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1. Introduction
• The selection of the optimal pipeline route, diameter, material, wall thickness, pump
station location, pump units and operational equipment or facilities is typically the
result of economic analysis and investment capital evaluation of the most reasonable
scenarios developed through
the design phase.
• Typically, even before the detailed design of a pipeline system has begun, an order-of-
magnitude cost study will be performed, with the goal of determining the feasibility of
continuing to invest time and capital in the design phase of the project.
• For a typical cross country pipeline project, the cost of pipe and its
associated construction and installation costs can be as much as 80% of
the capital investment , therefore , the selection of the pipe, with regard
to the type of material, size etc. is very important.
• Design and engineering cost, which cover the cost of design and cost of
“engineering” of the piping system, purchasing, procurement and
construction supervision.
• Contractor‘s fees (Technology Fee)
• For a small piping system , and for simple choices between alternative
processing schemes , the decisions can usually be made by comparing
the capital and operating costs. More sophisticated evaluation
techniques and economic criteria are needed when decisions have to be
made between large, complex piping systems, particularly when the
piping systems differ widely in scope, time scale, etc.
Lines in the first group are sized on the basis of available pressure drop,
while those in the second must be based on an economical pipe size ( the
smaller the pipe , the less the pipe costs but the higher the pumping costs, and thus an
optimum size must exist).
Paradoxically, however, it is uneconomical to make economic studies on each process
line for a proposed plant. The designer, therefore, must have some means of
determining which lines justify careful cost analysis.
The designer can select a conservative line size which will definitely fulfill the
requirements. But will the next smaller size be more economical? The only manner in
which this can be determined definitely is by careful economic analysis.
If the possible saving , however, is not far from the cost in the man-hours required to
make the study, it is better to select the conservative size without further use of
valuable time.
If, on the other hand, the possible savings are substantial, then further detailed study is
indicated.
Purpose:
The following example will illustrate the concept of the inch-meter and the inch-dia:
Q.1 Elbow 2" size, 20 nos., are to be fitted in a pipeline. Find out the inch dia?
The costs of process industry pipe work are usually sub-divided as below:
2. Materials: The cost of all bought out materials , i.e. pipe flanges, fittings, valves,
expansion units, etc.
4. Erection: The cost of erecting on-site fabricated pipe work and pressure testing. This
includes preliminaries, variation orders and error
rectification if any.
For liquids, a velocity in excess of 20 ft/s should never be specified in order to avoid
erosion of the pipe. On suction lines to the pump, the pressure drop should always be
less than 50% of the total head developed by the pump.
Unplasticised polyvinyl
4 Sock, weld 1.79
chloride
9. Material Estimation
There are three main topics of pipe work estimation as mentioned below:
1. Erection
2. Supports
3. Testing of completed pipelines
The schedule of rates under the fabrication and erection work are established in “man
hours” which should be representative of the gang time to complete the operation. The
type of rate will depend on the client and contractor relationship on the basis of the
contractor’s tenders.
The rates shall be included or excluded, allowances for construction plant, tools, tackle
and consumables.
Typical rates for various piping materials are enclosed for reference. These include
labour, consumables, tools, tackles and overheads.
13. Typical Rates for Fabrication, Erection and Testing of Pipelines for
Costing with Example
a) Mild steel (MS), B and C class piping: Rs. 45/- per inch dia per metre
length.
b) SS 304 piping ( Sch 5): Rs. 90/- per inch dia per metre length.
Q. Find out the labour cost for making a MS reducer of 2" x 4" size?
Q. Find out the labour charges for fabrication and erection of a MS pipeline of 50 NB
(2") MS “B” or MS “C” of 400 m length fabrication and erection?
Typically the quantum of pipe fabrication, erection and testing of pipe work shall be
expressed as shown below:
SS Condensor Copper
Raw material Factors
tube Condensor tube
Sheet width mm
Packing and
Rs/kg 1.00 0.79 1.40
forwarding
• All raw material i.e. pipe, reducers, bends, flanges, sockets etc. and
hardware i.e. nut, bolts, gaskets etc. shall be supplied by client.
