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TABLE OF CONTENTS
I.
INTRODUCTION
II.
III.
IV.
STANDARD FORMS
VI.
1
1442-0001
INTRODUCTION
The purpose of the PIPING DISCIPLINE MANUAL is to define procedures and job
descriptions and to maintain consistency in the production of the piping portion of detailed
conceptual, lump sum, and definitive estimates. It is intended to set forth correct piping
procedures, material pricing requirements, take off theory, and application of correct workhours. The information should serve as a guideline for an estimate's technical content.
This is to be a working" discipline manual; its organization parallels the activities of a
typical project. First, the estimator must identify the major areas of the project (i.e., scope,
drawings, specifications, dates, etc.). Then, activity responsibility must be determined
within each code of account (i.e., labor, purchasing, shop fabrication, field run, etc.). Once a
plan has been established, the quantity survey begins. After the takeoff has been completed
with work-hours, material dollars, and qualifications, the chief estimator then reviews the
estimate. Technical content, accuracy, and historical comparisons are performed. After
these adjustments, the estimate is turned over to the principal estimator. The estimate then
proceeds through the formal reviewing process to completion.
This manual also has typical details and standards that may be used when no other
drawings or definitions pertinent to the project are available.
Additionally, each piping estimator has the responsibility to suggest ways to revise and
update the manual. The ultimate responsibility for the accuracy of this manual belongs to
the chief piping estimator.
Always be mindful that we are all working together and toward the same goal, any
information that the estimator receives that is beneficial to the other estimators should be
shared. It is also the responsibility of the estimator to communicate with the estimators in
other disciplines to assure uniformity of the estimate.
Finally, the estimator must ask questions if uncertain about a particular situation. He must
be willing to seek advice from those with experience and to research and be able to support
any assumptions that are made. All-important aspects of the piping estimate should be
clarified in writing in the estimate qualifications.
1
1442-0002
K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
D--DEMOLITION - All work required for dismantling or removal of any existing piping and insulation
systems to clear site of decommissioned systems. These accounts are to include transportation or disposal
costs, if required. For relocation accounts, only the dismantling portion of the work is to be included in this
section. Any new work subsequent to the dismantling activities is to be included in the respective section .
D43 DEMO FOR DISPOSAL - PIPING - Use this account only if the item is not to be salvaged or
relocated. This account includes demolition and disposal of existing piping systems including fittings,
flanges, manual valves, and in-line instruments. Removal techniques may include cold or hot cutting. The
sale of scrap or other credits related to this activity are included in this account. Quantities are measured as
center to center lengths of pipe removed (LF or LM).
D46 DEMO FOR DISPOSAL - INSULATION - Use this account only if the item is not to be salvaged
or relocated. This account includes demolition and disposal of existing insulation, other than asbestos
containing materials. Asbestos abatement costs are included in other accounts. The sale of scrap or other
credits related to this activity are included in this account. Quantities are measured as lengths of insulation
removed (LFI or LMI).
D53 DEMOLITION FOR SALVAGE PIPING - Use this account only if the item is to be salvaged.
This account includes the demolition and salvage of existing piping systems including fittings, flanges,
manual valves, and in-line instruments. Removal techniques may include cold or hot cutting. The sale of
scrap or other credits related to this activity are included in this account. Quantities are measured as center
to center lengths of pipe removed (LF or LM).
D56 DEMOLITION FOR SALVAGE INSULATION - Use this account only if the item is to be
salvaged. This account includes the demolition and salvage of existing insulation, other than asbestos
containing materials. Asbestos abatement costs are included in other accounts. The sale of scrap or other
credits related to this activity are included in this account. Quantities are measured as lengths of insulation
removed (LFI or LMI).
D63 DEMOLITION FOR RELOCATION - PIPING - Use this account only if the item is to be
relocated. This account includes only the removal for relocation of existing piping systems including
fittings, flanges, manual valves, and in-line instruments. Removal techniques may include cold or hot
cutting. For costs to relocate and reinstall the item, use the appropriate control code as though the item was
new. Quantities are measured as center to center lengths of pipe removed (LF or LM).
D66 DEMOLITION FOR RELOCATION - INSULATION - Use this account only if the item is to be
relocated. This account includes only the removal for relocation of existing insulation, other than asbestos
containing materials. Asbestos abatement costs are included in other accounts. For costs to relocate and
reinstall the item, use the appropriate control code as though the item was new. Quantities are measured as
center to center lengths of insulation removed (LF or LM).
D97 SCAFFOLDING - Cost of scaffolding including rental and purchase of materials, and labor
for storage, erection and dismantling.
Quantities will be Lot (LOT).
D98 -CONCEPTUAL DESIGN ALLOWANCE - For estimating use only. The intent of the conceptual
design allowance is to provide for the normal growth of engineered and bulk material quantities during the
engineering design process. These historical percentages are based on the level of definition at the time of
quantity development. These percentages are reflected in real quantities so that the estimate reflects the
actual quantities installed. This allowance is not intended to be a source to cover out-of-scope cost.
Quantities will be Lot (LOT).
D99 -CONSTRUCTION PRACTICES ALLOWANCE - For estimating use only. The intent of the
construction practice allowance is to provide for the material cost only associated with additional material
consumed due to normal construction practice. There will be no labor or man-hours associated with this
code. This allowance also covers standard waste and is not intended to cover out-of-scope costs.
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K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
U4 UNDERGROUND PIPE These accounts are for all labor and material required for
underground process and drainage piping systems. Costs shall include, but not be limited to, pipe,
fittings, flanges, coatings, trench excavation, backfill, sand bedding, kicker blocks, shoring, and
dewatering.
All excavation trenching and backfill shall be performed with due care around/under cables,
pipes, or adjacent structures; protecting and supporting of these items may be required.
Waste or over-excavation shall not constitute additional quantities.
The cost also includes additional excavation and subsequent backfill for working space and
for temporary supporting of trench sides. Trenches shall be excavated in accordance with safety
practices.
Trenches shall be kept free from water to ensure work can proceed.
Work shall include repair of internal and external coatings on metallic systems.
Costs to supply labor and material to repair these coatings shall be included in these accounts
Quantities are measured center-to-center through fittings, flanges, valves, and
other in-line devices. At bends, measurement shall be to the intersection point,
branches are measured from the outer wall of the main pipe. Material handling,
unloading / storage of materials, and clean-up to be included in the appropriate
account.
U41 PRESSURE PIPE LESS THAN 12- All costs of piping materials, fabricating, placing,
and testing of Underground piping up to and including 10 in pressure flow service including pipe,
fittings, valves, and other items and appurtenances. Specialty items, such as hydrants and monitors
are included in this account. Pipe bollards are not included in these accounts and shall be included
in concrete accounts, C. Quantities are measured as center to center lengths of pipe installed
(LF or LM).
U42 PRESSURE PIPE 12 & LARGER All costs of piping materials, fabricating, placing,
and testing of Underground piping 12 & larger pipe in pressure flow service including pipe,
fittings, valves, and other items and appurtenances. Specialty items, such as hydrants and
monitors are included in this account. Pipe bollards are not included in these accounts and shall
be included in concrete accounts, C. Quantities are measured as center to center lengths of pipe
(LF or LM).
U43 GRAVITY PIPE LESS THAN 12- All costs of piping materials, fabricating, placing,
and testing of underground piping up to and including 10 in gravity flow service including pipe,
fittings, valves, and other items and appurtenances. Quantities are measured as center to center
lengths of pipe installed (LF or LM).
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K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
U44 GRAVITY PIPE 12 & LARGER All costs of fabricating, placing, and testing of
underground piping 12 & larger pipe in gravity flow service including pipe, fittings, valves, and
other items and appurtenances. Quantities are measured as center to center lengths of pipe
installed (LF or LM).
U45 MANHOLES - All material and labor costs for installing precast manholes, catch basins,
and sumps. Costs for excavation and backfill shall be included. Quantities are measured as each
installation (EA).
Concrete or precast costs for these items will be included with concrete accounts.
U90 PUMP AND BAIL - All material and labor costs for normal pump and/or bailing of all
excavated trenches. Quantities will be for all u/g piping measured as total (LOT).
U98 -CONCEPTUAL DESIGN ALLOWANCE - For estimating use only. The intent of the
conceptual design allowance is to provide for the normal growth of engineered and bulk material
quantities during the engineering design process. These historical percentages are based on the
level of definition at the time of quantity development. These percentages are reflected in real
quantities so that the estimate reflects the actual quantities installed. This allowance is not
intended to be a source to cover out-of-scope cost.
Quantities will be (LF or LM).
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K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
L01 PIPELINE These accounts are for work required for all costs to supply and install crosscountry product pipelines. Costs shall include, but not be limited to, pipe materials, pipe coatings,
clearing, grade & surveys, ditching & trenching, field bending, alignment, welding, testing,
drying, and purging. Where routings require installation in and/or under waterways, adequate
anchoring costs shall be included.
Also includes routing surveys, clearing of right-of-way, removal of landscaping, bedding,
backfill, final
grading to final elevations, replacement of disturbed areas to its original condition
and the installation of pipeline markers and warning signs. For aboveground
Transmission lines, sleepers and supports area included in this account. All excavation,
Trenching, and backfill shall be performed with due care around/under cables,
pipes, or adjacent structures; protecting and supporting of these items may be
Required. Waste in bulk shall not constitute additional quantities. The cost also includes
Additional excavation and Subsequent backfill for working space and for temporary supporting of
trench sides. The area shall be kept free from water to ensure work can proceed.
Quantities are measured center-to-center through fittings, flanges, valves, and
other in-line devices. At bends, measurement shall be to the intersection point;
Branches are measured from the outer wall of the main pipe. Material handling,
Unloading / storage of materials, and clean-up to be included in the appropriate
account. Costs for permanent roads are included in the Site Preparation accounts.
Bidders shall store all materials at the site. Pipe and fittings will be manufactured with external
coatings. Costs to supply labor and material to repair these coatings shall be included in these
accounts.
L13 ROAD CROSSINGS All costs associated with pipeline installation at road crossings to
include casing installation, testing, and markers and/or warning signs.
Crossings will be concrete box culverts with 12 thick walls, as required by specification.
L14 RIVER CROSSINGS All costs associated with pipeline installation at river crossings.
Crossing may be open cut submerged or bored, as required by specification.
CATHODIC PROTECTION All costs of installing, terminating, and testing a
Complete cathodic protection system for pipelines.
NOTE:
If other ELECTRICAL work is included in this contract, the CATHODIC
PROTECTION shall be in ACCOUNT CODE E.
Also note that, if desired, account 0601 can be divided, as further breakdown,
Into:
L01
L02
L03
L04
L11
L13
L14
L15
Permanent materials
Survey, clear, grade right-of-way
String, weld, & lower in
Ditching and trenching
Clean, test, & finals clean up
Road crossings
River crossings
Specialty items.
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K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
P ABOVEGROUND PIPE All cost of pipe materials, labor, temporary materials, and
permanent materials, and consumables required to install aboveground piping systems as defined
by engineering documents and specifications. Material handling, unloading/storage of materials,
and clean up to be included in these accounts.
Rates shall include, but not be limited to, supply materials, labor costs to fabricate and erect pipe,
fittings, flanges, valves, in-line instruments, and specialty items. All work activities required to
insure complete installation of piping systems shall include, but not be limited to, lifting,
installation, weld out, mechanically connect, hydrotest, and support piping systems. Work for
activities in these accounts shall be through mechanical completion. Costs to be separated by size
and material type.
Costs to perform non-destructive examination (radiography, hardness, etc.), post weld heattreating, steam blow, and chemical cleaning shall be included in these accounts.
Costs to supply, erect, and maintain scaffolding, according to project safety requirements, shall be
included in these accounts.
Quantities are to be measured center to center through fittings, flanges, valves, and other in-line
devices. At bends, measurement shall be to the intersection point. Branches are measured from
the outer wall of the main pipe.
Waste shall not constitute additional quantities.
P11 SPOOL FABRICATION 2 & less Quantity reflects the supply of piping material and
field shop fabrication of welded pipe spools for process and utility service sizes 2 & less. Pipe
spools will be installed in account P31. Quantities are measured as center to center lengths of
pipe fabricated (LF. Or LM.).
P12 SPOOL FABRICATION 2-1/2 thru 10 Quantity reflects supply of piping materials
and field shop fabrication of welded pipe spools for process and utility service sizes 2-1/2
through 10. Pipe spools will be installed in account P32. Quantities are measured as center to
center lengths of pipe fabricated (LF. or LM.).
