ton]

121

 

11. TEMPORARY WORKS, SPACE REQUIRED AND CONNECTIONS AT THE SITE

  1. TEMPORARY WORKS

1.1 MANAGEMENT SITE OFFICES

OPTION 1

OFFICE BUILDINGS & CANOPIES [m²] Average nu num mber of sta tafff

 

OPTION 2 CONTAINERS

  [pc.] 1 containe nerr for 2 office wo worrkers

x 1,0 =……….m²

1.2 SITE OFFICES

No of foremen

1 container for 3 foremen

x 4 =……….m²

1.3 LOCKER ROOM 1.4 TOOLS STORE 1.5 ENCLOSED STORE 1.6 SANITARY FACILITIES 1.7 MESS ROOMS

Maximum number of workers x 0,3 = ……….m²  Average number number o workers workers x 0,275 =……….m² Average number of workers x 0,2 =……….m² 1 container for 50 workers  Average number number of workers workers x 0,5 =……….m²

1 container for 40 direct   labourers 1 office + 1 cargo container for 90 direct labourers 1 cargo container for 75   direct labourers   1 container for 30 workers

1.8 PREFABRICATION HANGAR  1.9 MAINTENANCE WORKSHOP 1.10 CANOPIES FOR  TECHNICAL GAS 1.11 ENCLOSED STORE FOR CAPITAL EQUIPMENT

 Average number number of workers workers x 3 =……….m² 8 m² fo forr ea each ch ma main inte tena nanc nce e worker work er (elect (electrici rician, an, mecha mechanic) nic) Average number of workers x 0,15 =……….m² =……….m² 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 0,2 0,2 m2/to /ton n

1 co cont ntai aine nerr fo forr 2 ma main inte tena nanc nce e workers wor kers (elec (electric trician, ian, mech mechanic) anic)

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2. AREA NEEDED

METHOD OF CALCULATING CALCULATING THE AREA IN [m²]

2.1 OU OUTDOOR AR AREA FO FOR TH THE JO JOB SI SITE MANAGEMENT SITE OFFICE BUILDINGS

A su sum of of ne net ar area fr from ea each it item: 1.1 + 1.3 + 1.6 + 1.7 increased 4 times

2.2 OUTDOOR AREA FOR WORKSHOPS AND BULKING OF EQUIPMENT

A sum of net area from each item: 1.4 + 1.8 + 1.9 + 1.10 increased 3 times

2.3 OUTDOOR AREA FOR SORTING PREFABRICATED ITEMS

Double the area of item 2.2

2.4 2. 4 OU OUT TDOO OOR R STOR ORE E AT THE JO JOB B SITE

Ge Gen era er all lly yplant , ev ever ery y jocontractor b sit ite e has aneeds few pala lant nts. s. Onneach the fenced area for storing the capital equipment and consumables. The area for that purpose would be: 20 ÷ 50 m²

2.5 OUTDOOR AREA FOR PARKING MACHINERY

Job sites to: 50 direct labourers 100 direct labourers   above: 100 direct labourers

750 m² 1000 m² 1200 m²

2.6 OUTDOOR REA FOR STORING CAPITAL EQUIPMENT

1,5 m² per ton of capital equipment

3. CONNECTIONS NEEDED

METHOD OF ESTIMATE

3.1 POWER CONNECTIONS

1 main connection: maximum number of   welding rectifiers x 15 kVA  Connections at the plants: at least 1 off  75 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 DR DRINKING WA WATER CO CONNECTIONS

Quantity: 30 ÷ 40 lilitre/man/day Connections: Connection s: every sanitary facility 1" ÷ 1 1/4"

3.4 SEWERAGE CONNECTIONS

1 connection for each sanitary facility

3.5 TELEPHONE LINES

2 telephone lines at least

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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 t he quantity of radiograms, he should know only the quantity of butt welds and if he wants to calculate precisely the quantity of welding rods and electric power, power, he should know the quantity of all types of welds. The estimate of the quantity of other oth er types of welds such as nozzle welds and socket welds, the estimator can base on the butt welds quantity. quantity.  The quantity of butt welds can be estimated in several ways: 1.

ESTIMA ESTI MATE TE OF BUT BUTT T WELD WELDS S BASE BASED D ON ON A LIS LIST T OF MA MATE TERI RIAL AL - PIPES, FITTINGS AND FLANGES

1.1 .1..

