Costing of Pipelines - 1 _ PIPING GUIDE

8/12/2019 Costing of Pipelines - 1 _ PIPING GUIDE

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Piping Design Process Piping PDMS Piping Pipe Calculator

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Ankit Chughgoogle.com/+AnkitChugh

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detailing.

2. Materials: The cost of all bought out materials , i.e. pipe flanges, fittings, valves, expansion units, etc.

3. Fabrication: The cost of site fabrication , off- site fabrication, done in a

shop away and adjacent to site.

4. Erection: The cost of erecting on-site fabricated pipe work and pressure testing. This includes

preliminaries, variation orders and error

rectification if any.

Economic

Fluid Velocity (ft/s)

Pipe diameter d (in)

Pressure drop available(Ib/in2) / 100 ft

Remark

Pump discharge pipe

(d/3 + 5) ft/s2.0

Pump suction pipe

(d/6 + 1.3) ft/s0.4

Steam or gas line

20 d ft/s0.5

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.

7. Suggested Steam Pipe Velocities in Pipe Connecting Steam Turbines

SERVICE - STEAM TYPICAL RANGE -ft/s

Inlet to turbine 100 - 150

Exhaust, non-condensing 175 - 200

Exhaust - condensing 400 500

8. Relative Economics of Various Materials of Construction

S.No. Material Connection Factor

1

Carbon steel (C.S.), A-53,

seamless Welded 1.00

2

Carbon steel (C.S.), A-53,

welded galvanised Screwed 0.84

3 Wrought iron, galvanised Screwed 1.61

4Unplasticised polyvinyl

chlorideSock, weld 1.79

5 Carbon steel, lead lined Flanged 4.11

6 Carbon steel, PVC lined Flanged 4.76

7 Stainless steel Welded 15.00

9. Material Estimation

There are three main topics of pipe work estimation as mentioned below:

S.No. Stage Accuracy Basis

1 Preliminary +/- 25% Based on %age of total plant cost

2 First control +/- 20 % Based on completed P and Is etc.

3 Second control +/- 10 %Final P and I , all pipe work details, drawings,

material list etc.

10. Fabrication Cost Estimation

The contents of fabrication cost estimation comprise the following:

1. Fabrication

2. Fabrication / Welding

3. Welding

4. Supports

11. Erection Cost Estimation

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PDMS Articles

PDMS - REPRESENTATION

The Database Listing Form

Positioning Radial Nozzles

PDMS SYNTAX'S

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PDMS Positioning Commands (Piping)

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PDMS SYNTAX EXAMPLES

STRUCTURE, EQUIPMENT & OTHERS

Remaining Commands of PDMS

PDMS COMMANDS: PIPING COMMANDS

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The contents of fabrication cost estimation comprise the following:

1. Erection

2. Supports

3. Testing of completed pipelines

12. Rates for Fabrication and Erection

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 contractors 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.

c) PVC Piping: Rs.45/- per meter length.

d) Cu Piping: Rs. 100/- per inch dia metre.

e) Pipe fitting reducer, bend etc.

SS 304: Rs. 125/- per inch dia

MS: Rs. 60/- per inch dia

Copper: Rs.140/- per inch dia

f) Fabrication and erection of MS supports= Rs. 4500/- per MT.

Q. Find out the labour cost for making a MS reducer of 2" x 4" size?

Ans: MS Reducer 2" x 4" = 4 x60 = Rs.240/- (Considering 4" dia)

Q. Find out the labour charges for fabrication and erection of a MS pipeline of 50 NB (2") MS B or MSC of 400 m length fabrication and erection?

Ans: 2 x 400 x 45 = Rs.36,000/-

Typically the quantum of pipe fabrication, erection and testing of pipe work shall be expressed as shown

below:

1. MS B and C class piping : 12450 inch m tr

2. SS 304 piping : 2850 inch mtr

3. PVC piping : 285 inch mtr

4. Cu piping: 695 inch mtr

14. Typical Calculation for Piping Cost

Raw material Factors SS Condensortube

CopperCondensor tube

Sheet width mm

Raw material base

rateRs/kg 78.50 140.00

Packing and

forwardingRs/kg 1.00 0.79 1.40

Conversion Rs/kg 40.00 50.00

Excise % 16.00 19.09 30.62

Sales tax/ VAT % 4.00 5.53 8.88

Insurance % 0.20 0.29 0.46

Transportation Rs/kg 2.00 2.00

Total Cost Rs/kg 146.19 233.37

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Modvat Benefit Rs/kg 19.09 30.62

Cost to Co. Rs/kg 127.11 202.74

Rs/mtr 93.81 246.74

15. General Scope of Work for Piping Fabrication and Erection

Fabrication, cutting, welding, assembly in position as per drawing.

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 ofnon return va lve, 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.

After assembly, complete pipeline to be welded by taking necessary

precautions to avoid stresses. If stresses developed , those are to be

removed and w elded as per standard practice and instructions of the

site co-ordinator.

One in-position weld is allowed for line which cannot be welded on

ground.

After welding , finishing and grinding , pipeline to be hydraulically tested at pressure specified in the

order.

After hydraulic testing, pipeline to be painted with redoxide ( one coat).

After painting, pipeline to be assembled in position and with necessary

clamps and supports.

16. List of Tools, Tackles and Machinery Required to Carry Out the Piping Works

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

17. Contractor Manpower List of Piping, Fabrication and Erection

For piping, fabrication and erection:

1. Experienced Mechanical Engineer as in-charge

2. Supervisor3. Highly skilled fitter for SS 304

4. Highly skilled fitter for MS B and C class piping and fabrication

5. Welders for SS TIG, Welders for SS Tacking, Welders for MS Tacking

6. Helpers/Riggers

18. Additional Cost Information

Piping cost may v ary between 20 to 66 %.

Piping cost may be a headache to the estimator as he/she is asked to

give the cost even before engineering and execution.

The estimator needs to convert the preliminary flow sheet into a fair

approximation of an actual design.

The estimator should have the skill to draw quick and rather accurate

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free hand isometric sketches, which will be of inestimable value.

19. Methods used for Estimation

Piece by piece method ( Detailed costing)

Finagling factor ( 40 % of equipment cost)

N system.

20. N System

The N system is based on the fact w hich 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 Nsystem was introduced by R.A. Dickson (Chem. Eng. Nov 1947, PP 121-123)

21. How to use the N System

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.

Continued to Costing of Pipelines - 2

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