P13 SPOOL FABRICATION 12 and Larger Quantity reflects supply of piping materials
and field shop fabrication of welded pipe spools for process and utility lines in sizes 12 and
larger. Pipe spools will be installed in account P33. Quantities are measured as center to center
lengths of pipe fabricated (LF. or LM.).
P31 SPOOL ERECTION 2 & less Quantity reflects pipe spool erection of welded pipe
spools for process and utility service sizes 2 & less. Outside fabrication cost of spools will be
included in this account. In the event pipe spools are fabricated at a field shop, material cost will
not be included in this account. Erection labor rates to include but not limited to valve handling,
specialty handling, bolting, and welding.
Quantities are measured as center to center lengths of pipe installed (LF or LM).
P32 SPOOL ERECTION 2-1/2 thru 10 Quantity reflects pipe spool erection of welded
pipe spools for process and utility service sizes 2-1/2 through 10. Outside fabrication cost of
spools will be included in this account. In the event pipe spools are fabricated at a field shop,
material cost will not be included in this account. Erection labor rates to include but not limited to
valve handling, specialty handling , bolting, and welding.
Quantities are measured as center to center lengths of pipe installed (LF or LM).
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K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
P33 SPOOL ERECTION 12 and Larger Quantity reflects pipe spool erection of welded
pipe spools for process and utility lines in sizes 12 and larger. Outside fabrication cost of spools
will be included in this account. In the event pipe spools are fabricated at a field shop, material
cost will not be included in this account. Erection labor rates to include but not limited to valve
handling, specialty handling, bolting, and welding.
Quantities are measured as center to center lengths of pipe installed (LF or LM).
P41 FIELD RUN 2 & LESS Quantity reflects the material and labor cost of all pipe
systems to be field run in place for process and utility lines sizes 2 and less. Erection labor rates
to include but not limited to valve handling, specialty handling, bolting, and welding.
Quantities are measured as center to center lengths of pipe installed (LF or LM).
P42 FIELD/RACK RUN 2-1/2 thru 10 Quantity reflects the material and labor cost of all
pipe systems to be field run in pipe racks for process and utility lines in sizes 2-1/2 through 10.
Erection labor rates to include but not limited to valve handling, specialty handling, bolting, and
welding.
Quantities are measured as center to center lengths of pipe installed (LF or LM).
P43 FIELD/RACK RUN 12 and Larger Quantity reflects material and labor cost of all pipe
systems to be field run in Pipe racks for process and utility lines in sizes 12 and larger.
Erection labor rates to include but not limited to valve handling, specialty handling, bolting, and
welding.
Quantities are measured as center to center lengths of pipe installed (LF or LM).
P51 DELUGE SYSTEMS Quantity reflects labor and material cost of deluge pipe systems.
Quantities are measured as center to center lengths of pipe installed (LF or LM).
P67 PIPE SPECIALTIES Used only for material cost of pipe mechanical specialties. Such
devices shall include, but not be limited to strainers, traps, hoses, paddle blinds, expansion joints,
etc. Quantities are measured as each (EA)
P68 ERECTION MATERIALS Used only for material cost of bolts, nuts, & gaskets.
P69 VALVES Used only for material cost of all manual valves. Supply of RSV and actuated
valves are included in the instrument account.
P71 TESTING All labor & material costs required to perform visual, mechanical, and pressure
test of piping systems as defined by engineering documents, specifications, and applicable codes.
Work shall include provision and subsequent removal of all temporary supply lines, pressure
sources, and test water. Costs shall include completion of punch list check out.
Quantities are measured as lot (LOT)
P72 TIE-INS AND HOT TAPS All labor cost associated with tie-ins.
Quantities are measured as each (EA)
P73 OTHER SERVICES All costs associated with X-raying, stress relieving, pipe.
Quantities are measured as each (EA)
P75 PIPE CLEANING All costs associated with cleaning and pickling pipe.
Quantities are measured as Lot (LOT)
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K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
P81 SHOP PIPE SUPPORTS All costs associated with the supply, fabrication, and
attachment of pipe supports, plates, shoes, guides, hangers, angles, and springs in an outside pipe
fabrication shop.
Quantities are measured as lot (LOT)
P82 PIPE SUPPORTS All costs associated with the supply, fabrication, and erection of pipe
supports, plates, shoes, guides, hangers, angles, and springs by the field erection crews.
Quantities are measured as center to center lengths of pipe installed (LF. or LM.).
P97 SCAFFOLDING - Cost of scaffolding including rental and purchase of materials, and labor
for storage, erection and dismantling.
Quantities will be Lot (LOT).
P98 -CONCEPTUAL DESIGN ALLOWANCE - For estimating use only. The intent of the
conceptual design allowance is to provide for the normal growth of engineered and bulk material
quantities during the engineering design process. These historical percentages are based on the
level of definition at the time of quantity development. These percentages are reflected in real
quantities so that the estimate reflects the actual quantities installed. This allowance is not
intended to be a source to cover out-of-scope cost.
Quantities will be (LF. or LM.).
NOTE:
1.)
- 7 -Page 7 of 8
K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
VCOATINGS AND COVERINGS - All costs to supply and install coatings and insulation for process
and utility piping systems are included in these accounts. Material handling, unloading / storage of
materials, disposal of wastes, and clean-up are to be included in the appropriate account.
V11 PAINT PIPING All costs to apply pipe coatings defined by engineering documents, specifications,
and applicable codes. Costs shall include supply of bulk paint materials, solvents, thinners, and disposal of
waste materials. Labor costs shall include surface preparation and application of primer and finish coats,
and clean up of work areas.
Quantities are measured as surface area of pipe per coat based on center to center lengths of pipe to be
painted (SF or SM).
Waste does NOT constitute basis for additional quantities. Touch up does NOT constitute basis for
additional quantities.
V21 PIPE INSULATION
INSULATION - All costs to supply and install insulation materials as defined by engineering
documents, specifications, and applicable codes.
Waste does NOT constitute basis for additional quantities.
Material handling, unloading / storage of
Materials, and clean up to be included.
Stop ends where required. Also includes supplying and installation of jacketing, vapor barrier,
insulating coatings, mastic adhesives, rings, banding, clips, springs, and associated
hardware. At bends, measurement shall be to the intersection point; branches are measured from
the outer wall of the main pipe
Quantities are measured center-to-center through fittings, flanges, valves and
other in-line devices (LFI of LMI).
V97 SCAFFOLDING - Cost of scaffolding including rental and purchase of materials, and labor
for storage, erection and dismantling.
Quantities will be Lot (LOT).
V98 -CONCEPTUAL DESIGN ALLOWANCE - For estimating use only. The intent of the conceptual
design allowance is to provide for the normal growth of engineered and bulk material quantities during the
engineering design process. These historical percentages are based on the level of definition at the time of
quantity development. These percentages are reflected in real quantities so that the estimate reflects the
actual quantities installed. This allowance is not intended to be a source to cover out-of-scope cost.
Quantities will be (LFI. or LMI.).
V99 -CONSTRUCTION PRACTICES ALLOWANCE - For estimating use only. The intent of the
construction practice allowance is to provide for the material cost only associated with additional material
consumed due to normal construction practice. There will be no labor or man-hours associated with this
code. This allowance also covers standard waste and is not intended to cover out-of-scope costs.
Quantities will be Lot (LOT).
- 8 -Page 8 of 8
UNDGR1.XLS
MATERIALS
ITEM
PIPE
FITTING
JOINT (OPTIONAL)
PIPE
CLAY
FITTING
JOINT (OPTIONAL)
AREA DRAINS
PIPE
FLOOR DRAINS FRP HAND LAY-UP PIPE
EQUIPMENT DRAINS
JOINT
JOINT
PIPE
PVC
PIPE
CHEMICAL
FITTING
CEMENT JOINT JOINT
JOINT
PVC
PIPE
PUSH-ON JOINTS FITTING
JOINT
PIPE
FRP
FITTING
JOINT
JOINT
PIPE
POLYETHYLENE PIPE
OR
FITTING
POLYPROPYLENE JOINT
JOINT
PIPE
PIPE
D&W
D&W - REPAIR
CARBON STEEL PIPE
WITH
FITTING HANDLE
DOPE & WRAP
FITTING
JOINT
JOINT
JOINT
WELD
PIPE
PIPE
PIPE ENCASEMENT
CARBON STEEL FTTNG ENCASEMENT
WITH
PIPE
EXTRUDED
FITTING HANDLE
POLYETHYLENE FITTING
ENCASEMENT
JOINT
JOINT
JOINT
WELD
PIPE
PIPE
D&W (OPTIONAL)
D&W - REPAIR (OPT)
STAINLESS
PIPE (OPTIONAL)
STEEL
JOINT
FITTING HANDLE
JOINT
JOINT (OPTIONAL)
FITTING (OPTIONAL)
WELD
P - PIPE
M - MECHANICAL
I/E - INSTR./ELECTR.
S/C - SUBCONTRACT
STORM
PROCESS
SANITARY
OILY/WATER
RCP
ACTIVITY
MATL
LAY
HANDLE
DIAPER GROUT JOINT
LAY
HANDLE
GROUT JOINT
SPOOL FABRICATION
LAY
BUTT-WRAP
BOLT-UP
FIELD FABRICATION
LAY
HANDLE
SOCKETWELD - CHEM
BOLT-UP
LAY
HANDLE
PUSH-ON
LAY
HANDLE
SOCKETWELD - CHEM
BOLT-UP
FIELD FABRICATION
LAY
HANDLE
FUSION WELD
BOLT-UP
FIELD FABRICATION
LAY
FOR PIPE ONLY
FOR PIPE ONLY
GEEB TESTING
P
P
P
P
P
P
V
FABR
P
P
P
P
P
P
V
P
V - S/C
P
V
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
P
P
P
P - S/C
P
P
P
P
PAGE 3
LABOR OTHER
EQUIP
P
P
V
P
P
S/C
P
P
P
EQUIP
NONE
P
P
P
P
P - S/C
P
P
V
P
P
P
EQUIP
NONE
P
P
P
P
EQUIP
P - S/C
P
S/C
P
P
P
V
P
P
P
S/C
P
P
EQUIP
P
NONE
P
P
P
P - S/C
UNDGR1.XLS
STORM
PROCESS
SANITARY
OILY/WATER
AREA DRAINS
FLOOR DRAINS
EQUIPMENT DRAINS
MATERIALS
DOUBLE WALL
CONTAINMENT
CARBON STEEL
WITH
DOPE & WRAP
DOUBLE WALL
CONTAINMENT
CARBON STEEL
WITH
EXTRUDED
POLYETHYLENE
ENCASEMENT
PER JOB
REQUIREMENTS
PER JOB
REQUIREMENTS
ALL
MATERIALS
ALL
ROAD CROSSINGS
R/R CROSSINGS
(AREAS WHERE)
(EXCAVATION NOT)
(ALLOWED)
P - PIPE
I/E - INSTR./ELECTR.
O - OPTIONAL
CASING
CARBON STEEL
ITEM
PIPE
PIPE
D&W
D&W - REPAIR
PIPE
FITTING HANDLE
FITTING
JOINT - CARRIER
JOINT - CLOSURE
JOINT
JOINT
WELD
SPECIAL
ACTIVITY
SHOP FABRICATION
LAY
FOR PIPE ONLY
FOR PIPE ONLY
GEEB TESTING
MATL
V
FABR
PAGE 4
LABOR OTHER
V
P
V
P
P
P
EQUIP
NONE
P
P
P
P
P
P - S/C
P
MATERIALS
LEACH FIELD
(SANITARY SEWER)
VITRIFIED CLAY
MANHOLE
CATCH BASIN
PRE-CAST
RCP
MANHOLE
CATCH BASIN
CAST IN-PLACE
CONCRETE
CONCRETE
LIFT STATION
PRE-CAST
PIPING
PER JOB
REQUIREMENTS
CONCRETE
LIFT STATION
CAST IN-PLACE
PIPING
PER JOB
REQUIREMENTS
MISCELLANEOUS
CULVERTS
(STORM DRAINAGE)
P - PIPE
I/E - INSTR./ELECTR.