Pipi Pi ping ng in pl plan ants ts

1.2.. 1.2

- Pipe - Bends

1 1,8

weld/24 m weld/piece

-- T Peipees caps - Reducers - Weldolets - Neck flanges

2 1,5 1,5 1 1

w e we elld d//p piie ecce weld/piece weld/piece weld/piece

Piping Pip ing bet betwee ween n plant plantss pip pipera eracks cks and sle sleepe eperr ways ways

- pipes - pipes - pipes - pipes - pipes

to 3" 4"- 6" 8"-10" 12"-14" above 16"

1 1 1 1 1

weld/5,0 m weld/6,0 m weld/7,5 m weld/9,0 m weld/10,0 m

- fittings and flanges: as for the piping in a plant (item 1.1.) 1.3.. 1.3

Combin Com bined ed piping piping (in plan plants ts and and betwee between n the plant plants) s)

If there are no separate lists of materials for piping in the th e 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 of the piping between the plants plant s (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.

ESTIMA ESTI MATE TE OF BU BUT TT WEL WELDS DS BA BASE SED D ON ON A LI LIST ST OF MA MATE TERI RIAL AL - FITTINGS AND FLANGES ONLY  - Bends - Tees

2 3

weld/piece weld/piece

- Pipe caps - Reducers - Weldolets - Neck flanges

1 2 1 1

weld/piece weld/piece weld/piece weld/piece

 The pipe-to-pipe welds are not considered because it is deemed deemed that the quantity of such welds is deemed to be similar to the number of fitting-to-fitting welds.  This is the most most widely used method for estimating estimating the butt welds. I know from experience that this method is not a reliable one. If applied, it should be calculated in the following way: - Piping in the plant: decrease the weld number by - Combined piping (in plants and between th the e plants): increase by

c. 10 ÷ 12% c. 8 ÷ 12%

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3. ESTIMATE OF BUTT BUTT WELDS BASED ON THE PIPING LENGTHS - MEASURED ON THE LINE AXIS

Diameter to 1 1/2"   2"   3"   4"   6"   8"   10 10"   12 12"   14 14"

Plant 4,50* 0,80 0,85 0,90 0,95 1,00 1,05 1,10 1,15

1 butt weld/length [m] Line Combined 4,50 4,50 4,70 1,20 5,00 1,25 5,30 1,30 6,00 1,35 6,80 1,40 7,50 1,45 8,20 1,50 9,00 1,55

          

1 1,,2 30 0 1,35 1,50 1,60 1,70

9 9,,6 90 0 10,00 10,00 10,00 10,00

16 1 16 18 8"" 20" 24" 28" 30"

1 1,,6 60 5 1,70 1,85 1,95 2,00

Town network   3,00 3,20 3,30 3,50 4,00 4,80 5,60 6,80 7,80 8 8,,5 80 0 9,00 9,20 9,40 9,50

  32"  above 34"

1,75 1,80

10,00 10,00

2,10 2,20

9,50 9,50

*In the case of to 11/2" piping, the fittings are mostly with the socket welds and therefore there are fewer butt welds.

m x 3,2281 = ft

4. ESTIMATE OF TOTAL WELDS (ALL TYPES)  This estimate can be used u sed 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: - Pip Pipin ing g bet betwe ween en pl plan ants ts (p (pip iper erac acks ks an and d sle sleep eper er wa ways ys): ): - Combined piping: - Town networks:

30 ÷ 35% 10 ÷ 15% 20 ÷ 25% 3 ÷ 5%

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 list. 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).

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radiographic inspection.  The following table is mostly used to determine the percentage of radiographic

 TYPE OF STEEL CARBON STEEL

  WORKING TEMPERATURE TEMPERA TURE [°C] - 20 ÷ 100 101 ÷ 300 301 ÷ 4  40 00

Class 3 125 lb 150 lb 0% 5% 0% 5%

C - STEEL LOW  TEMPERATURE  TEMPERA TURE

- 45 ÷ - 21

 —

— 

 5 %

10%

30%

100%

Mo - STEEL

- 20 ÷ 300 301 ÷ 450

 —  —

—  — 

 5 % 10%

10% 30%

30% 100%

100% 100%

CrMo - STEEL

 - 20 ÷ 450 451 ÷ 580

 —  —

—  — 

30% 30%

30% 100%

100% 100%

100% 100%

- 99 ÷ 500 501 ÷ 700 - 196 ÷ - 100

0%  —  —

5% —  — 

10% 30% 30%

30% 30% 100%

30% 100% 100%

100% 100% 100%

 AUSTENITE STEEL (STAINLESS)

150 lb 5% 5% 10%

Class 2 300 lb 5% 10% 30%

Class 1 600 lb >900 lb 10% 100% 30% 100% 30% 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