TECHNICAL CALCULATIONAND ESTIMATOR'SMAN-HOUR MANUALMarko Buliæ
Marko BuliæTECHNICAL CALCULATION AND ESTIMATOR'SMAN-HOUR MANUALERECTION OF PROCESS OR CHEMICAL PLANTSI.II.III.IV.V.VI.VII.VIII.IX.X.PIPING ABOVE GROUNDPIPELINESSTEEL STRUCTURESPROCESS EQUIPMENTSTORAGE TANKS CYLINDRICAL AND SPHEROIDALWELDING AND FLAME CUTTINGCORROSION PROTECTIONTHERMAL INSULATIONESTIMATESPIPING ABOVE GROUNDESTIMATE POINTS FOR BUILD-IN ITEMSXI.WEIGHT FACTORSXII. TECHNICAL CALCULATIONMANNER OF DATAS COMPILINGXIII. MAN HOURS FOR OVERHAULS INPETROCHEMICAL PLANTSXIV. FACTORS AND MAN HOURS FOR PIPING ANDSTEEL STRUCTURE WORKS IN CALL FORTENDERS OF “TECHNIP” COMPANYXV.APPENDIXZAGREB, 2003.(Completed edition)All right reserved.This book, or parts thereof, may not be reproducedin any form without permission of the author.
Thank you for showing interest in buying our book TECHNICAL CALCULATION AND ESTIMATOR'SMANHOURS MANUALYou can buy the electronic version of the Manual containing all the figurest and other related data at thefollowing prices:1.COMPLETE MANUAL (239 pages)2.EACH CHAPTERIIIIIIIVVPIPING ABOVE GROUND - 36 pages 20*PIPELINES - 7 pages 20*STEEL STRUCTURES - 7 pages 20*PROCESS EQUIPMENT - 10 pages 20*STORAGE TANKS - CYLINDRICAL &SPHERICAL - 11 pages 20*WELDING AND FLAME CUTTING - 18 pages 20*CORROSION PROTECTION - 3 pages 20*THERMAL INSULATION - 3 pages 20*ESTIMATES - 11 pages 20*PIPING ABOVE GROUND - ESTIMATE POINTSFOR BUILD-IN ITEMS - 76 pages 20*WEIGHT FACTORS - 7 pagesTECHNICAL CALCULATIONMANNER OF DATA COMPILING - 4 pagesMANHOURS FOR OVERHAULS INPETROCHEMICAL PLANTS - 16 pages 20*FACTORS AND MANHOURS FOR PIPING ANDSTEEL STRUCTURE WORKS IN CALL FOR TENDERSOF “TECHNIP” COMPANY - 3 pages 20*VIVIIVIIIIXXXIXIIXIIIXIVIndividualsLegal entityUS 600US 1000US 180US 75US 80US 70US US US US US 80US 75US 35US 35US 100US 130US 120US 55US 55US 165US 130US 15US 215US 25US US 630012013011010US 80US 130US 60US 100NOTE: 20* THE FIRST 13 PAGES OF THE MANUAL AND 7 PAGES OF THE APPENDIX3.A PERSONALISED ANALOGUE VERSION OF THE MANUAL COULD BE ORDERED AS WELL.4.Please, email us your full address and indicate the purchase option you have decided for.We shall send you the electronic manual immediately.As soon as your payment is received we shall send you the password that will enable you toopen and use the e-manual.We congratulate you on your choice and thank you for buying our electronic Manual.1
PREFACEAll 40 years of my working life, I spent on erection of different process plants most of which were oil industry projectsin the country and abroad, in Europe and North Africa. Since 1978 with occasional interruptions because ofsimultaneous involvement in several different projects, I worked mostly on technical calculations. I have madehundreds and hundreds calculations based on all kinds of tenders and erection of mech anical equipment. Thetenders were written in various foreign languages and alphabet, even in Cyrillic. I am fully aware of the problems anestimator encounters when working on technical calculations for specific technologies. Very often tenders were notcomplete and not detailed enough, and the time required for a good technical calculation is getting every dayshorter. It is not easy to present exact technical figures and quantities for the equipment or operations not fullydefined, hard to comprehend, or even unknown to the