MATERIALS
ALL
ALL
ITEM
PIPE
PIPE
GRAVEL
DISTRIBUTION BOX
TOP W/ COVER
CONE
SHELL
CONCRETE BASE
INTERNAL GROUT
PIPE
TOP W/ COVER
CONE
SHELL
CONCRETE BASE
INTERNAL GROUT
PIPE
TOP W/ COVER
SHELL
CONCRETE BASE
PUMP
INSTRUMENTATION
PIPE FAB
PIPE ERECTION
FTTG HANDLE
JOINT
TOP W/ COVER
SHELL
CONCRETE BASE
PUMP
INSTRUMENTATION
PIPE FAB
PIPE ERECTION
FTTG HANDLE
JOINT
FLOOR DRAINS
JOINT
CLEAN-OUTS
JOINT
P-TRAP
JOINT
ALL
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
LAY
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
HANDLE & SET
AS REQUIRED
HANDLE & SET
AS REQUIRED
HANDLE & SET
AS REQUIRED
ALL
C - CIVIL
V - VENDOR
MATL
FABR
PAGE 5
LABOR OTHER
P
P
P
C
P
P
P
C
C
P
C
C
C
C
C
C
P
P
C
M
I/E
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
C
C
C
M
I/E
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
P
P
P
P
P
P
C
P
P
P
C
C
P
C
C
C
C
C
C
P
P
C
M
I/E
C
C
C
M
I/E
P
P
P
P
P
P
C
UNDGR1.XLS
MATERIALS
FIRE PROTECTION
C900 PIPE
ITEM
PIPE - PVC
FITTING - D.I.
JOINT - PIPE
JOINT -FTTG
PIPE (OPTIONAL)
FITTING (OPTIONAL)
THRUST BLOCK
MEGA-LUGS
(PIPE RESTRAINMENT)
PIPE
FITTING
JOINT - PIPE PO
DUCTILE IRON
JOINT - PIPE MJ
INTERNALLY LINED JOINT -FTTG
PIPE (OPTIONAL)
CARBON STEEL
WITH
DOPE & WRAP
CARBON STEEL
WITH
EXTRUDED
POLYETHYLENE
ENCASEMENT
CARBON STEEL
INTERNALLY LINED
ACTIVITY
LAY
HANDLE
BOLT-UP MJ
POLYETHYLENE
ENCASEMENT
POLYETHYLENE
ENCASEMENT
INSTALL
INSTALL
LAY
HANDLE
MATL
FABR
P
P
PAGE 6
LABOR OTHER
P
P
NONE
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
BOLT-UP MJ
BOLT-UP MJ
POLYETHYLENE
P
ENCASEMENT
FITTING (OPTIONAL)
POLYETHYLENE
P
ENCASEMENT
THRUST BLOCK
INSTALL
P
RODDING/CLAMPS
INSTALL
P
COATING (ROD/CLAMP)APPLY (OPTIONAL)
P
PIPE
FIELD FABRICATION
P
PIPE
LAY
D&W
FOR PIPE ONLY
V
D&W - REPAIR
FOR PIPE ONLY
P
PIPE
GEEB TESTING
FITTING
HANDLE
FITTING
DOPE & WRAP FTTGS
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
WELD
X-RAY
S/C
THRUST BLOCK
AS REQUIRED
P
PIPE
FIELD FABRICATION
P
PIPE
LAY
PIPE & FITTING
POLYETHYLENE SLV
P
PIPE
GEEB TESTING
FITTING
HANDLE
FITTING
HEAT SHRINK SLEEVE
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
JOINT
HEAT SHRINK SLEEVE
P
WELD
X-RAY
S/C
THRUST BLOCK
AS REQUIRED
P
INTERNAL LINER
PIPE & FITTINGS
V
FIELD WELD
INTRNL LINER REPAIR P - S/C
P
P
P
P
P
P
P
P
EQUIP
NONE
P
P
P
P
P & S/C
P
P
P
P
EQUIP
NONE
P
EQUIP
P
P
P
P
P & S/C
P
P - S/C
P - PIPE
I/E - INSTR./ELECTR.
M - MECHANICAL
S/C - SUBCONTRACT
C - CIVIL
V - VENDOR
UNDGR1.XLS
FIRE PROTECTION
MATERIALS
MATERIALS
ALL
ITEM
FIRE HYDRANT
ACCESSORIES
CONCRETE BASE
GRAVEL
JOINT
JOINT
VLV INDICATOR POST
VALVE
VALVE JOINT
JOINT
VALVE BOX
VALVE
VALVE JOINT
VALVE JOINT
FIRE MONITOR
JOINT
JOINT
SPRAY/FOAM NOZZLE
JOINT
HOSE HOUSE
CONCRETE BASE
INSULATION FLG KIT
JOINT
CATHODIC PROTECT
VALVE
JOINT
JOINT
HOSE & REEL
GUARD POST (PIPE)
ROAD CROSSINGS
R/R CROSSINGS
(AREAS WHERE)
(EXCAVATION NOT)
(ALLOWED)
P - PIPE
I/E - INSTR./ELECTR.
O - OPTIONAL
CASING
CARBON STEEL
TESTING
TRENCH
TRENCH
TRENCH
TRENCH
TRENCH
TRENCH
JACK & BORE
PIPE CASING
JOINTS
EXTERNAL COATING
INTERNAL COATING
EXTERNAL COATING
INTERNAL COATING
END CLOSURES
IF REQUIRED
CASING VENT
IF REQUIRED
BORING MACHINE
BORING MACHINE
BORING MACHINE
BORING MACHINE
BORING MACHINE
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
MATL
INSTALL
INSTALL
INSTALL
PLACE
BOLT-UP
BOLT-UP MJ
INSTALL
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
BOLT-UP
BOLT-UP MJ
INSTALL
BOLT-UP
INSTALL
INSTALL
INSTALL
BOLT-UP
PROVIDE COUNT
OF JOINTS
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
INSTALL
P
P
C
P
AS REQUIRED
EXCAVATION
BACKFILL - SOIL
BACKFILL - SAND
SPOILS
SHORING
DEWATERING
PIPE CASING
FABRICATION
BUTTWELD
PIPE
(IF REQUIRED)
JOINT
(IF REQUIRED)
INSTALL
FIELD FABRICATION
INSTALL
EXCAVATE TRENCH
BACKFILL TRENCH
INSTALL IN TRENCH
REMOVE FM TRENCH
CRUSHED ROCK PAD
C - CIVIL
V - VENDOR
FABR
P
P
C
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
C
P
P
E
P
P
C
P
E
P
P
P
C
P
P
P
P
PAGE 7
LABOR OTHER
P
P
P
P
C
P
P
P
P
P
P
P
S/C
P
P
V
V
P
P
P
P
P
P
P
P
P
P
P
C
UNDGR1.XLS
UTILITIES
MATERIALS
ITEM
PIPE
PIPE
FITTING
JOINT - PIPE
JOINT - FTTG
PIPE
PVC
FITTING
PUSH-ON JOINT JOINT - PIPE
JOINT - FTTG
PIPE
FITTING
DUCTILE IRON
JOINT - PIPE PO
INTERNALLY LINED JOINT - PIPE MJ
JOINT - FITTING
PIPE (OPTIONAL)
PVC
CHEMICAL
CEMENT JOINT
FITTING (OPTIONAL)
C900 PIPE
PIPE - PVC
FITTING - D.I.
JOINT - PIPE
JOINT - FTTG
PIPE
FITTING
JOINT - PLAIN
JOINT - PLAIN
JOINT - FLANGED
JOINT - FLGD MJ
PIPE
PIPE
FRP
FITTING
JOINT
JOINT
PIPE
POLYETHYLENE PIPE
OR
FITTING
POLYPROPYLENE JOINT
JOINT
CONCRETE
STEEL
CYLINDER
PIPE
P - PIPE
I/E - INSTR./ELECTR.
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
FIELD FABRICATION
LAY
HANDLE
SOLVENT CEMENT
SOLVENT CEMENT
LAY
HANDLE
-NONE-NONELAY
HANDLE
- NONE BOLT-UP MJ
BOLT-UP MJ
POLYETHYLENE
ENCASEMENT
POLYETHYLENE
ENCASEMENT
LAY
HANDLE
MATL
P
FABR
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
P
P
P
P
P
P
BOLT-UP MJ
LAY
HANDLE
SEAL WELD
DIAPER GROUT
BOLT-UP
BOLT-UP MJ
FIELD FABRICATION
LAY
HANDLE
SOCKETWELD - CHEM
BOLT-UP
FIELD FABRICATION
LAY
HANDLE
FUSION WELD
BOLT-UP
C - CIVIL
V - VENDOR
PAGE 8
LABOR OTHER
P
P
P
P
P
P
P
P
P
P
P
P & S/C EQUIP
P
UNDGR1.XLS
UTILITIES
(PRESSURE)
(PIPING)
MATERIALS
ITEM
ACTIVITY
MATL
FABR
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
D&W
FOR PIPE ONLY
V
D&W - REPAIR
FOR PIPE ONLY
P
CARBON STEEL PIPE
GEEP TESTING
WITH
FITTING
HANDLE
DOPE & WRAP
FITTING
DOPE & WRAP FTTGS
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
WELD
X-RAY
S/C
SPECIALTY HANDLE SAME AS A/G
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
PIPE & FITTING
POLYETHYLENE SLV
P
CARBON STEEL PIPE
GEEB TESTING
WITH
FITTING
HANDLE
EXTRUDED
FITTING
HEAT SHRINK SLEEVE
P
POLYETHYLENE JOINT
ERECTION BUTTWELD
ENCASEMENT
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
JOINT
HEAT SHRINK SLEEVE
P
WELD
X-RAY
S/C
INTERNAL LINER
PIPE & FITTINGS
V
CARBON STEEL FIELD WELD
INTRNL LINER REPAIR P - S/C
INTERNALLY LINED
ALL OTHER ACTIVITIES SEE CARBON STEEL THIS PAGE
PIPE
PIPE
STAINLESS STEEL FITTING
JOINT
JOINT
WELD
SPECIALTY HANDLE
PIPE
PIPE
PVC
FITTING
JOINT
JOINT
SPECIALTY HANDLE
P - PIPE
I/E - INSTR./ELECTR.
M - MECHANICAL
S/C - SUBCONTRACT
FIELD FABRICATION
P
LAY
HANDLE
ERECTION BUTTWELD
BOLT-UP
X-RAY
S/C
SAME AS A/G
FIELD ASSEMBLY
P
LAY
HANDLE
CHEMICAL SOCKETWELD
BOLT-UP
SAME AS A/G
C - CIVIL
V - VENDOR
PAGE 9
LABOR OTHER
P
P
P
EQUIP
NONE
P
P
P
P
P - S/C
P
P
EQUIP
NONE
P
EQUIP
P
P
P
P
P & S/C
P - S/C
P
P
NONE
P
P
P - S/C
P
P
NONE
P
P
UNDGR1.XLS
1.0
GENERAL
=
Thoroughly read and understand scope of work and specifications as applies to
demolition - highlight pertinent items and any unusual requirements and pass these
items on to assigned project estimator.
2.0
QUANTITY TAKEOFF
=
Quantify piping for removal by a centerline to centerline takeoff, by type of material.
=
Indicate type of demolition (disposal, salvage, relocation, etc.)
=
Highlight all piping on all demolition drawings that indicate demolition.
Input or Import the data into CAPS.
=
1
1442-0010
1.0
GENERAL
Thoroughly read and understand the scope of work and specifications as applies to
underground piping. Highlight pertinent items and any unusual requirements and
pass these items on to assigned project estimator.
2.0
=
=
=
=
=
=
=
=
=
=
=
=
DRAWING TAKEOFF
Quantify underground pipe by centerline takeoff by piping system and spec.
Count all fittings and pipe appurtenances per checklist.
Highlight all piping on all drawings that indicate underground pipe.
Quantify labor activities for each type of construction, i.e. push-on, weld, or
mechanical joints (see checklist).
Count manhole and catch basins by size and depth. Advise civil estimator of the
number of foundations for catch basins and manholes.
Calculate excavation and backfill for each trench operation. Use common trench if
lines are routed adjacently.
Allow for hand excavation where machine use is inappropriate or dangerous.
Quantify shoring if required.
Quantify shore box use if application is appropriate.
1
1442-0011
UNDERGROUND PIPING
a. Drains, sewers (storm, sanitary, process)
b. Pressure drains
c. Fire systems
d. Type of pipe - C.S., Bondstrand, Concrete (RCP), Fiberglass, PVC
e. Excavation requirements, depths, slope, backfill, bedding, shoring, dewatering
f.
Take-off by system (firewater, drains, storm sewer, process, etc.)
g. Testing is normally 6% of pipe erection work hours
h. Bolts, nuts, gaskets, supports
i.
