Industrial Process Plant Construction Estimating and Man-Hour Analysis

Cover
Front-Matte_2019_Industrial-Process-Plant-Construction-Estimating-and-Man-Ho
	Front Matter
Copyrigh_2019_Industrial-Process-Plant-Construction-Estimating-and-Man-Hour-
	Copyright
Preface_2019_Industrial-Process-Plant-Construction-Estimating-and-Man-Hour-A
	Preface
Introductio_2019_Industrial-Process-Plant-Construction-Estimating-and-Man-Ho
	Introduction
		Introduction
		Labor productivity and analysis
			Labor-Man-hour unit rates
			Productivity measurement
			Validate and clarify man-hour table using graphic analysis
		Regression analysis and correlation
			Method of least squares
				Linear regression: Fitting a straight line
				Elements of a regression equation (linear, first-order model)
				Assumptions of linear regression
				Method of least squares
					Least squares line
			Correlation
				Correlation coefficient
				Coefficient of determination, r2 or R2
		Nonrepetitive one-cycle time study and man-hour analysis
		Estimating methods
			Comparison method
			Estimating equipment by comparison
			The main advantages of comparison method
		Comparison of graphic analysis of data (Fig. 3)
		Unit quantity method
		Factors affecting labor productivity and impacts of overtime
			Labor factors
		Work sampling and man hour analysis
1
	Introduction to construction statistics using Excel
		Section introduction-Introduction to construction statistics using Excel
		Graphic analysis of data
			Straight-line graph
		Linear regression and method of least squares
			Linear regression: Fitting a straight line
			Elements of a regression equations (linear, first-order model)
			Assumptions of linear regression
			Method of least squares
				Least square line
		Using Excel to forecast boiler tube replacement
		Correlation
			Correlation coefficient
			Coefficient of determination, r2
			Excel functions
		Time series
			Simple moving average
			Excel functions
			Simple exponential smoothing
		The mean, variance and standard deviation measures of central tendency statistical formulas for the mean, variance a ...
			The mean, variance and standard deviation measures of central tendency
			The mean, variance and standard deviation measures of central tendency
2
	Process piping
		Section introduction-Piping schedules and tables
		Piping section general notes
			General welding notes
		Schedule A-Oil refinery piping
			Handle and install pipe, carbon steel, welded joint
				Facility-Oil refinery
			Welding butt weld, carbon steel, and SMAW-Uphill
				Facility-Oil refinery
			Welding-SOL, TOL, and WOL
				Facility-Oil refinery
			PWHT craft support labor
				Facility-Oil refinery
			Field bolt up of flanged joints by weight class
				Facility-Oil refinery
			Field handle valves/specialty items by weight class
				Facility-Oil refinery
		Schedule B-Diesel power plant piping
			Handle and install pipe, carbon steel, and welded joint
				Facility-Diesel power plant
			Welding butt weld, carbon steel, and SMAW-Downhill
				Facility-Diesel power plant
			Welding-SOL, TOL, and WOL
				Facility-Diesel power plant
			PWHT craft support labor
				Facility-Diesel power plant
			Field bolt up of flanged joints by weight class
				Facility-Diesel power plant
			Field handle valves/specialty items by weight class
				Facility-Diesel power plant
		Schedule C-Solar power plant piping
			Handle and install pipe, carbon steel, and welded joint
				Facility-Solar power plant
			Welding butt weld, carbon steel, and SMAW-Uphill
				Facility-Solar power plant
			Welding-SOL, TOL, and WOL
				Facility-Solar power plant
			Welding stub in
				Facility-Solar power plant
			PWHT craft support labor
				Facility-Solar power plant
			Field bolt up of flanged joints by weight class
				Facility-Solar power plant
			Field handle valves/specialty items by weight class
				Facility-Solar power plant
		Schedule D-Alloy and nonferrous weld factors
			Welding percentages for alloy and nonferrous metals
		Schedule E-Industrial plant piping
			Welding, carbon steel, and socket weld
				Facility-Industrial plant
			Hydrostatic testing
				Facility-Industrial plant
			Cut and prep weld joint
				Facility-Industrial plant
