Industrial Construction Estimating Manual

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