Dope and Wrap
1. U/G pipe should be taken off by systems (Sanitary sewer, Storm sewer, Firewater,
etc.) and put into the estimate this way with detail subtotal cards following each
system. Comment cards should be used to designate each system.
2. The material and installation cost for pipe, fittings, valves, precast manholes, precast
catch basins, thrust blocks, hydrostatic testing, excavation and backfill should be
included per system.
3. If manholes, catch basins and seal slabs are to be poured in place, the civil estimators
will be responsible for installation. Pipe estimators need to, check with the civil
estimators to, be sure they are taking care of these items.
4. An erection material line needs to be put in the U/G account. This covers the cost of
bolts, gaskets, dope and wrap material, rods, lead, etc. Quantities will be in lump sum
(LS) dollars. This card will be similar to the P68 account for aboveground pipe.
UNDERGROUND GRAVITY SYSTEMS
1. Line sizes
2. Sewer identification i.e., process, sanitary, and numerical identification (line number).
3. Material specifications
4. Manhole locations, and number.
5. Dimensional ponds, lagoons, setting basins, oxidation ponds, and other field
construction equipment.
6. Any tie-in points including existing line size and material of construction.
7. Finished grade elevation.
8. Curbed, diked, and paved areas.
9. Valves
10. Liquid seal, and vent requirements.
1
1442-0012
2
1442-0012
MATERIALS
LEACH FIELD
(SANITARY SEWER)
VITRIFIED CLAY
MANHOLE
CATCH BASIN
PRE-CAST
RCP
MANHOLE
CATCH BASIN
CAST IN-PLACE
CONCRETE
CONCRETE
LIFT STATION
PRE-CAST
PIPING
PER JOB
REQUIREMENTS
CONCRETE
LIFT STATION
CAST IN-PLACE
PIPING
PER JOB
REQUIREMENTS
MISCELLANEOUS
CULVERTS
(STORM DRAINAGE)
P - PIPE
I/E - INSTR./ELECTR.
MATERIALS
ALL
ALL
ITEM
PIPE
PIPE
GRAVEL
DISTRIBUTION BOX
TOP W/ COVER
CONE
SHELL
CONCRETE BASE
INTERNAL GROUT
PIPE
TOP W/ COVER
CONE
SHELL
CONCRETE BASE
INTERNAL GROUT
PIPE
TOP W/ COVER
SHELL
CONCRETE BASE
PUMP
INSTRUMENTATION
PIPE FAB
PIPE ERECTION
FTTG HANDLE
JOINT
TOP W/ COVER
SHELL
CONCRETE BASE
PUMP
INSTRUMENTATION
PIPE FAB
PIPE ERECTION
FTTG HANDLE
JOINT
FLOOR DRAINS
JOINT
CLEAN-OUTS
JOINT
P-TRAP
JOINT
ALL
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
LAY
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
HANDLE & SET
AS REQUIRED
HANDLE & SET
AS REQUIRED
HANDLE & SET
AS REQUIRED
ALL
C - CIVIL
V - VENDOR
MATL
FABR
PAGE 5
LABOR OTHER
P
P
P
C
P
P
P
C
C
P
C
C
C
C
C
C
P
P
C
M
I/E
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
C
C
C
M
I/E
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
P
P
P
P
P
P
C
P
P
P
C
C
P
C
C
C
C
C
C
P
P
C
M
I/E
C
C
C
M
I/E
P
P
P
P
P
P
C
UNDGR1.XLS
MATERIALS
FIRE PROTECTION
C900 PIPE
ITEM
PIPE - PVC
FITTING - D.I.
JOINT - PIPE
JOINT -FTTG
PIPE (OPTIONAL)
FITTING (OPTIONAL)
THRUST BLOCK
MEGA-LUGS
(PIPE RESTRAINMENT)
PIPE
FITTING
JOINT - PIPE PO
DUCTILE IRON
JOINT - PIPE MJ
INTERNALLY LINED JOINT -FTTG
PIPE (OPTIONAL)
CARBON STEEL
WITH
DOPE & WRAP
CARBON STEEL
WITH
EXTRUDED
POLYETHYLENE
ENCASEMENT
CARBON STEEL
INTERNALLY LINED
ACTIVITY
LAY
HANDLE
BOLT-UP MJ
POLYETHYLENE
ENCASEMENT
POLYETHYLENE
ENCASEMENT
INSTALL
INSTALL
LAY
HANDLE
MATL
FABR
P
P
PAGE 6
LABOR OTHER
P
P
NONE
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
BOLT-UP MJ
BOLT-UP MJ
POLYETHYLENE
P
ENCASEMENT
FITTING (OPTIONAL)
POLYETHYLENE
P
ENCASEMENT
THRUST BLOCK
INSTALL
P
RODDING/CLAMPS
INSTALL
P
COATING (ROD/CLAMP)APPLY (OPTIONAL)
P
PIPE
FIELD FABRICATION
P
PIPE
LAY
D&W
FOR PIPE ONLY
V
D&W - REPAIR
FOR PIPE ONLY
P
PIPE
GEEB TESTING
FITTING
HANDLE
FITTING
DOPE & WRAP FTTGS
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
WELD
X-RAY
S/C
THRUST BLOCK
AS REQUIRED
P
PIPE
FIELD FABRICATION
P
PIPE
LAY
PIPE & FITTING
POLYETHYLENE SLV
P
PIPE
GEEB TESTING
FITTING
HANDLE
FITTING
HEAT SHRINK SLEEVE
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
JOINT
HEAT SHRINK SLEEVE
P
WELD
X-RAY
S/C
THRUST BLOCK
AS REQUIRED
P
INTERNAL LINER
PIPE & FITTINGS
V
FIELD WELD
INTRNL LINER REPAIR P - S/C
P
P
P
P
P
P
P
P
EQUIP
NONE
P
P
P
P
P & S/C
P
P
P
P
EQUIP
NONE
P
EQUIP
P
P
P
P
P & S/C
P
P - S/C
P - PIPE
I/E - INSTR./ELECTR.
M - MECHANICAL
S/C - SUBCONTRACT
C - CIVIL
V - VENDOR
UNDGR1.XLS
FIRE PROTECTION
MATERIALS
MATERIALS
ALL
ITEM
FIRE HYDRANT
ACCESSORIES
CONCRETE BASE
GRAVEL
JOINT
JOINT
VLV INDICATOR POST
VALVE
VALVE JOINT
JOINT
VALVE BOX
VALVE
VALVE JOINT
VALVE JOINT
FIRE MONITOR
JOINT
JOINT
SPRAY/FOAM NOZZLE
JOINT
HOSE HOUSE
CONCRETE BASE
INSULATION FLG KIT
JOINT
CATHODIC PROTECT
VALVE
JOINT
JOINT
HOSE & REEL
GUARD POST (PIPE)
ROAD CROSSINGS
R/R CROSSINGS
(AREAS WHERE)
(EXCAVATION NOT)
(ALLOWED)
P - PIPE
I/E - INSTR./ELECTR.
O - OPTIONAL
CASING
CARBON STEEL
TESTING
TRENCH
TRENCH
TRENCH
TRENCH
TRENCH
TRENCH
JACK & BORE
PIPE CASING
JOINTS
EXTERNAL COATING
INTERNAL COATING
EXTERNAL COATING
INTERNAL COATING
END CLOSURES
IF REQUIRED
CASING VENT
IF REQUIRED
BORING MACHINE
BORING MACHINE
BORING MACHINE
BORING MACHINE
BORING MACHINE
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
MATL
INSTALL
INSTALL
INSTALL
PLACE
BOLT-UP
BOLT-UP MJ
INSTALL
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
BOLT-UP
BOLT-UP MJ
INSTALL
BOLT-UP
INSTALL
INSTALL
INSTALL
BOLT-UP
PROVIDE COUNT
OF JOINTS
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
INSTALL
P
P
C
P
AS REQUIRED
EXCAVATION
BACKFILL - SOIL
BACKFILL - SAND
SPOILS
SHORING
DEWATERING
PIPE CASING
FABRICATION
BUTTWELD
PIPE
(IF REQUIRED)
JOINT
(IF REQUIRED)
INSTALL
FIELD FABRICATION
INSTALL
EXCAVATE TRENCH
BACKFILL TRENCH
INSTALL IN TRENCH
REMOVE FM TRENCH
CRUSHED ROCK PAD
C - CIVIL
V - VENDOR
FABR
P
P
C
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
C
P
P
E
P
P
C
P
E
P
P
P
C
P
P
P
P
PAGE 7
LABOR OTHER
P
P
P
P
C
P
P
P
P
P
P
P
S/C
P
P
V
V
P
P
P
P
P
P
P
P
P
P
P
C
UNDGR1.XLS
UTILITIES
MATERIALS
ITEM
PIPE
PIPE
FITTING
JOINT - PIPE
JOINT - FTTG
PIPE
PVC
FITTING
PUSH-ON JOINT JOINT - PIPE
JOINT - FTTG
PIPE
FITTING
DUCTILE IRON
JOINT - PIPE PO
INTERNALLY LINED JOINT - PIPE MJ
JOINT - FITTING
PIPE (OPTIONAL)
PVC
CHEMICAL
CEMENT JOINT
FITTING (OPTIONAL)
C900 PIPE
PIPE - PVC
FITTING - D.I.
JOINT - PIPE
JOINT - FTTG
PIPE
FITTING
JOINT - PLAIN
JOINT - PLAIN
JOINT - FLANGED
JOINT - FLGD MJ
PIPE
PIPE
FRP
FITTING
JOINT
JOINT
PIPE
POLYETHYLENE PIPE
OR
FITTING
POLYPROPYLENE JOINT
JOINT
CONCRETE
STEEL
CYLINDER
PIPE
P - PIPE
I/E - INSTR./ELECTR.
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
FIELD FABRICATION
LAY
HANDLE
SOLVENT CEMENT
SOLVENT CEMENT
LAY
HANDLE
-NONE-NONELAY
HANDLE
- NONE BOLT-UP MJ
BOLT-UP MJ
POLYETHYLENE
ENCASEMENT
POLYETHYLENE
ENCASEMENT
LAY
HANDLE
MATL
P
FABR
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
P
P
P
P
P
P
BOLT-UP MJ
LAY
HANDLE
SEAL WELD
DIAPER GROUT
BOLT-UP
BOLT-UP MJ
FIELD FABRICATION
LAY
HANDLE
SOCKETWELD - CHEM
BOLT-UP
FIELD FABRICATION
LAY
HANDLE
FUSION WELD
BOLT-UP
C - CIVIL
V - VENDOR
PAGE 8
LABOR OTHER
P
P
P
P
P
P
P
P
P
P
P
P & S/C EQUIP
P
UNDGR1.XLS
UTILITIES
(PRESSURE)
(PIPING)
MATERIALS
ITEM
ACTIVITY
MATL
FABR
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
D&W
FOR PIPE ONLY
V
D&W - REPAIR
FOR PIPE ONLY
P
CARBON STEEL PIPE
GEEP TESTING
WITH
FITTING
HANDLE
DOPE & WRAP
FITTING
DOPE & WRAP FTTGS
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
WELD
X-RAY
S/C
SPECIALTY HANDLE SAME AS A/G
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
PIPE & FITTING
POLYETHYLENE SLV
P
CARBON STEEL PIPE
GEEB TESTING
WITH
FITTING
HANDLE
EXTRUDED
FITTING
HEAT SHRINK SLEEVE
P
POLYETHYLENE JOINT
ERECTION BUTTWELD
ENCASEMENT
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
JOINT
HEAT SHRINK SLEEVE
P
WELD
X-RAY
S/C
INTERNAL LINER
PIPE & FITTINGS
V
CARBON STEEL FIELD WELD
INTRNL LINER REPAIR P - S/C
INTERNALLY LINED
ALL OTHER ACTIVITIES SEE CARBON STEEL THIS PAGE
PIPE
PIPE
STAINLESS STEEL FITTING
JOINT
JOINT
WELD
SPECIALTY HANDLE
PIPE
PIPE
PVC
FITTING
JOINT
JOINT
SPECIALTY HANDLE
P - PIPE
I/E - INSTR./ELECTR.