			PVC piping
				Facility-Industrial plant
			Copper piping
				Facility-Industrial plant
			Screwed pipe
				Facility-Industrial plant
		Schedule K-Underground drainage piping for industrial plants
			Handle and install pipe and cast iron-Lead and mechanical joint
				Facility-Industrial plant (underground drainage piping)
			Handle and install pipe and cast iron soil-No hub
				Facility-Industrial plant (underground drainage piping)
			Handle and install pipe, concrete, and vitrified clay
				Facility-Industrial plant (underground drainage piping)
			Pipe trench-Machine, hand excavation, backfill, and sand bedding
		Schedule G-Simple foundations for industrial plants
		Schedule M-Pipe supports and hangers
			Facility-Industrial plant, pipe supports, and hangers
		Standard and line pipe-Wall thickness
3
	Oil refinery
		Section introduction
		Stripper unit
			Scope of field work required for stripper unit
				Scope of work-field erection
		Stripper unit estimating data
			Vessels/columns-Pressure equipment sheet 1
			Horizontal vessels-Pressure equipment sheet 2
			Heaters, heat exchangers, and air coolers sheet 3
			Pump-Centrifugal sheet 4
			Filter and reactor sheet 5
		Stripper unit estimate
			Vessels/columns-Pressure equipment sheet 1
			Horizontal vessels-Pressure equipment sheet 2
			Heaters, heat exchangers, and air coolers sheet 3
			Pump-Centrifugal sheet 4
			Filter and reactor sheet 5
			Recycle compressor reciprocating sheet 6
		Stripper unit-Equipment installation man-hours
4
	Waste heat boiler
		Equipment descriptions
			Boiler pressure parts
			Structural steel and boiler casing
		General scope of field work required for each 400,000lb./h waste heat boiler 400,000lb./h membrane wall boiler with  ...
		400,000lb./h waste heat boiler estimate data
			Drums, generating tubes, headers, side, front and rear wall panels sheet 1
			Erect headers and panels, weld water wall tubes, burner, soot blower, superheater sheet 2
			Down comers and code piping sheet 3
		Waste heat boiler installation estimate
			Drums, generating tubes, headers, side, front and rear panels sheet 1
			Erect headers and panels, weld water wall tubes, burner, soot blower, superheater sheet 2
			Down comers and code piping sheet 3
		Waste heat boiler-Equipment installation man-hours
		Scope of field work required for structural steel and boiler casing
		Structural steel and boiler casing estimate data
			Structural steel sheet 1
			Boiler casing sheet 2
		Structural steel installation estimate
			Structural steel sheet 1
			Boiler casing sheet 2
		Structural steel and boiler casing-equipment installation man hours
5
	Pulp and paper
		Recovery boiler
		Reheat recovery boiler
		General scope of field work required for each recovery boiler sheet 1
			Scope of work-field erection
		General scope of field work required for each recovery boiler sheet 2 scope of work-field erection
		Recovery boiler estimate data
			Erect drum, generating bank, integral economizers multiple header type sheet 1
			Erect headers and panels, furnace wall and roof tubes, weld tubes and panels sheet 2
			Erect/weld super heater, supply and riser tube, down comers, attemperators, sheet 3
			Install smelt spout and hood and auxiliary boiler support steel and equipment, sheet 4
		Recovery boiler installation estimate
			Erect drum, generating bank, integral economizers multiple header type sheet 1
			Erect headers/panels, wall/roof tubes, weld tubes and panels sheet 2
			Erect super heater, supply/riser down comers, attemperators sheet 3
			Install spout and hood and auxiliary boiler steel and equipment, sheet 4
		Recovery boiler installation man-hours
		General scope of field work required for each reheat recovery boiler sheet 1
			Scope of work-field erection
		General scope of field work required for each reheat recovery boiler sheet 2
			Scope of work-field erection
		General scope of field work required for each reheat recovery boiler sheet 3
			Scope of work-field erection
		Reheat recovery boiler estimate data
			Erect drum, generating bank, integral economizers multiple header type sheet 1
			Erect headers and panels, furnace wall and roof tubes, weld tubes and panels sheet 2
