Pressure Vessel Coster

7/18/2019 Pressure Vessel Coster

http://slidepdf.com/reader/full/pressure-vessel-coster 1/204

VESSEL COSTER

Pressure Vessel

Cost Estimating

Programby

for

3100 South Gessner Road Suite 610

Houston, TX 77063

USA

web site: www.codeware.com

Phone: 713 - 781 - 6636Fax: 713 - 781 - 6685e-mail: [email protected]

[email protected]





LICENSE AGREEMENT

< LICENSE AGREEMENT - i >

1LICENSE AGREEMENT

1) ACCEPTANCE

By use of the program contained herein, Customer agrees to accept on the followingterms and conditions a nontransferable and nonexclusive license to use this program.

2) TERM

This Agreement shall be in force from the date Customer purchases this program licenseuntil terminated by Customer or by Codeware. Customer may terminate the agreementby returning to Codeware the original program, activation device(s), documentation andany and all copies of disks and documentation. Codeware may terminate this Agreement

upon written notice to the Customer if Customer fails to comply with any of the terms ofthis Agreement.

3) LICENSE

Each program license granted under this Agreement authorizes the Customer to use theprogram on one computer installation at a time. The program may be stored on morethan one computer so long as it is in actual simultaneous use on only one computer. Useon networks is permissable with specific permission and under some restrictions. ThisAgreement and any of the licenses, programs, or materials to which it applies may not beassigned, sublicensed, or otherwise transferred by Customer without prior writtenconsent from Codeware.

4) COPYRIGHT

This program may not be reverse assembled or reverse compiled, in whole or in part.

5) DISCLAIMER OF WARRANTY

This program is provided "as is", without warranty of any kind, either expressed orimplied, including, but not limited to, the implied warranties of merchantability andfitness for a particular purpose. The entire risk as to the quality and performance of theprogram is with you. Should the program prove defective, you assume the entire cost of

all necessary servicing, repair, or correction.

6) LIMITATION OF LIABILITY

In no event will Codeware be liable for any damages, including any lost profits, lostsavings or other direct, incidental, or consequential damages arising out of the use orinability to use such program even if Codeware has been advised of the possibility ofsuch damages, or for any claim by any other party.



LICENSE AGREEMENT

< LICENSE AGREEMENT - ii >

7) GENERAL

If any of the provisions of this Agreement are invalid under statute or rule of law in any jurisdiction, they are to that extent to be deemed omitted from this Agreement. Anyother act involving reproduction, transfer, use, rental, or other dealing in the original orcopy of the program is prohibited and will violate the terms of the license agreement.

Trademarks

Windows 95, Windows 98, Windows NT, Excel, Access and Word are registeredtrademarks of Microsoft Corporation.

HP LaserJet is a registered trademark of Hewlett Packard Company.

Pentium is a registered trademark of Intel Corporation.

Formula One is a registered trademark of Visual Components. This product contains

Formula One from Visual Components. Copyright 1994 - 1997. All rights reserved.

Printing History

Revised May 2004. Changes indicated by revision bars.

The information contained in this document is subject to change without notice.



TABLE OF CONTENTS

< TABLE OF CONTENTS - i >

1TABLE OF CONTENTS

LICENSE AGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

INSTALLING COSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hardware Key Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Installing Coster Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Network Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Uninstallating Coster Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

COSTER QUICK START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Estimate a Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Review the Data Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

USING COSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

How To Use Coster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Coster Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Coster Dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Keys used in Coster: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Customizing Coster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Navigating and Modifying the Database Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

FILE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Cost a Codeware File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Costing the Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Retrieve Coster Estimate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Open or Cancel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Backup Coster Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Repair Coster Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

LABOR MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fitup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Vacuum Rings (layout, fitup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Grinding Rates (normal, flush, smooth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Davit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Platform/Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Saddles (fit ting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Skirt Base Ring (layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Tray Support Rings (layout, installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

MATERIAL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Couplings/Fittings Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1



TABLE OF CONTENTS

< TABLE OF CONTENTS - ii >

Cylinder Costs (purchased) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Flanges (ASME B16.5/16.47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Formed Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Pipe Cost Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Plate Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Structures/Rings/Tray Supports Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Misc Items (user defined) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Stock Plate Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Davit Material Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Gasket Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Platform/Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Stud Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Ring Type Joint R Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Ring Type Joint RX Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

DEFAULTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Alias Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Currency/Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Hydrotest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

COSTER SPREADSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

General Spreadsheet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Insert Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Customize the Template (CostSS.xls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Coster Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Coster's Estimate Spreadsheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Estimate Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

X-Ray Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Vessel Total Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Plate Usage (Bill of Materials) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Summary (Create a Customized Report) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

DATABASE TREE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

HELP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

About Coster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Coster Directories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Database Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

CALCULATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1General Calculations For All Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Interpolation Method Used by Coster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

How Coster Determines Material Layout and Plate Requirements (Default Method) . . . . . . . . . . 11-3

How Coster Determines The Layout of Conical Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

How Coster Determines The Layout of Skirt Base Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

Cutting Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

Cutting Sketches With Drop Dimensions (includes allowance for squaring of plate) . . . . . . . . . 11-10

Custom Cut Plates (Alternate Material Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13



TABLE OF CONTENTS

< TABLE OF CONTENTS - iii >

Purchased Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16

Cylinder Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16

Transition Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20

Vacuum Rings Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23

2:1 Heads, F&D Heads, Hemispherical Heads Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27