M - MECHANICAL
S/C - SUBCONTRACT
FIELD FABRICATION
P
LAY
HANDLE
ERECTION BUTTWELD
BOLT-UP
X-RAY
S/C
SAME AS A/G
FIELD ASSEMBLY
P
LAY
HANDLE
CHEMICAL SOCKETWELD
BOLT-UP
SAME AS A/G
C - CIVIL
V - VENDOR
PAGE 9
LABOR OTHER
P
P
P
EQUIP
NONE
P
P
P
P
P - S/C
P
P
EQUIP
NONE
P
EQUIP
P
P
P
P
P & S/C
P - S/C
P
P
NONE
P
P
P - S/C
P
P
NONE
P
P
UNDGR1.XLS
1.0
GENERAL
=
Thoroughly read and understand the scope of work and specifications as applies to
aboveground piping - highlight pertinent items and any unusual requirements and
pass these items on to assigned project estimator.
2.0
MATERIAL TAKEOFF
=
When valves are a responsibility of the contractor, the valve takeoff must come from
P&ID's. Highlight each valve on P&ID. If valves are furnished by others, the takeoff
from ortho's or isometrics is sufficient. Attention must always be given to vent and
drain valves. When the valve count has been completed, it should be forwarded to
purchasing for inquiry.
=
When making material takeoff, highlight everything--plans, elevations, etc. --whether
it be on isometrics or orthographics. Outside shop fabrication - if critical services exist,
(i.e., chrome, heavy wall, C.S., or exotic materials), these lines should be considered a
priority item. If schedule or estimate time frame is a concern, takeoff of critical lines
should be forwarded as soon as possible to fabrication specialist, or procurement for
outside pricing.
=
The P&ID should be marked up as the line by line takeoff occurs. This may flag an
early problem. If working from ISO's, an early decision will be made as to the
verification required back to the ortho's.
=
When P&IDs, orthos, or isos are not available back check line list for scope
completeness.
==
3.0
MATERIAL PRICING
=
When time permits, all pricing for alloy materials should be solicited by outside
suppliers.
=
In-house pricing, with appropriate discounts, is available for all field run carbon steel
materials.
=
All shop fabrication information should be supplied to the fabrication specialist for
outside pricing.
=
Apply normal percentages for erection materials, specialties, and hanger materials
when detail information is not available.
4.0
MISCELLANEOUS
=
Refer to checklists for additional items to consider.
1
1442-0015
CHECKLIST
The following is a list of items to be followed when an estimator is assigned to a project
estimate.
1. Obtain and read scope of work and understand the responsibility matrix. It is
important that all task force members understand the scope and responsibility for the
project.
2. Determine if, drawings or electronic data ( IPMS, Engineering Input Form, etc. ) will
be provided. If drawings are provided, check drawings against drawing transmittal.
3. Identify material specifications pertinent to underground piping, aboveground piping,
insulation and paint. If these are not available, immediately notify the project
estimator and determine if they will be available.
4. Determine what the estimate milestone dates are (i.e., review dates, date that detail
information is due to the project estimator, subcontractor bid due dates, etc.)
5. Review piping estimate manpower needs with the Chief Estimator based on these
considerations:
A. OUTSIDE SHOP FABRICATION
B. PRICING REQUIREMENTS
C. ESTIMATE SCHEDULE
6. Identify outside shop fabrication requirements.
7. Determine how many cost/schedule areas the estimate is to be divided into. Also,
identify what the parameters for the cost/schedule areas are. The project estimator
will provide this information.
8. Determine if any additional engineering is required before the estimate can be
completed (i.e., are utility systems engineered?).
9. Determine cleaning, pickling, stress relieving, and radiographic inspection
requirements.
10. Determine fabrication requirements (i.e., field shop, outside shop).
11. Determine paint labor (i.e., subcontract or direct, are spools blasted & primed).
12. Determine whether insulation is subcontract or direct.
13. It is important that the piping estimator review drawings of other disciplines to assure
complete coverage of project scope.
14. Establish a tentative appointment to review estimate with Chief Estimator to allow
adequate time to make changes prior to turnover of estimate disk to Project Estimator.
1
1442-0006
The following piping related items are significant enough to be addressed to assure
consistency in our work. Make a habit of checking specifications and/or construction needs
for any requirements of these items.
COTTON BALL PIPE CLEANING
1.
STEAM BLOW
2.
Whenever a major steam system is in the estimate scope, work hours and materials for
steam blow are required and should be input into the other services account, 1773. For
every high pressure main steam header, include materials and labor for 200 feet of
pipe, the same size as the header, one valve, and target plate materials.
Also, include work hours for four men for four blows for 24 hours each to monitor the
blow out process.
For low and intermediate pressure headers include enough pipe material and labor to
route the blow out line twenty feet above the highest rack level. Add 100 work hours
for assistance.
3.
On paper machines, add fifty feet of pipe on each dryer section and thirty work hours
for assistance.
4.
Workhours for pipe fitter assistance on pump alignments should be included in the
spool erection account. The pump alignment count need only be by size for rotating
and reciprocating pumps, compressors, and turbines. Small, metering type pumps do
not require alignment.
5.
Turn around time for valve inquiries: Suppliers are quoting as a courtesy and often
have difficulty with the information that is forwarded to them from the RFQ package.
The estimator may need to do some extra PC work to make a better package for them
2
1442-0006
to respond to. If it takes a day or two to edit some valve data to our current report,
then that may pay off in a faster response. This may also be beneficial by serving as a
double check on coding work.
FIREWATCH
6.
ESTIMATE FILING
After an estimate is completed, follow the KB&R Estimating file protocol to save electronic
files generated during the estimate.
ESTIMATE TO P.E.
On all Estimates involving the same company, it is important to insure that the estimator
use any labor rates and pricing from previous estimates, particularly if the current estimate
is an update of a previous effort. This may cause some extra work, but many times the
estimate is scrutinized for inconsistencies. The ESP template provided by the Project
Estimator (P.E.), should contain any final factors used at the time the previous estimate was
completed.
When the ESP template is turned over to the P.E., give him a copy of your nd a copy of the
piping system summaries. Remember that the estimator should look over the P.E.'s
combined estimate for correct totals and units. If this is not practical, the copies will be a
welcome reassurance to the P.E. in that eleventh hour crunch. Also, it is nice to have a pipe
only" Estimate for review time.
To assure all the information in the understood and included by the project estimator, the
piping estimator is to provide the following to the P.E. at the time the file is turned over:
1. A copy of `CODES.DIR' file (highlight any changes you have made).
2. A copy of the PERCENTAGE, ALLOWANCES, AND FACTORS from your template
(again, highlight all changes).
3. A copy of the OVERALL SUMMARIES report.
3
1442-0006
Make sure that this printed information is the latest and matches that on the ESP piping
template. At this point, the P.E. can get the templates combined and give a printout back to
the estimator to confirm completeness of the Estimate.
Certain statistics should be prepared for department reviews.
The following list should be ready for discussion at reviews:
1. Average pipe size - aboveground and underground
2. Percentage of C.S. pipe to total pipe (w/o D.A.).
3. Percentage of alloy pipe to total pipe (w/o D.A.).
4. Percentage of fabricated pipe to total pipe (w/o D.A.).
5. Percentage of field run pipe to total pipe (w/o D.A.).
6. Percentage of insulated pipe to total pipe (w/o D.A.).
7. Percentage of small bore pipe to total pipe (w/o D.A.).
8. Percentage of P67, P68, P71, P81 and P82 accounts.
9. Percentage on P98 and P97 accounts.
10. If time permits, a written comparison of current job to past similar projects.
Prepare qualifications on a daily basis. See Qualifications & Backup" in this manual.
4
1442-0006
REVIEW HINTS
The following is a list of items that are frequently brought up during the review cycle of the
estimate:
1. Type of drawings used to determine quantities;
2. Basis of pricing;
3. Average pipe size;
4. Purchasing responsibility;
5. Labor responsibility;
6. Missing information;
7. Events that cloud the accuracy of the estimate;
8. Assumptions and reasons why assumptions were made;
9. Sources of vendor quotes;
10. Reasons for unit work hour deviations from the norm;
11. Percentages used in respective accounts;
12. Outside shop fabrication or field shop fabrication or field run pipe;
13. Basis of piping take-off (line by line, quantities provided, etc.);
14. Basis of paint and insulation take-off;
15. Unique site conditions or plant requirements;
16. Line list;
17. Small bore piping quantity/large bore piping quantity ratio;
18. Inter-discipline checks;
19. Predominant pipe metallurgy;
20. Insulation requirements (hot/cold, single/double layer, material type, jacketing).
21. Special conditions that, cause a deviation from normal procedures.
5
1442-0006
TO:
PROJECT MANAGER or
PROJECT CONTROL MANAGER
DATE: DDMMMYY
FROM:
PAGE: 1 of ??
SUBJECT:
This memorandum constitutes an assessment of the risks associated with the Class M" MTO estimate for the subject
project. Information contained herein was developed with input from the following groups:
Piping Design
Systems Engineering
Piping Specifications
A.
MTO BASIS
1.
P&ID's Issue "R" and Issue "1" received from Systems Engineering, as identified on the attached "Definitive
Estimate P&ID Basis, dated DDMMMYY.
2.
Conceptual MTO of all aboveground (A/G) lines identified on the P&ID's utilizing the current Plot Plan and
preliminary planning studies, where available.
3.
4.
5.
Class M Piping MTO plan for the Definitive estimate, from (Name of Work Group Leader), dated DDMMMYY.
B.TAKEOFF METHODOLOGY
1.
The shop/field fabrication philosophy used for the MTO consisted of the following:
a.
Shop Fabrication
(1) All A/G material types 2" and larger (except PVC, threaded piping, and cement lined firewater piping).
(2) All configured U/G cooling water piping and cooling water piping over 24".
b.
Field Fabrication
(1) All U/G material (except cooling water piping mentioned above).
(2) All material types 1-1/2" and smaller.
(3) All yard rack pipe.
(4) All PVC and threaded pipe.
(5) All A/G cement lined firewater piping.
2.
Takeoff was performed for the pipe, flanges, and fittings in accordance with the Estimate MTO Plan. The
MTO's were performed using KELWAY "EE" input forms. The data was entered into the material control
system.
3.
The U/G MTO was extracted from the current PDS model (unchecked state as of DDMMMYY) and entered
directly into the material control system.
4.
All MTO data was segregated within the material control system on a unit level, design area, service, line
number, and sheet basis.
5.
This data is further identified by material type, point of fabrication, A/G and U/G, coating and insulation
systems.
6.
Process steam trap quantities are provided as part of Systems Engineering SP listing. These trap quantities
are in addition to the traps defined by Piping Design as part of the steam trace takeoff effort.
7.
Manholes and catch basins are quantified and typically priced as "precast" items using local vendor quotes
No sleeving or encasement of U/G lines for any reason is included in the estimate.
2.
Tie-ins are not fully defined and routing is estimated based on "best guess" location information.
3.
A complete set of nomenclature was not available for parity review of design takeoff data. The lack of
complete and accurate nomenclature is also a hindrance in the area of paint and insulation code input and
verification.
4.
The piping takeoff is based on less than 100% of planning drawings and P&ID's are a mixture of revisions.
The standard basis of a FCE is availability of all planning drawings and Issue 2 P&IDs.
5.
The group (contract personnel) performing the takeoff was not familiar with the corresponding takeoff
forms/procedures. This situation creates a continuous learning curve which ultimately affects the degree of
takeoff accuracy, continuity and amount of rework to successfully process the data.
6.
Utility piping such as emergency eyewash stations, utility stations, subheader lines for utility distribution were
not individually taken-off.
7.
No allowances are provided or material identified for temporary facilities or construction services.
8.
Shop/field split is based on 2" and larger welded material (both A/G and U/G) being shop fabricated.
9.
Interconnecting piping for vendor skids is not defined, and subject vendors have not provided requested
material lists to support a computation of basic construction workhours.
10.
Offsites U/G drainage/treatment requirements are not clearly defined and the minimal assumptions made to
determine requirements are subject to change/growth.
11.
The terminal points of the package units are estimated by the envelope size of the unit, and the actual details
of required hook-ups are not available (i.e., API Plan Pumps).
12.
No allowances are made for the risks associated with an early buy function. All blanket orders should be
established with liberal and lengthy return agreements to support normal developmental changes being made
at minimal or no cost.
13.
The Piping specifications were in a constant state of change during the estimate takeoff, i.e., items not in
specification. Additional checking and reviews were required.
14.
The PIMATO/VAMATO MTO is based on approximately 60% Issue R and 40% Issue 1 P&ID's. The quantities
generated by PIMATO for large O.D. lines (over 12") and long runs of pipe (over 100 feet) were reviewed for
accuracy and adjusted if necessary. An estimated 15% of all lines have been checked.