estimator. Technical terms and expressions written indifferent languages and dialects are often incorrect and specific for individual branches. Enormous experience isneeded, an ability to assess and estimate, and even the courage to write down the technical quantities and figures.That was the reason for collecting various technical bibliography, standards, catalogues, man hours and rates fromthe European and USA countries. I have made the analyses, comparisons, simulations, new measures, and manhourtables. A great deal of that was verified in practice during the plant erection. I surveyed the results and analyses ofas-built designs. On many occasions, I sought a compromise between different opinions and standpoints. Too manythings collected on too many places. Finally, I decided to write this manual for discriminative estimators. It isimportant to understand that there are no identical projects or jobs in this business, that each project is specific andthat no automatism or copying is possible. Approach to any job should be serious and professional and a technicalcalculation should be made with the assistance of this Manual. Many people try to include the man hours from thetables into the computer systems, which I oppose. Those are the people, which instead of using a computer, acomputer uses them. An estimator himself must choose the values and define the man hours taking into account allthe elements that might have any influence on them. Only when the relevant man hours are estimated and selected,a computer can be used. A saying “Switch on your brain before switching on the computer” should be followed.The most complex work in developing these man hours was the work on the man hours for piping above ground. Abasis I used was a system for estimating the value of erection works of a German Company LINDE, which Icompleted and modified. Generally, for elaboration of the man hours for erection/installation of process equipment,I used the English man hours of the Oil and Chemical Plant Constructors Association, but I used other sources aswell.The source or the author was noted for other tables and if I modified them, I provided the modification basis. Wherethere are no such notes, I am the only author.A complete edition of this manual in the Croatian language and its sections were published in 1997 and2000. This is why I have not given a unified percentage of the production efficiency but each chapter has its own.Marko BuliæZagreb Croatia, 20032
CONTENTSpagePREFACE.2INTRODUCTION.11ABBREVIATIONS & UNITS.13CHAPTERI. PIPING ABOVE GROUND.14DERIVED OPERATING TIME STANDARD FORTABLES FACTOR OF BASIC ASSEMBLY1. PIPES (ANSI B. 36.10).141.1PIPE - INSTALLATION ON PROCESS PLANT.141.2PIPE - INSTALLATION ON PIPE RACK OR SLEEPER WAY.152.FITTINGS (ANSI B. GHT TEE.172.3.2REDUCED TEE.172.4REDUCERS - CONCENTRIC AND ECCENTRIC.181. PIPES (DIN 2448/2458).191.1PIPE - INSTALLATION IN PROCESS PLANT.191.2PIPE - INSTALLATION ON PIPE RACK OR SLEEPER WAY.211.3STEAM TRACING (ANSI & DIN).231.4INSTRUMENT AND CONTROL PIPING.231.5STEAM DISTRIBUTORS AND CONDENSATE COLLECTORSFABRICATED FROM PIPES AND FITTINGS.231.6STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS FABRICATEDFROM READY MADE DISTRIBUTORS FOR 4 CONNECTIONS.232. FITTINGS S - CONCENTRIC AND ECCENTRIC.283. FLANGES.303.1WELDING NECKS.303.2SLIP - ON.313.3SOCKET WELDING.313.4LAP JOINT STUB END.313.5BLIND.313.6ORIFICE COMPLETE.314. SMALL FITTINGS.324.1WELDOLETS, SOCKOLETS, NIPOLETS, etc.324.2HALF COUPLINGS FOR WELDINGS.324.3FITTINGS WITH SOCKET ENDS.324.4THREADED FITTINGS.323