• Fitment includes assembly of fittings i.e. flanges, bends, valves, reducer, fabrication
of tees, fitment of non return valve, valves, gaskets, nut bolts, sockets for pressure
gauges fabrication and fitment of thermowell, etc. Pipe work shall be carried out as per
piping drawings/ specifications/ instructions given to construction engineer.
To be arranged by contractor:
1. Rectifier
2. H.F. unit
3. Transformer
4. Grinders- AG7
5. Winch – 5 MT
6. Chain block 3 MT 11 mtr. Lift
7. Ropes / pulleys
8. FF2 grinder
9. Hacksaw/Files etc. and other tools and tackles.
10. Pipe voice
11. G Q 4 Grinder
12. Abrasive cutting machine
13. Gas cutting
20. N System
The N system is based on the fact which has been tested many times, that the costs of
strings of pipes of different sizes but of the same material and class of pipe bear
constant relations to each other. The N system was introduced by R.A. Dickson (Chem.
Eng. Nov 1947, PP 121-123)
Step I : Calculate the cost of the reference sizes of the strings of pipe in question.
StepII : Then use the N factors to get the cost of the same string in the required size.
Costing of Pipelines - 2
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Piping always represents a sizable part of the total installed cost of any process plant. It
may run to 20 percent or even more of the entire cost of the plant, including land and
buildings, and may total from around 10 percent to as high as two-thirds of the cost of
the equipment. But piping is usually complicated and often consists of a myriad of
small, rather inexpensive parts. Its estimation can therefore be a headache to the
estimator.
It makes his problem no easier that he is often asked for a reasonable estimate long
before the final plans exist and before the project engineers have any idea how much
piping will actually be needed. In this case, he must not only be an estimator, but he
must be able quickly to convert the preliminary flow sheet into a fair approximation of
an actual design to know what his estimate will involve. For this purpose the ability to
make quick and rather accurate free-hand isometric sketches is of inestimable value.
However, the estimation of the piping need not be arduous if the estimator will make
use of the N system developed by the another during the last several years. This
system, first disclosed in Chemical Engineering (R.A. Dickson, Chem. Eng., November,
1947, pp 121-123) has now been carried much further and includes most kinds of pipes
with which the chemical engineer is likely to be concerned.
The first requires picking of each length of pipe with its fittings and valves
and pricing the material and labour costs in detail, then adding them all up for the total
cost. The second consists in taking a percentage of the total cost of a project as the cost
of the piping. This percentage the “finagling factor,” is supposed to be around 40
percent.
* The author wishes to express his appreciation to the firms listed and to
may others who prefer to remain anonymous, but who helped by furnishing cost data
on which the N-factor tables are based. Specific acknowledgement is made to
Armstrong Cork Co., Inc.; Mundet Cork Corp.; Johns Manville, Inc.; Cooper Alloy
Foundry Co.; Taylor Forge and Pipe Works; Andrews Knapp Construction Co.; Knapp
Mills Inc.; The Saran Lined Pipe Co.; The Rie-Wil Co.; and The Duriron Co.
See, for example, Table 10-33 of the N factors. The costs of different sizes of steel Pipe,
butt-welded, schedule 40, black, with fittings and valves as specified, will be to each
other approximately as the N factors. As the table shows, a string of 2-in nominal
diameter pipe will cost 1.84 times as much as the same string in 1 in.
Hence, 208/119 = 1.84, the N factor for 2-in. pipe in terms of 1 in. pipe as unity.
Not only has the N-factor System been tested thoroughly, but it also shows up
satisfactorily over a period of time. Several checks of this fact have been made. For
example, table 10-39 was selected at random, and comparable strings were figured for
4- and 12-in. pipe, using first the costs of 1935, and then July, 1949, costs. Despite the
fact that the costs of each string had risen approximately 83 per cent from 1935 to
1949, the N factor for 4-in. pipe for 1935 was 0.249, and for 1949; 0.248.
How the N-factor System Is Used: To use the tables, first calculate the cost of the
reference sizes of the strings of pipe in question. Then use the N factors to get the cost
of the same string in the required size.
The tables cover only the cost of putting the strings of pipe together. The costs of
burying or supporting pipelines are easily calculated. Moreover, many times the
proposed lines lie on the ground or are supported on existing structures. These
conditions are far too variable to include in any tables of costs.