15.
Fittings were taken-off directly from the P&ID's. After comparisons of the ratios of fittings per 100 feet were
made with historical data, additional elbows and fittings were added to the estimate to better reflect historical
ratio's.
16.
17.
Approximately 2700 3/4" block valves were added to the estimate to account for low-point drains that are not
shown on the P&ID'S. This amount is approximately one low point drain for every 1 line taken-off (based on
historical data). Although the material cost of these valves may be minimal, the impact on Construction
workhours has been found to be significant.
18.
A special effort has been made to accurately identify the Expanded Nomenclature" piping and valves that
does not typically show up on the P&ID's. A detailed MTO of utility stations, sample coolers, pump drains and
cooling water pipe for pump casings, steam trap and steam tracing manifold piping, lube and seal oil piping,
and eye wash and safety shower piping was included in this estimate. Housekeeping drains will not be
required for this project.
19.
Piping associated with the site prep subcontract package has been included in the estimate. Quantities of
related piping has been given to Construction to back-out labor for these materials.
20.
Piping associated with the ISBL ARU unit has been included based on preliminary P&ID's provided by the
vendor.
21.
Manholes and catch basins have been included as a separate line item in the estimate based on quoted prices
for this project. Quantities have been given to Construction to calculate workhours.
22.
The proposed change to sewer pipe from ditches in the OSBL is not included in the estimate.
23.
Piping quantities have been included (for computation of basic construction workhours) for vendor furnished
materials to be installed by the Company in the OSBL unit for the Ethylene and Propylene product lines, and
vendor supplied items 7802U, 8701L, 8703L, 8704L, 8705L, and 8706L.
24.
A definitive estimate (quantitative) review was conducted on DDMMMYY, and included an extensive review
of all items pertaining to the Class M estimate.
25.
All MTO quantities are neat with no contingencies or construction spares applied (other than identified in this
document).
D.AUDIT/CHECK PROCEDURES
1.
All input sheets were reviewed for completeness and compliance with specifications before entry to the
Company material control system.
2.
All output documents were reviewed for completeness and to ensure that every input document created a
corresponding output document.
3.
Data should be compared with other similar in-house projects so that differences can be
investigated/validated.
4.
Nomenclatures, where available, and PDS line number extract reports were reviewed to ensure all lines have
corresponding takeoffs.
5.
Random checks of base document planning drawings and P&ID's were performed to ensure inclusion of all
lines. Random checks of large bore lines with large quantities are reviewed to verify takeoff accuracy.
6.
Statistical reports are reviewed to validate the relationships of piping component quantities (i.e., fittings per
hundred lineal feet).
7.
A review of small bore versus large bore quantities was conducted to ensure completeness of takeoff (as a
ratio).
8.
Orifice flange quantities were checked versus P&ID quantities to ensure takeoff totals represents sets (pairs).
9.
Nomenclature information, where available, was used to check insulation/paint codes assigned to takeoff.
10.
The relationship of projected isometrics versus identified tonnage is investigated and exceptions stated.
11.
Project and department estimate procedure check lists were completed to ensure all basic areas of the
estimate are addressed.
E.TAKEOFF ALLOWANCES
The following factors should be applied to the FCE takeoff quantities to account for takeoff and summarization
accuracy. These factors reflect how accurately the materials were defined based on the quality of the source
documents, equipment data available, and certainty of routing.
These factors provide an assessment of how accurately materials were estimated (measured) based on the quality
of the documents used and amount of checking.
(PROJECT SPECIFIC)
CATEGORY
A/G PIPING
UNIT 01
<1-1/2"
14%
2" - 24"
UNIT 02
UNIT 50
17%
20%
10
15
>26"
U/G PIPING
<1-1/2"
15
18
20
2" - 24"
10
13
15
10
10
10
>26"
PIPING VALVES
F.
GROWTH ALLOWANCES
The following factors should be applied to the FCE quantities to allow for a Systems Engineering assessment of
the potential for change and/or growth within the P&ID's, specifications, and nomenclature information per Systems
Engineering Risk Memo.
CATEGORY
UNIT 01
UNIT 02
UNIT 50
<1-1/2"
10%
10%
2" - 24"
10
>26"
PIPING VALVES
G.
H.
20%
The following items either have not been specifically addressed in the defined MTO or were not included in
the definitive scope of work with an allowance:
a.
Tie-ins are routed to a battery limit only and are not finalized regarding the tie-in sequence and third party
responsibilities.
b.
Utility stations and subheaders are "factorized", but not separately taken-off.
c.
Vendor-provided skids with interconnecting piping are routed to the unit envelope, but actual hookups
are not defined.
d.
e.
Some percentage of planning release drawings are available at the time of the estimate.
f.
Significant additions (eighteen lines, 6" and larger) were made to P&ID's as late changes, and some lines
are not identified (except in the sense of overall tonnage), although being part of the FCE (eleven lines,
4" and larger).
ITEM
TAKE-OFF
ALLOW
GROWTH
ALLOW
HIGH/LOW %
U/G PIPING-ALL
A/G PIPING
SHOP FAB
CS >2"
ALLOY >2"
FIELD FAB:
CS <1-1/2"
CS >2"
ALLOY <1-1/2"
ALLOY >2"
PVC/CU
/
/
/
/
/
I.
CTE RECOMMENDATION
Based on a review of the methods used to prepare the Class M cost estimate and the corresponding risk items,
Piping Design makes recommendations against further contingencies to be applied to the estimate. The Work
Group Leader and the CTE sign the written recommendations and attach the Completed Checklist.
CTE
1.0
GENERAL
=
Thoroughly read and understand the scope of work and specifications as applies to
insulation. Highlight pertinent items and any unusual requirements and pass these
items on to assigned project estimator.
=
The insulation specifications must be very carefully read. Often, the insulation is more
expensive than the piping. Omissions are costly; therefore, make all possible double
checks against line list and/or P&ID's.
=
Determine before pipe takeoff is started whether or not valves, flanges, and fittings
receive removable, replaceable covers.
2.0
=
MATERIAL TAKEOFF
A.
B.
C.
D.
=
3.0
MATERIAL PRICING
=
When insulation specifications are initially examined, the insulation-pricing technician
should be notified as to the general requirements of the specification. Any special
material requirements may require outside sources.
=
.
Steam Trace
Hot Oil Trace
Glycol Trace
Electric Trace
May require heat transfer cement and channel (see job specification). Insulation OD
must accommodate tracer sizes and number of each.
1
1442-0020
GENERAL
=
Thoroughly read and understand the scope of work and specifications as applies to
painting. Highlight pertinent items and any unusual requirements and pass these
items on to assigned project estimator. Check line list to verify all pipe painting.
=
1
1442-0022
Solvent Cleaning
SSPC-SP 1
Procedure for removal of detrimental foreign matter such as oil, grease, soil, drawing and
cutting compounds, and other surface contaminants from steel surfaces by the use of
solvents, emulsions, cleaning compounds, steam cleaning, or similar materials and
methods which involve a solvent or cleaning action.
Hand Tool Cleaning
SSPC-SP 2
Procedure for removal of loose mill scale, loose rust, and loose paint by hand brushing,
hand sanding, hand scraping, hand chipping, or other hand impact tools, or by a
combination of the above methods.
Power Tool Cleaning
SSPC-SP 3
Procedure for removal of loose mill scale, loose rust, and loose paint with power wire
brushes, power impact tools, power grinders, power sanders, or by a combination of the
above methods. It is not intended that all mill scale, rust, and paint be removed by this
process; however, loose mill scale, loose rust, loose paint and other detrimental foreign
matter will be removed
White Metal Blast Cleaning
SSPC-SP 5, NACE No. 1
Procedure for removal of all mill scale, rust, rust scale, paint, or foreign matter by the use of
abrasives propelled through nozzles or by centrifugal wheel. Defined as a surface with a
gray-white, uniform metallic color, slightly roughened to form a suitable anchor pattern for
coatings. The surface, when viewed with magnification, shall be free of all oil, grease, dirt,
visible mill scale, rust, corrosion products, oxides, paint, or any other foreign matter. The
color of the clean surface may be affected by the particular abrasive medium used.
1
1442-0036
2
1442-0036
COATING CALCULATIONS
Volume
Total Volume
Solids
D.F.T.
% Volume Solids
Spread Rate
Theoretical Coverage
Effects of Thinning:
Volume Solids
New
Cost/Mil Sq. Ft
1604
W.F.T
Sq.
Ft.
Total
Solids
Cost/Gal.
Coverage
Example:
What is the cost/mil sq. ft. of a coating having 45% volume solids and a cost of $17.50 per gallon?
(Volume Solids) 45% X 1604
721.80 (Coverage)
(Cost/Gal) 17.50
(Coverage) 721.80
2.42
cents
(Cost/Mil
sq.
Ft.)
1
1442-0023
PIPELINE ESTIMATING
IS PERFORMED BY
KELLOGG BROWN & ROOT TECHNICAL
SERVICES
PIPELINE ENGINEERING GROUP
1
1442-0024
1
1442-0025
LABOR
=
State adjustments/inclusions to labor such as: firewatch, safety considerations, etc.
=
Do not reflect productivity adjustments unless advised by chief estimator.
MATERIALS
=
State pricing philosophies such as quotations received, in house pricing, domestic or
foreign sourcing, freight, etc.
INSULATION
The following qualification should be included in each estimate:
=
This estimate is based on new construction environment and does not include
inefficiencies for maintenance and turnaround type work, hot work, shift work, or
overtime.
=
Furnishing and applying framework, angles, rings, pins, clips, nuts, blocks, saddles,
etc., for insulation and support of insulation has not been included in this estimate.
=
This estimate is based on the assumption that we will be permitted to insulate
completely all equipment flanges, manways, piping, fittings, flanges and valves,
2
1442-0025
=
=
QA/QC
=
Workhours for pipe inspection is excluded from our estimates. This is normally a
construction staff position and these hours are normally allowed in indirect costs.
QUALIFICATIONS FROM A TYPICAL ESTIMATE
Having made a careful review of the bid documents and after visiting the site of the work,
Kellogg Brown & Root submits this proposal based upon the following clarifications and
qualifications:
=
We have made no provisions or allowances in our price for the removal, repair, or
relocation of any underground obstruction not clearly shown on the drawings.
=
All owner-furnished equipment and materials are to be supplied to us at such times
and in such a manor as to assure continuity of work for our labor forces.
=
All existing installations (i.e.) are to be in proper location and elevation and in
accordance with the referenced data provided for this bid, thereby eliminating any
requirements for subsequent modifications repairs, relocation, or any rework of any
kind.
=
We will utilize excavated materials for backfill purposes, and we have included no
purchased or imported backfill materials in our price.
=
We will dispose of all excess excavated and waste materials within the plant limits.
=
We have made no provisions or allowances in our price for any unexpected work
stoppages due to the owner's ongoing operations and/or request.
=
Our price is based on radiographic inspection of piping welds per specifications
and/or ANSI 31.1, 31.3, and 31.8 code requirements.
3
1442-0025
=
=
=
=
=
=
All existing lines that are to be tied into are to be purged free of product and made safe
by owner prior to our craftsmen beginning the tie in work.
Owner is to provide adequate power for our 8 bank welding machines within 100 feet
of the working area.
We base our price upon being awarded all phases of this project.
We have made no provision for allowances in our price for any piping work not
explicitly shown on the bid drawings.
Our work forces are to be allowed adequate access to the work areas. We have made
no provisions or allowances in our price for any unreasonable interferences that may
occur from other contractors working at this jobsite.
We have made no provisions or allowance in our price to provide spark-proof boxes
for welding. Should you elect to require spark-proof boxes, we will provide nonpressured boxes for $600.00 each or pressurized boxes for $750.00 each.
We base our price upon all excavated materials as being free of contaminants and/or
hazardous waste.
We have made no provision for allowances in our price for unreasonable delays in
obtaining permits (hot work and vessel entry), waiting for fire watch or waiting for
owner's representatives.
We have made no provisions or allowances in our price for asbestos abatement.
All owner furnished piping materials are to be supplied fully fabricated and piecemarked for erection with no repairs, rework, modifications or alterations being
required.
Our price is based upon utilizing local water sources for hydrotest water. Costs are
excluded for treatment of such water.
Our price is based on disposal of such water in existing drainage systems.