5. VALVES. . .335.1VALVES WITH FLANGED ENDS.335.2VALVES WITH WELDING ENDS.345.3VALVES FOR THREADED ENDS.345.4PRESSURE GAUGES.345.5THERMOMETERS.34RATES FOR TENDER CALCULATIONS.351.MANHOUR ESTIMATE FOR INSTALLATION OF PIPING.352.EFFECT ASSESSMENT FOR QUICK CALCULATION.362.1PIPING IN PROCESS PLANT.362.2PIPES (CARBON STEEL - NOT INSULATED) - MEAN VALUE.372.3FITTINGS (CARBON STEEL) - MEAN VALUE.382.4VALVES - MEAN VALUE.392.5PIPE SUPPORTS.392.6AVERAGE DIAMETER - Manner of Calculation.393.RATES FOR INSTALLATION OF POLYETHYLENE PIPING.404.RATES FOR ERECTION OF PVC & FRP PIPING.415.CARBON STEEL PIPING CEMENT LINED INSIDE.416.PIPING MADE OF STEEL AND GREY CAST-IRON.427.RATES FOR PIPING BASED ON INCH-DIAMETER (ID).438.RATES FOR UNITS OF OPERATION - BASED ON INCH-DIAMETER (ID).449.RATES FOR PIPING WELDING.4610.MAN HOURS FOR WELDING OF PIPING.4711.WORK CALCULATION - MAN HOURS FOR PIPING MODIFICATION AT SITE.4812.INSTALLATION OF PIPING ABOVE - GROUNDPrefabrication and installation breakdown.49CHAPTERII. PIPELINES.501.PIPE TRANSPORT.502.PIPE STRINGING.513.BENDING OF PIPES.514.PIPE JOINTING.525.WELDING.536.WRAPPING.537.LAYING IN TRENCH.538.SPECIAL POINTS.548.1BORING UNDER ROADS AND RAILROADS.548.2BREAK OUT OF ROADS.548.3CONNECTING PIPELINE SECTIONS.548.4CROSSING WATERCOURSES.558.5INSTALATION OF CLEANING STATIONS.558.6PUTTING UP PIPELINE MARKERS.558.7OTHER SPECIAL POINTS.559.PRESSURE TESTS.5610.PRELIMINARY AND FINISHING WORKS.564
CHAPTERIII. STEEL STRUCTURE ERECTION. . .571. BASIC MAN HOURS - UNIT.571.1SORTING THE STRUCTURE.571.2PRE-ERECTION OF STRUCTURE.571.3TRANSPORT OF STRUCTURE TO ERECTION PLACE.571.4INSTALLATION OF ANCHOR BOLTS.571.5STRUCTURE ERECTION.571.6INSTALLATION OF LOST FORMWORK.581.7INSTALLATION OF WIRE ROPE CLAMPS.581.8REAMING OF HOLES.581.9BOLTING FROM SCAFFOLDING.582. ERECTION OF MISCELLANEOUS STEEL STRUCTURES.592.1BASIC MANHOUR RATES.593. CORRECTION FACTORS.594. STEEL STRUCTURES IN OIL REFINERIES AND PETROCHEMICAL PLANTS.614.1LIGHT STRUCTURE (to 30 kg/m).614.2MEDIUM-WEIGHT STRUCTURE (31 60 kg/m).614.3HEAVY STRUCTURE (above 60 kg/m).614.4MISCELLANEOUS STRUCTURES.614.5PIPE HANGERS AND SUPPORTS.615. ERECTION AND DISMANTLING OFMISCELLANEOUS STEEL STRUCTURES.625.1ERECTION OF STEEL STRUCTURES - ACC. TO THE WEIGHT.625.2MISCELLANEOUS STRUCTURES.625.3REMOVAL OF STEEL STRUCTURE AND MISCELLANEOUS ITEMS.66CHAPTERIV. ERECTION OF EQUIPMENT IN PETROCHEMICAL INDUSTRY.671. STATIONARY EQUIPMENT.671.1ALL EQUIPMENT TO 0,5 TON.671.2TOWERS above 0,5 TON.671.3TOWERS CONSISTING OF MORE PIECES.671.4PACKAGE UNIT.671.5OTHER EQUIPMENT.671.6BRIDGE CRANES.671.7LIFTS.671.8ELECTROSTATIC PRECIPITATORS.681.9MARINE LOADING ARMS.682. ROTARY EQUIPMENT.682.1CENTRIFUGAL PUMPS.682.1.1MAN HOURS BASED ON POWER [kW].682.1.2MAN HOURS BASED ON WEIGHT [kg].692.1.3MAN HOURS BASED ON THE CAPACITY.692.2COMPRESSORS.702.2.1COMPRESSORS DRIVEN BY ELECTRIC MOTOR.702.2.2COMPRESSORS DRIVEN BY GAS TURBINE.705
3. TOWERS & VESSELS - INSTALLATION OF INTERIORCOMPONENTS & EQUIPMENT.713.1INSTALLATION OF TRAYS AND DEMISTERING PADS.713.2VESSELS & TOWER PACKINGS.713.3OPENING AND CLOSING OF MANHOLES.713.4ERECTION OF PLATFORMS, LADDERS AND FLOOR GRIDS.724. EQUIPM