			Erect/weld SH, reheater, supply/riser tube, down comers, attemperators, sheet 3
			Install smelt spout and hood and auxiliary boiler support steel and equipment, sheet 4
			Install tubular air heater, flues and ducts
		Reheat recovery boiler installation estimate
			Erect drum, generating bank, integral economizers multiple header type sheet 1
			Erect headers, panels, furnace wall, roof tubes, weld tubes and panels sheet 2
			Erect superheater, reheater, riser tube, down comers, attemperators, sheet 3
			Install smelt spout and hood and auxiliary boiler support steel and equipment, sheet 4
			Install tubular air heater, flues and ducts
		Reheat recovery boiler installation man-hours
6
	Industrial package boiler
		Industrial package boilers
			Modular design
		General scope of field work required for each D-type package boiler sheet 1
			Scope of work-field erection
		D-type package boiler estimate data
			Set boiler and install piping, flues, stack, economizer, and structural steel sheet 1
		D-type package boiler installation estimate
			Boiler and piping, flues, stack, economizer, and structural steel sheet 1
			D-type package boiler installation man-hours
		General scope of field work required for each field erected package boiler sheet 1
			Scope of work-field erection
		Field erected package boiler estimate data
			Drums, tubes baffles, steel, casing, wind box, burner, sheet 1
		Field erected package boiler installation estimate
			Drums, tubes baffles, steel, casing, wind box, burner, sheet 1
		Field erected package boiler installation man-hours estimated actual
		General scope of field work required for each air heater
		Air heater estimate data
			Air heater sheet 1
		Air heater installation estimate
			Air heater sheet 1
		Air heater installation man-hours
		General scope of field work required for FD fan
			Fans
		FD fan estimate data
			FD fan sheet 1
		FD fan installation estimate
			FD fan sheet 1
		FD Fan Installation Man-Hours
		Field erected package boiler man-hour breakdown
7
	Diesel power plant
		Section introduction-Piping and equipment
			Diesel power plant
		General scope of field work required for diesel power plant
			Scope of work-field erection
		Engines, couplings, and generators (B2) estimate data
		Engines, couplings, and generators (B2) estimate
		Engines, couplings, and generators (B2) installation man hours
		Engines and Aux platforms (A3) estimate data
		Engines and Aux platforms (A3) estimate
		Engines and Aux platforms (A3) installation man-hours
		Installation of pipe modules (B3) estimate data
		Installation of pipe modules (B3) estimate
		Installation of pipe modules (B3) installation man hours
		Exhaust gas system (A11) estimate data
		Exhaust gas system (A11) estimate
		Exhaust gas system (A11) installation man-hours
		Installation of SCR and urea system (A13) estimate data
		Installation of SCR and urea system (A13) estimate
		SCR and urea system (A13) installation man-hours
		Installation of cooling system (A10) estimate data
		Installation of cooling system (A10) estimate
		Cooling system (A10) installation man-hours
		Installation of intake air system (A11) estimate data
		Installation of intake air system (A11) estimate
		Intake air system (A11) installation man hours
		Installation of fire water system (A14) estimate data
		Installation of fire water system (A14) estimate
		Fire water system (A14) installation man hours
		Installation of utility gas heating system estimate data
		Installation of utility gas heating system estimate
		Utility gas heating system estimate installation man hours
		Installation of lube oil system (pump and tanks) estimate data
		Installation of lube oil system (pump and tanks) estimate
		Lube oil system (pump and tanks) installation man-hour
		Installation of utility water estimate data
		Installation of utility water estimate
		Utility water installation man hour
		Installation of secondary pipe support estimate data
		Installation of secondary pipe support estimate
		Secondary pipe support installation man hours
		Installation of valves list estimate data
		Installation of valves list estimate
		Valves list installation man-hour