An example of use: Assure that several strings of pipe of various sizes have been taken
from the flow diagram of a small project involving some additional piping.
First consult the index of N-factor tables. The specifications of the pipe, fittings and
valves in Table 10-33 correspond to those required. The reference size, i.e., the size for
which N = 1.00, is 1 in.
Next, calculate the cost of hypothetical string of 1-in. pipe of the required
specifications. (Or take the cost from Table 10-33, giving the cost of the
reference string in July, 1949. Then “factor” this cost to date of use.)
Calculate all the strings taken from the flow diagram as 1-in. pipe, then multiply by the
N factor for the actual size:
For comparison, the total cost of piping calculated by the conventional pieceby - piece
system would be S764, as shown in the following check:
What Data Are Needed: The N-factor tables were derived by actual calculation of the
installed costs of typical strings of pipe in all the sizes mentioned in each table, and in
all the different weight and materials of construction listed in the 66 tables. For
uniformity, all have been calculated on the basis of July, 1949, materials and labour
costs in the New York area. For each specification the costs so calculated for the several
sizes have been compared with the cost of one reference size which is taken as 1.00.
The comparative costs of the other sizes of the same material are then listed as
multipliers of the reference size. In Table 10-1, for example, the sizes range from ½ to
12 in. The reference size is 3 in, and the N factors (i.e. relative costs compared with
that
of the reference size range from 0.320 to 6.730).
Hence, the N factors are all based on the reference size (or in a few cases, two reference
sizes) for each piping specification, and to figure any string of pipe, it is necessary only
to figure the cost for the reference size in that particular specification. Once the cost of
the reference size is known, the costs for any other size or for several sizes can be
determined immediately by multiplying by the proper N factor. This means that it is
necessary to keep up-to-date the cost data only for the reference size (or sizes) in each
specification, since the N factors remain constant through an extremely wide range of
material and labour cost variations.
Estimating without Current Data: This means also that it is unnecessary to keep up-to-
date data even on the costs for the reference strings, if a somewhat lower degree of
estimating accuracy can be tolerated than is possible by having up-to-date figures. For
this purpose, each of the tables includes as a second part (or in some cases, as a second
and third part) the detailed calculations for the reference size or sizes for these
materials are based on July, 1949 costs. As long as labour and material costs do not
change much from July, 1949, these figures can be used directly. But since such costs
are not likely to be stated in the future, it is possible to “factor” them to the date of use
by the judicious use of one or more of the available cost indexes, in comparison to the
index for July, 1949.
Cost Indexes: Many cost indexes are available monthly in the Survey of Current
Business, published by the U.S. Department of Commerce. Among these are several
building cost indexes for various kinds of labour and for a number of basic materials.
The Survey, as well as the magazine Engineering News-Record, also publishes the ENR
Construction Cost Index, which is widely used by estimators in dealing with plant and
equipment cost variations, although it is intended to cover only heavy construction
costs. Some organisations have successfully applied their own modifications to the
ENR Index in using it to “factor” plant and equipment costs. The magazine Chemical
Engineering regularly publishes the comparative equipment cost indexes for process
industries compiled quarterly by the evaluation engineering firm of Marshall and
Stevens, together with this firm’s 1947 industry average, covering equipment costs in a
wide range of industrial and commercial activities.
None of these indexes applies directly to piping costs and must therefore be used with
care. However, experience has indicated that such “factoring” can be sufficiently
accurate at least for pre-construction cost estimating. The only indexes that actually
deal with piping cost, as far as the author knows, are not so readily available as those
mentioned. These are the Handy Indexes of Public Utility Costs, put out for the estate
of William W. Handy by Whitman, Requard and Associates, of Baltimore, and
Benjamin L. Smith and Associates, of Albany. This compilation is issued every six
months and lists several kinds of piping including gas mains and power plant piping.
Table for N System
Pipe: aluminium, Aleoa alloy 618-T6, standard weight, bare, 1/2 “ to 12”
Fittings: aluminium, welding
Valves: ½” and 1" aluminium, screwed, gate; 1 ½” to 12" aluminium, flanged, gate,
125#
Reference size: 3#