4
1442-0025
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)
FOREMAN
2
4
PIPEFITTER
PIPELAYERS
(HELPERS)
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)
FOREMAN
1
4
PIPEFITTER
PIPELAYERS
(HELPERS)
1 EQUIPMENT OPERATOR
AG Ductile Iron to 12"
1/4
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)
1
1442-0028
FOREMAN
2
4
PIPEFITTER
PIPELAYERS
(HELPERS)
1 EQUIPMENT OPERATOR
CREWS FOR UNDERGROUND PIPING
UG Ductile Iron and RCP Crew to 12"
1/4
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)
FOREMAN
1
4
PIPEFITTER
PIPELAYERS
(HELPERS)
1 EQUIPMENT OPERATOR
UG HDPE and PVC Crew to 12"
1/4
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)
FOREMAN
1
4
PIPEFITTER
PIPELAYERS
(HELPERS)
1 EQUIPMENT OPERATOR
2
1442-0028
FOREMAN
1
2
PIPE
PIPELAYERS
FITTER
(HELPERS)
WELDER
1 EQUIPMENT OPERATOR
UG Welded Pipe Over 12"
1/2
FOREMAN
2
4
PIPE
PIPELAYERS
FITTER
(HELPERS)
WELDERS
1 EQUIPMENT OPERATOR
CREWS FOR ABOVEGROUND PAINT AND INSULATION
Pipe Painting
1/2
FOREMAN
PAINTERS
HELPERS
FOREMAN
INSULATORS
HELPERS
3
1442-0028
1.0
GENERAL
=
Upon initial kickoff of piping estimating effort, procurement and sub contract scope
must be identified.
=
If estimating responsibilities include material pricing, a definitive list of procurement
packages should be made.
=
For lump sum estimates, a detail Bill of Materials shall be prepared from piping
takeoff for formal inquiries.
=
For Control Estimates, purchase agreements, existing purchase orders, and/or
pending project inquiries may be used and should be expedited from project.
2.0
VALVES
=
Since valve takeoff is performed early in the Estimating effort, a valve summary
should be prepared for inquiry as early as possible.
=
=
Include the following in preparation of valve inquiry package:
1) Scope delivery & quote requirements
2) Valve List- with tag number, size, type and model
3) Valve specifications
3.0
PIPE FABRICATION
=
If project is lump sum and completed drawings are in scope of work, the fabrication
inquiry should include such drawings to achieve a true lump sum price from
fabricators.
=
If fabrication price is to be worked from our takeoff, a unit price fabrication inquiry
should sent out with approximate quantities anticipated for project.
=
Any fabrication inquiry must be coordinated through chief estimator and/or
fabrication specialist.
=
Pertinent dates are required with these inquiries and must be obtained from project
scope of work and/or construction support personnel.
=
Include the following in preparation of fabrication inquiry package:
1) Scope-delivery and quote date requirements.
2) All pertinent drawings (or representative Bill of Material)
3) Specifications
4.0
PIPING BULK MATERIALS (including underground)
=
After piping takeoff is complete, bulk material inquiries should be issued.
1
1442-0029
Segregate Bill of Materials by types and materials. This will assist expediting inquiries
by targeting type of material to correct supplier.
5.0
INSULATION
=
Since the insulation takeoff is generated from the piping quantities, the insulation
specifications should be reviewed with the Insulation Pricing Technician prior to
completion of takeoff effort.
=
Any special material pricing can then be expedited with adequate lead-time to
complete insulation pricing.
=
If scope of work is based on issued for construction isometric drawings and insulation
work is to be a subcontract, a formal inquiry should be prepared. The subcontracts
department of procurement should be employed to assist in issuance of a formal
inquiry.
=
If a unit rate subcontract is required, a standard format should be followed as
provided by the subcontracts department of procurement.
2
1442-0029
PIPING FLEXIBILITY
Piping flexibility is one of the most important, least understood functions of piping design.
Today flexibility analysis, or stress analysis as it is often called, is delegated to a computer.
Consequently, the piping designer's responsibility is normally limited to a quick check to
determine if the piping layout is within reasonable tolerances. If the quick check shows it is
outside these limits, he turns the problem over to stress specialists. A stress specialist
translates data to an input sheet, turns this over to the computer group and later receives a
computer output sheet. Then if the piping system is too rigid, the stress specialist may
suggest corrective modifications; but the ultimate responsibility rests with the designer.
A computer run, including formulation of input and diagnosis of output, is expensive but
certainly warranted if the quick check method suggests a need for it. However, thousands
of dollars are wasted on computer analysis of lines of visibly adequate flexibility or of lines,
which would be accepted if a quick check method were used. Piping designers who know
nothing about flexibility analysis are quick to request a full stress analysis rather than take
a chance.
Although several books could be written on piping stress analysis, this chapter must be
limited to presenting a quick check method and explaining it so that all readers can
understand and apply it to their problems.
The competent piping designer will make every effort to provide adequate flexibility in his
piping using a minimum number of fittings. When a quick check determines that the
system is not flexible enough, he reviews the system to determine whether or not he can
redesign, maybe adding an elbow or two to increase flexibility. Then he uses the quick
check method again. If his system proves adequate, he has saved the expense of full
analysis. If the system is still slightly rigid and the designer believes that computer analysis
may prove his system to be within flexibility allowances then he should ask for the stress
analysis.
The quick check method has a built-in safety factor; many arrangements, which prove
slightly stiff by the quick check method, actually come out OK when full analysis is made.
Purpose of Analysis
A hot piping system will expand or elongate. A cold piping system will contract or shrink.
Both of these actions create stress problems. A stress analysis determines the forces at
anchor points, stresses in the piping system, and bending moment at any point. For any of
these factors an allowable is known. For any force generated at an anchor point, often an
equipment nozzle, there must be at least an equal resisting force. If a system throws 20,000
1
1142-0037
pounds of force into an anchor designed to withstand 15,000 pounds of force, it will give. If
the anchor happens to be an equipment nozzle this give means a rupture and possibly an
explosion and fire. Before designing piping systems for adequate flexibility, the designer
must know what forces are allowable.
Allowable Forces
Allowable forces and moments are a nightmare to the piping designer responsible for
providing a piping system that will not overstress the equipment to which it attaches. It is
hard, sometimes, to find out just what the allowables are.
Specific equipment allowables must be obtained from equipment manufacturers. If the
forces involved are figured and passed on to the vendor, the nozzle can often be reinforced
to withstand forces greater than normal, but it must be remembered that even the
manufacturer has force tolerance limitations.
Piping Flexibility Design
It is preferable to provide adequate flexibility in piping systems by using loops or other
configurations constructed of pipes and fittings. Sometimes space or cost is prohibitive;
expansion joints such as the bellows, Barco ball or sliding type must absorb movement.
Piping flexibility should always be achieved with the minimum number of anchors and
guides feasible. Axial expansion joints must be guided on each side and anchored at the
end of pipe runs to withstand hydrostatic testing thrust. U-type loops must be anchored on
both sides of the pipe run to work.
=
Lines, which are to be purged by, steam or hot gas must be checked to make sure that
they will be adequately flexible during the purging operation.
=
Closed relief systems and hot blowdown or pumpout system must also be carefully
thought out.
=
Temperatures in start-up lines often surpass operating temperatures.
=
Exchanger bypasses may still be cold while the inlet and outlet lines are already hot,
resulting in excessive stresses.
=
Always review systems at their worst operating conditions such as during start-up
when a hot line will be feeding into a cold tower or vice versa.
Unit systems, such as a steam system having a large diameter header in the unit pipeway
and smaller size branches feeding into equipment, are often provided with unnecessary
and expensive expansion loops and anchors. Before loops are designed, every effort should
be made to make the branches flexible enough to withstand header expansion. An anchor
placed near the center of the run can be used to direct header expansion by forcing 50% of
2
1142-0037
the expansion to either side of and away from the anchor, distributing expansion along the
header and thereby simplifying branch flexibility.
Flexibility must be considered from the beginning in every system designed. During the
original layout - which may be freehand on a scratch pad - flexibility must be uppermost in
the piping designer's mind. A quick check should be made of all lines 8" or larger during
this initial stage. If flexibility appears to be a problem, smaller lines should be reviewed
and quick checked, too. If a line is too stiff and must be rerouted, the time to find out is
early in the design. Many dollars and man-hours can be wasted making finished drawings
of piping systems, which are too stiff. When this happens and is finally discovered, the
designer must start over completely.
One of the many differences between a draftsman and a designer is that while the
draftsman can only draw the pipe, the designer knows flexibility, process, instrumentation,
flow of fluids and many other specifics which must be considered during the piping layout
and design stage.
The Quick Check Method
The purpose of the quick check method is to determine whether or not a piping system is
adequately flexible without the formal calculations required for a full stress analysis.
Ordinarily if a system is within the quick check guidelines, no further flexibility analysis is
required.
To make use of this method the piping designer must establish some basic facts.
=
Anchor points must be known or assumed.
=
Design pressures and temperatures, expansion coefficients for the metal involved and
any branch or equipment restraints must be included.
=
Special design conditions such as start-up, cydic operation, steam tracing, etc. must be
known.
The lengths of pipe solved for are based on standard weight carbon steel pipe. Alloy
piping, other than austenitic stainless steel and aluminum, may be laid out on the same
basis.
When pipe wall thickness differs from standard weight, a correction factor of ratioing
moment of inertias must be applied. In this case:
Minimum h (adjusted)
= moment
of
inertia,
pipe
specified
moment of inertia, std. wt. pipe
3
1142-0037
When anchor expansion adds to the thrust from the L leg, a correction ratio of linear
expansion must be applied. In this case:
Minimum h (adjusted)
= anchor
movement
+
leg
L
movement
leg L movement
x
minimum h in the formula
The minimum length of h leg required to provide an adequately flexible member must be
tested by applying a factor A which corrects for design temperature. (See Table S-1 for
definitions) The formula is:
Minimum h = A x Do
For the A coefficient of carbon steel pipe, see Table 5-2.
For L-shaped configurations (see Figure S-1) the following formulas apply:
h2 = 0.025 DoLT
Minimum
Maximum L
=
400
(h)2
DoT
Test h = A x
Formula for
Do
Expansion Loop
DoT
expansion
loop,
found in most hot
have
too
much
absorbed
by
a
configuration:
= 0.02 DoLT or
(h)2
2500
Minimum W = 0.5 h
Preferred W= 1.5 h
To
test
for
minimum
h:
Do
125
4
1142-0037
Expansion Loop
Force
As an expansion loop
transmitted to the
calculate the anchor
pipe stress of the
8 and the following
This
example
elbows
and
is
of 4" through 14".
For
force at each
F=CxE x
assumes use of LR
restricted to line sizes
L
Distance in Feet
Between Anchors
anchor:
Ip
5
1142-0037
H
GUIDE
X
40 PIPE DIA. MIN.
L
Figure 5-8. Guided Expansion Loop
6
1142-0037
Computer
Aided
Piping
Summary
TABLE OF CONTENTS
SUBJECT
PAGE
I. INTRODUCTION
11
11
12
16
18
21
22
23
25
26
26
26
APPENDIX
A.
FORMATS
B.
ENCODERS
XVI.
FORMATS
XVII. ENCODERS
I. INTRODUCTION
A. THE PRODUCT
CAPS is a series of programs which aid the piping estimator by eliminating the manual tasks of
summarizing and sorting data into the various like items, accounts, areas, etc. "CAPS" also is a data
transfer system. The mundane process of typing in page after page of "greensheets" in the program
estimate format is eliminated. The CAPS program writes the greensheets for you directly in ESP format.
The code of accounts, 'S' & 'T' cards, comments, and units are automatically filled in with this process.
B. THE REPORTS 1. PIPING SUMMARY REPORT Summaries by like material is sorted into the aboveground, underground, and demolition accounts by
areas, bid item, and work packages.
2. PAINT SUMMARY REPORT Summaries of the surface area of pipe are generated by area, bid item, and work packages. Quantities are
also sorted into shop fab and field run amounts and the output is written in PC ESTIMATE format once
again.
3. INSULATION SUMMARY REPORT A summary of insulated pipe, fittings, flanges, and valves is generated. Like the previous reports, this is
transferred directly onto your diskette by areas, types of insulation, bid items, and work packages.
4. VALVE SUMMARY - A printed report summarizing all valves from take-offs by tag number.
This report is used as a Bill of Material to be turned over to purchasing for inquiring valve prices.
C. THE PROCESS
2.
3.
4.
I.
ANALYZE PROJECT
SCOPE
II.