		Installation of manometer/thermometer list estimate data
		Installation of manometer/thermometer list estimate
		Manometer/thermometer list installation man hour
		Leaking channel set estimate data
		Leaking channel set estimate
		Leaking channel set installation man hour
		Man hour breakdown
			Diesel power plant
				Owner-furnished equipment
8
	Coal-fired power plant
		Equipment descriptions
			Equipment descriptions-Coal-fired boiler pressure parts sheet 1
			Equipment descriptions-Coal-fired boiler pressure parts sheet 2
			Equipment descriptions-Auxiliary equipment
			Equipment descriptions-Fan system sheet 1
			Equipment descriptions-Fan system sheet 2
			Equipment descriptions-Electrostatic precipitator sheet 1
			Equipment descriptions-Electrostatic precipitator sheet 2
			Equipment descriptions-Structural steel and boiler casing
			Equipment descriptions-Ductwork and breeching and bottom ash handling system
		General scope of field work required for each coal-fired boiler sheet 1
		General Scope of Field Work Required for Each Coal-Fired Boiler Sheet 2
		General scope of field work required for each coal-fired boiler sheet 3
		General scope of field work required for each coal-fired boiler sheet 4
		General scope of field work required for each coal-fired boiler sheet 5
		General scope of field work required for each coal-fired boiler sheet 6
		Coal-fired boiler estimate data
			Install drum, erect headers, panels, furnace wall, roof tubes, weld tubes/panels sheet 1
			Install and weld attemperators, superheater, and reheat components sheet 2
			Tubes, down comers, accessories, burner, soot blowers, economizer sheet 3
			Tubes, down comers, accessories, burner, soot blowers, economizer sheet 4
		Coal-fired boiler installation estimate
			Drum, headers, panels, furnace wall, roof tubes, weld tubes/panels sheet 1
			Drum, headers, panels, furnace wall, roof tubes, weld tubes/panels sheet 2
			Install and weld attemperators, superheater, and reheat components sheet 3
			Install and weld attemperators, superheater, and reheat components sheet 4
			Tubes, down comers, accessories, burner, soot blowers, economizer sheet 5
			Tubes, down comers, accessories, burner, soot blowers, economizer sheet 6
		Coal-fired boiler installation man-hours
		General scope of field work required for each coal silo and coal pulverizer coal silo
		Coal silo and pulverizer estimate data
			Install coal silo and pulverizer sheet 1
		Coal silo and equipment installation estimate
			Install coal silo and pulverizer sheet 1
		Coal silo and pulverizer installation man hours
		General scope of field work required for each air heater
		Air heater estimate data
			Install air heater sheet 1
		Air heater equipment installation estimate
			Install air heater sheet 1
		Air heater installation man hours
		General scope of field work required for each selective catalytic reduction unit
		Selective catalytic reduction unit estimate data
			Install selective catalytic reduction unit sheet 1
		Selective catalytic reduction unit equipment installation estimate
			Install selective catalytic reduction unit sheet 1
		Selective Catalytic Reduction Unit Installation Man Hours
		General scope of field work required for each FD, ID, primary air fan & pulverized seal air fan
		FD, ID, primary air fan & pulverizer seal air fan estimate data
			Install FD, ID, primary air fan & pulverizer seal air fan sheet 1
		FD, ID, primary air fan & pulverizer seal air fan equipment installation estimate
			Install FD, ID, primary air fan & pulverizer seal air fan sheet 1
		FD, ID, primary air fan & pulverized seal air fan installation man hours
		General scope of field work required for each bottom ash handling system
		Bottom ash handling system estimate data
			Install bottom ash handling system sheet 1
		Bottom ash handling system installation estimate
			Install bottom ash handling system sheet 1
		Bottom ash handling system-Installation man hours
		General scope of field work required ductwork and breeching
		ID, FD, primary air and over fire air ductwork estimate data
			Install ID, FD & primary air ductwork sheet 2
			Over fire ductwork sheet 2
		ID, FD, primary air and over fire air ductwork installation estimate
			Install ID, FD & primary air ductwork sheet 1
			Install over fire ductwork sheet 2
		ID, FD, primary air and over fire ductwork-Installation man hours
		General scope of field work required for each electrostatic precipitator
		Electrostatic precipitator estimate data
			Hoppers, casing/partition frames, support steel, diffusers, TEF's & IRB's sheet 1
			Slide plates, hopper platform, support steel access sheet 2
			Penthouse, casing, hoppers, weld casing, frames/beams sheet 3
			Frames/baffles, collecting plates, hopper auxiliaries, electrodes, hot roof sheet 4
			Set plates, rapper rods, Mfg. plates, penthouse, diffuser, alignment, rectifiers sheet 5
			Seal air system, dampers, stack, inlet/outlet plenum sheet 6
			Penthouse structural steel sheet 7
		Electrostatic precipitator installation estimate
			Hoppers, casing/partition frames, erect steel, diffusers, TEF/IRB sheet 1
			Slide plates, hopper platform, support steel access sheet 2
			Penthouse, casing, hoppers, weld casing, frames/beams sheet 3
			Frames/baffles, collecting plates, hopper auxiliaries, electrodes, hot roof sheet 4
			Perforated plates, rapper rods, Mfg. plates, penthouse, diffuser, alignment, rectifier set sheet 5
			Seal air system, dampers, stack, inlet/outlet plenum sheet 6
			Penthouse structural steel sheet 7
		Electrostatic precipitator-installation man-hours
		Scope of field work required for structural steel and boiler casing
		Structural steel and boiler casing estimate data
			Structural steel and boiler casing sheet 1
		Structural steel and boiler casing installation estimate
			Erect structural steel and boiler casing sheet 1
		Structural steel and boiler installation man-hours estimated actual
		Coal-fired boiler and auxiliary equipment man-hour breakdown
9
	Solar thermal power plant
		Solar thermal power plant
		General scope of field work required for each receiver
		Receiver estimate data
			Assemble and erect core columns and cross-braces sheet 1
			Install secondary steel, platforms and ladders sheet 2
			Install secondary steel, vertical struts sheet 3
		Receiver installation estimate
			Assemble and erect L1 core columns and cross-braces sheet 1
			Assemble and erect L2 core columns and cross-braces sheet 2
			Assemble and erect L3 core columns and cross-braces sheet 3
			Install L1 secondary steel, platforms sheet 4
			Install L2 secondary steel, platforms sheet 5
			Install L3 secondary steel, platforms sheet 6
		Receiver installation man hours
		General scope of field work required for receiver panel assemblies
		Receiver panel assembly estimate data
			Assemble and erect receiver panels sheet 1
		Receiver panel assembly installation estimate
			Assemble and erect receiver panels sheet 1
		Receiver panel assembly estimate data
			Assemble and erect receiver panels sheet 1
		Receiver panel assembly installation estimate
			Assemble and erect receiver panels sheet 1
		General scope of field work required for thermal enclosure
		Receiver thermal enclosure estimate data
			Assemble and erect thermal enclosure sheet 1
		Receiver thermal enclosure installation estimate
			Assemble and erect thermal enclosure sheet 1
		General scope of field work required for heat shield set
		Receiver heat shields set estimate data
			Assemble and erect heat shields set sheet 1
		Receiver heat shields set installation estimate
			Assemble and erect heat shields set sheet 1
		General scope of field work required for cranes, vents and trays
		Receiver cranes, vents and trays estimate data
			Assemble and erect cranes, vents and trays sheet 1
		Receiver cranes, vents and trays installation estimate
			Assemble and erect cranes, vents and trays sheet 1
		Receiver panel assemblies installation man hours
		General scope of field work required for each air cooled condenser
		Air cooled condenser estimate data
			Structural steel module/fan duct, stairways & walkways, A-frame & fan cowl/screens sheet 1
			Motor bridge, tube bundles, condensate headers & steam distribution manifolds sheet 2
			IC equipment & street pipe, wind walls, turbine exhaust duct sheet 3
			Street steam duct sheet 4
			Erect & weld turbine exhaust duct risers sheet 5