III.
IV.
ERRORCHK
V.
SUMMARIES DAT
OPTIONS
PAINT SUMMARY ~
VALVE SUMMARY
INSULATION SUMMARY ~
SPEC SUMMARY
PIPING ESTIMATE
INORDER ~
II.
SETUP
Select
JOB NAME
SPECS
INSULATION
PAINT
List all the paint systems required for the project. The system
will sort quantities accordingly. (Example Paint-1, Paint-2 etc.).
BID ITEMS
AREAS
SCHEDULE ID
NEW JOB
This option wipes out all the existing files in the CAPS directory
to prepare for the new job. A warning will popup to avoid any
accidental deletion of the residing caps files.
INPUT
DOS
SPFPC
IPMS IMPORT
EXCEL IMPORT
Select
INPUT SPECS
DOS
SPFPC
To exit to DOS.
To go to SPFPC program.
IPMS IMPORT
EXCEL IMPORT
CHECKS
ADDPSE
CHECKCAPS
to
FIXERRORS
Select
PRICING
PAPER OR
PETRO
PAINT
PAINT
PAINT SF-SM
PAINT M-SM
PAINT W/DWG
PAINT W/SID
CAPS.DAT.
Select
INSULATION
PRICE INS.
INSULATE
Select
ESTIMATES
GENERIC.
SATS.PRT
CSI
Gen. LF-LM
Gen. LM-LM
Gen. W/DWG
Select
MISC
Line by Line
ACLS to CAPS
CAPS to ACLS
Special report - This file exports the piping data to ACLS data
structure. Again, programming changes require supervisors
direction.
Valve Summary
Inorder
Direct to Sub
Caps to ESP
Other three options Log, Print, and Exit perform tasks as named.
INDIVIDUAL FILE
COMBINED FILE
AG. PRT
XPAY. PRT
JACKET. PRT
ESTIMATE . REL
PAINT. PRT
INSULATION. PRT
STAT. PRT
UG. PRT
Chart Combine-1
10
d. Insulation class- Identify the possible classes for pipe insulation. Copy
thickness chart, if available, for all estimators on the project.
5.
Pricing needs
a. Pipe fabrication- Advise Fabrication Specialist of materials of pipe, need
date, and when data will be available.
b. Piping bulks- Advise Purchasing what materials require outside pricing and
when data will be available.
c. Specialties- Brief Purchasing on needs & when info will be available.
d. Subcontracts-Insulation, painting, testing, cleaning, etc.
e. Valves-Valves may need to be inquired early.
11
The caps
program can do
certain things
very fast, but it
can not:
"THINK FOR YOU!!!"
B.
SET UP SPECS
1.Study project documents (line lists, P&ID's, drawings, etc.) for all possible specs to be
required for the takeoff.
Prepare a list of specs or reproduce appropriate pages.
2. To minimize input time, seek out existing CAPS specs already coded from previous
projects. Copy onto your diskette under the file name 'SPECS.DAT'.
b. If existing specs are drastically different, delete all spec entries and code new
specs as detailed in paragraph C.
12
j. SCHEDULE - cols. 51-60 - Pipe wall schedules (i.e. S/40, S/80, STD, XS,
etc.) are valid entries in this field.
k. END COND - cols. 62-63 - Enter the 2 digit code for end conditions per the
'FORMATS' Section.
l. FAC -
cols 64-65-
13
'FORMATS' Section.
n. When you are finished coding all needed specs save the file and submit
SPECS.DAT file in SAS program to run specs. Simply open the SAS program,
select INPUT, then INPUT SPEC. This will open the specs file. Closing this file
will automatically generate SPECS.PRT file. Print this file and check very
carefully or someone else have it manually checked to match the descriptions
exactly with the specifications. Make adjustments if necessary.
Each estimator assigned to the job should have the copy of the SPECS.PRT file. Each estimator
should be aware of what is loaded in the specs to know what fields or override in the take-off.
More on overrides in paragraph IV.D.8.
CAUTION
If a job with different specifications have been executed on your machine, you
must execute your SPECS.DAT file before you execute any of the menu tasks.
14
II SET UP SPECIFICATIONS
EXISTING SPECS -?
NEW SPECS-?
INPUT INTO
SPECS.DAT
RUN UPDATE
RERUN UPDATE
RECHECK
OF SPECS
ERRORS- ?
15
C.
ACTUAL TAKEOFF
1. The pipe estimating input form - see EXHIBIT
Observe coding rules for: OHs, I's, zero's, Zs
Left justify all entries with exceptions as noted.
2. Header lines-Input on header line applies to data that follows it until another header is
encountered. Header lines begin with "1$" in columns 1-2.
a.
NOTE
Code in service, line sequence number & spec as required to identify the line. The spec
entry must be coded in the same spaces every time. An imbedded or extra space will be
interpreted as a different spec. Also, do not code specs containing OHs with zeroes. To
the CAPS program you would have asked for an entirely different spec.
e.
DRAWING NUMBER - cols 28-39 - Optional entry
- Code in the most useful document to maintain trackability from takeoff to
drawings.
f.
UNIT - col. 42 - Not in use at this time
g.
AREA - cols. 44-47 - Optional entry for jobs with
multiple areas.
h.
BID ITEM - cols 49-52 - optional entry for jobs
requiring bid items to group cost for bid
form. This field will align with
program estimate bid item field when data is transferred into your module.
i.
LOCATION - col. 54 - This field tells CAPS very
important information. The only valid
entries are:
''Above ground (default value) 'P' Underground- pressure flow
'G' Underground- gravity flow
'D' Demolition- for scrap or disposal
This one entry tells the system
'R' Demolition- for relocation
programs to sort the data into
'T' Tie-ins (special use)
the underground, demolition,
'6' Pipe line code
and other accounts, so be careful
to code in the right letter.
16
j.
l.
m.
a. Col. 1 - If this is left blank, the caps programs thinks you want a remark line.
Only valid entries are:
'L' for labor
'M' for material
b. SIZE 1 - Col 3-8 - First size is for large ends on reducers and tees.
c. SIZE 2 - Col 10-15 - Size2 must always have a value, use decimals, not
fractions, and left justify each field.
17
g. P30, P10, P40 - Cols. 18-20 - Entries here define the logic of fabrication.
Once again, what you code defines which code of account the system
sorts the labor and material to.
Valid entries are:
'P40' for field run
'P30' for outside shop fab
'P10' for field shop fab
h. ITEM - Cols. 21-23-Enter the three-digit code for pipe,
90-degree ells, pipe labor, weld, & etc. from the 'FORMATS' section in this
guide. Again, watch those coding rules for OHs and zeroes, I's, and ones.
Updates of the 'FORMATS' section will be periodically distributed.
i. TAG NUMBER - Cols 25-40 - Enter tag nos. for valves, specialties, and any
information to alter normal encoders.
NOTE! It is important to code repetitive items the same way. For example:
'HOSEREEL' and 'HOSE REEL' are read as different tag numbers by CAPS. Likewise, a
tag number left blank will be read as a third, different tag number. Try keeping a list of
these entries. Copy for every estimator on the project whenever changes occur.
j. QUANTITY - Cols 42-48 - Left justify, no decimals for this entry.
k. OVERRIDES
MATL OVERRIDE - Cols 50-53 - Enter ASTM format per the 'FORMATS'
section. This will override the material value that you coded back in Section II.
Care must be used to assure this entry will add to similar material in other specs.
Avoid using this field unless absolutely necessary and you have a good
understanding of the workings of the CAPS programs.
OVERRIDES Cols. 55-78 - Left justify these entries. Once again, we have the
ability to override the pipe spec. If the drawing indicates a different flange
rating, wall thickness of pipe, end condition, or flange facing from what is coded
in the spec, you can account for the difference by adding the information in the
correct field.
18
D.
Use the following command: "X ALL;F $~ ALL" to find all the header lines.
Data entries such as AREA, BIDITEM, SPEC, LOC, INSULATION, AND
PAINT can be easily viewed for misalignment or omitted entries. All data must
be in the appropriate columns to be read correctly.
b. Make sure other data appears on header line as required by take-off (i.e.
AREA, BID ITEM, PAINT, INSULATION, etc.).
2.
ERRORCHECK a. Open CAPS. Across the top of the screen a series of pull down menu screens
will be displayed. Select the CHECK option, next select CHECK CAPS.
This task reads from your diskette data file 'CAPS.DAT'. Some common errors checked
for you are missing SPEC, invalid ITEM, omitted SIZE2, and others. This creates a
report, to be printed out and reviewed for error notations, called 'ERRORS.PRT'.
b. Print out this file (compressed print) and correct data corresponding to the
errors printed in the 'ERRORS.PRT' file or after running the CHECK CAPS
option select CHECK at the top of the screen and then select fix errors.
c.
d.
19
will assure that pricing requirements will be clear and few questions will
arise.
e. Verify that 'PIP's and 'PSE's quantities balance.
Material and labor quantities have to balance. Take this opportunity to
scan your print out for differences in the 'PIP' and 'PSE' quantities.
3. Sample error check run- see EXHIBIT 8.
This is an example of some errors:
20
E. SUMMARIZE DATA and APPLY RATES 1. Now that the take-off is complete and checked for errors it is time to summarize your
data for pricing and applying labor rates. Selecting PRICING allows the user to apply
rates (Paper or PetroCHEM) from the database.
2. Summary Report
a.
LOGIC ERRORS
21
PSE
BY KELLOGG BROWN & ROOT
FIELD RUN
BLANK
4. Units Report
A file is created on the C: drive, 'CRATES.PRT', that is for input of material and labor
units. Input units between asterisks. All units must contain a decimal. It is very important
to fill in all lines containing asterisks. If left blank, all entries that occur in the final file
'ESTIMATE.PRT' will be blank. Do not change any information in this file other than
data entry between asterisks. When all units are input you are ready to build your
Estimate deck with the appropriate codes option. 'CRATES.PRT' can be rerun if major
changes occur in the data file with out losing pricing or labor units already included.
F.
22
G.
PAINT SUMMARY:
Select PAINT from the menu bar.
The paint summary can be executed any time after all take-off is complete.
However, your time is best utilized if you execute the summarization option first.
While pricing for pipe is being worked up, you can work on the paint estimate.
If paint for 'BPF' or 'VBF' pipe is furnished by the vendor, then blast and prime
entries must be deleted from the data file.
Selection of this option will produce a file on your "C drive called
PAINT.PRT'. This file is the total paint requirements from your pipe take-off in
the 'CAPS.DAT' file sorted by area, bid item and type of paint into the painting
code of account.
Apply labor and material pricing from the Pipe Estimating Manual according to
the paint classification for your project.
When unit input is complete your paint estimate file is ready to be combined
with your pipe estimate. (See the INORDER option under MISC on the menu
bar.)
23
PAINT SUMMARY
24
H.
INSULATION SUMMARY
Select INSULATION from menu bar.
As in the above option, this option is best executed as soon as your take-off is complete so
that your insulation material prices and man-hour units can be worked up based on
specifications and other project criteria. Your insulation requirements will be sorted and
summarized into insulation type and thickness requirements and be written to a file named
'INRATES.PRT'. The material and man-hour units are applied to this file. After the proper
units are input pricing can be executed and the units will then be applied to insulation types
and thickness by area, bid items, and account codes. Select PRICE INS from the pull down
menu or the desired insulation option. You are now ready to combine the insulation portion
of your estimate with the pipe portion. (See the combine option MISC then INORDER on
menu.)
INSULATION SUMMARY
I.
VALVE SUMMARY
25
Select MISC from menu bar; next select VALVE SUMMARY from pull down
menu. This task summarizes valves by item or tag number and by size for purchasing.
This task is usually one of the first tasks completed due to the amount of time it takes for
pricing requirements. A completed run of the valve summary along with the valve
specifications should be given to procurement for inquiry.
J.COMBINE ESTIMATE FILES & RUN INORDER Selection of this task combines the pipe, insulation and paint files into one file called
'ESTIMATE.PRT'. This file is then sorted by area by account code. This file is renamed
'ESTIMATE.REL'.
K. TRANSFER ESTIMATE ONTO PROJECT ESP TEMPLATE Transfer the ESTIMATE.REL data to ESP using the CAPS to ESP function. You are
now ready to execute ESP.
Be sure to check your ESP file for percentage cards as required by the project. Some of
the percentage cards you might need for your individual project are as follows:
- P67
- P68
- P69
- P71
- P72
- P73
- P31
- P81
- P97
- P98
26