			Risers, shop tanks sheet 6
			Pumps, expansion joint, test sheet
		Air cooled condenser installation estimate
			Structural steel module/fan duct, stairways & walkways, A-frame & fan cowl/screens sheet 1
			Structural steel module/fan duct, stairways & walkways, A-frame & fan cowl/screens sheet 2
			Structural steel module/fan duct, stairways & walkways, A-frame & fan cowl/screens sheet 3
			Street steam duct sheet 4
			Erect & weld turbine exhaust duct risers sheet 5
			Risers, tanks sheet 6
			Pumps, expansion joint, test sheet 7
		Air cooled condenser installation man hours
			Facility-solar power plant (10 cell ACC)
		Solar plant equipment man hour breakdown
10
	Boiler tube replacement
		General scope of field work required for boiler tube replacement sheet 1
		Boiler tube replacement estimate data
			Boiler tube replacement sheet 1
		Boiler tube replacement installation estimate
			Boiler tube replacement sheet 1
		Boiler tube replacement installation man hours
11
	Sample estimates
		Section introduction
		Industrial process plant construction estimating process
		Sample estimate construction estimating process
		Sample estimate for assembly receiver tower IC pipe
			Handle and install pipe -welded joint sheet 1
			Welding BW, SW, & PWHT-arc uphill sheet 2
			Bolt up of flanged joint by weight class sheet 3
			Field handle valves/specialty items by weight class
			Pipe supports sheet 5
		Man hours for assembly receiver tower interconnecting pipe
		Sample equipment estimate estimates
		Waste heat boiler, 500,000 lb/h installation estimate
			Drums, generating tubes, headers, side, front & rear panels sheet 1
			Erect headers & panels, weld water wall tubes, burner, soot blower, superheater sheet 2
			Down comers & code piping sheet 3
		Waste heat boiler-pressure parts and piping installation man hours
		Comparison method-Air cooled condenser upper structure a-frame structural
			Air cooled condenser installation field erection estimate
			Air cooled condenser installation increased quantities estimate
			Air cooled condenser installation decreased quantities estimate
		Comparison and graphic analysis of data
12
	Statistical applications to construction
		Section introduction
		Analysis of Foreman's report
		Graphical analysis of process piping
		Graphical analysis for equipment
		Method of least squares for equipment
		Method of least squares for process piping
		Simple moving average forecast
		Application of the learning curve in construction
			U learning model
			Linear regression-Fitting U model to unit historical data for waste heat boiler erection
		Risk
			Expected-value method
			Range method
			Application of the range method for equipment
				Illustration: SCR-Exhaust stack silencer
			Contingency
			Application of the range method to contingency
		Bid assurance
			Expected profit
			Capture rate
		Application of optimal bidding strategy
A
	Areas of standard normal distribution
B
	Statistical and mathematical formulas
		Statistical formulas for the mean, variance, and standard deviation
			Method of least squares
				Least-square line
			Prediction for the total hours for a ``block´´ of production
			Linear regression-Fitting U model to unit historical data
			Calculating sample size
				Sample size: absolute precision
			Calculating error limits for a sample size
			Work sampling method
		Chapter 12 Analysis of risk probability in construction
			Expected value method
			Range method
			Capture rate
			Moving averages. Smoothing of time series
			Estimation of moving averages
			Exponential smoothing
			Cost index
C
	Excel functions and mathematical functions
		Excel functions
			Graphic analysis of data
		Excel functions
		Correlation
D
	Area and volume formulas
E
	Standard to metric
		Lengths
			Metric conversion
			Metric-standard conversions
			Standard-metric conversions
		Volumes
			Metric conversion
			Standard conversions
			Metric-standard conversions
			Standard-metric conversions
		Areas
			Metric conversion
			Standard conversions
			Metric-standard conversions
			Standard-metric conversions
F
	Boiler man-hour tables
G
	Glossary
Index
	Index
		A
		B
		C
		D
		E
		F
		G
		H
		I
		L
		M
		O
		P
		R
		S
		T
		U
		V
		W