Flat Heads Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29

Body Flange Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35

ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2 . . . . . . . . . . . . . . . . . . . . . 11-35

Packed Bed Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41

Platform/Ladder and Top Head Platform Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41

Tray Support Ring Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42

Insulation/Lining Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44

Saddles Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46

Skirt Base Ring Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-52

Skirt Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-64

Nozzle Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-68

Leg Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-87

Normalization and Impact Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-93

Davit Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-94

Grinding Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-95Blasting/Cleaning Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-95

Paint/Primer Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-96

Hydrotest Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-96

Post Weld Heat Treatment (PWHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-97

X-Ray Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-97

Welding Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-97

APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Coster Database Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i



TABLE OF CONTENTS

< TABLE OF CONTENTS - iv >



INSTALLING COSTER

< INSTALLING COSTER 1 - 1 >

1INSTALLING COSTER

System Requirements

Coster requires a Windows 95/98/NT4 Pentium computer or better with:

32 MB RAM minimum and 40 Meg free disk space.

A hardware key supplied by Codeware.

The hardware key, also called dongle or program activator, is needed to operate Coster. The keyplugs into the parallel printer port on the back of your computer. The cable to your printer thenplugs into the key. If the key is not installed, the following error message will be displayed.

Codeware Win 32 Key not found (15)

On some computers this message may also be displayed if the printer is turned off or is not on line.

COMPRESS version 5.x and version 6.x vessel files are compatible with Coster prior to andincluding build 963 (December 12, 2003). COMPRESS version 6.x vessel files generating .xml fileoutput are compatible with Coster builds 964 (February 19, 2004) and later.

Hardware Key Installation

Turn off the computer and printer if the printer is connected. Plug the key into the parallel printer

port of your computer. Reconnect the printer cable and turn the power on. You may find itconvenient to buy a short extension cable and plug the key into the middle of the two cables. Thismakes it easier to move the hardware key or to use multiple keys.

Installing Coster Files

Coster is distributed on a self-activating compact disk. To install Coster insert the CD and followthe prompts as they are presented.

Your computer may have its auto start feature disabled in which case inserting the CD will have noeffect. If this happens, go into Windows Explorer, locate the folder Coster on the CD, enter that

folder, and activate by double clicking the application file setup.exe. This will start the installationprocedure and present you with prompts to follow.

You will need to reboot your computer in order to run Coster the first time.

Network Installation

Coster will operate on Novel or Windows NT Server networks. A different hardware key is requiredfor network operation. You will be prompted for the type of installation to be performed (i.e., localor networked) when Coster is installed.



INSTALLING COSTER

< INSTALLING COSTER 1 - 2 >

Uninstallating Coster Files

You may uninstall Coster by using the Coster uninstall option on the program files menu or by usingthe Add/Remove Programs option located through the Start/Settings/Control Panel. You mayencounter a few warning messages during program removal as follows:

Error removing program groups

Some components could not be removed from your computer

If files exist in the Coster directory which were not originally installed by Coster, or theCOMPRESS program is installed under the same program group name (usually Codeware), thesemessages may appear. Files such as new vessel files (.cw6, and .xml), cost estimates (.xls), andbackup files of the database and spreadsheet template will cause this message to appear. Click OKand continue with the program uninstallation. These messages will not affect the reinstallation oroperation of Coster.

Do not remove Coster simply by erasing files. This could have unpredictable effects on yourcomputer.



COSTER QUICK START

< COSTER QUICK START 2 - 1 >

2COSTER QUICK START

This chapter is included to get you up and running with Coster as quickly as possible without havingto worry about all aspects of the program's menus, dialog boxes, methods, etc. These are fullydescribed in the chapters which follow. Here, we will give you a brief overview of how Costerworks using the Sample1 file.

Estimate a Vessel

Estimate a vessel by clicking on File, then Cost a Codeware File. Choose one of the sample vesselsfrom the available vessel files by double-clicking. You will be presented with a User SelectableItems dialog. Select how you want your vessel to be finished and click OK or press F3. (As ageneral rule, F3 advances to the next dialog). Now Coster searches for information among its data

libraries. If necessary you will be asked to supply more cost or labor information. Finally, Costerasks for total x-ray costs. Supply these values and press Enter.

The Vessel Detail Cost sheet of the cost estimate is displayed. You can move about the estimate

using the cursor keys. Notice the level of cost detail that is reported. Notice that the individualworksheet cells contain not just numbers but formulas. You can change the quantity of most items,and this change will be reflected in the labor hours and material costs for this item as well as the totalcosts for this vessel.

The estimate is divided into three main sections. The first section shows basic vessel elements suchas shells and heads. The second section itemizes nozzles and flanges. The third section presentsmiscellaneous items and user defined items which have been added after the estimate is complete.

There is also a "bottom line" summary of labor, material and total cost for the entire vessel.

A Bill of Materials (BOM) is displayed on the second sheet of the estimate. The BOM itemizes all

the parts of the vessel which were considered for costing. The sections of plate used for cylindersand transitions are listed. Pipe sections required for nozzles are listed. Waste materials areaccounted. There is also a listing of the plate usage (materials used, drop remaining, scrap material)and associated costs used to fabricate each component. Following the plate usage section is a tableshowing the weld type and radiography. Cutting sketches that were used for this vessel are shown atthe bottom of the bill of materials sheet.

A Summary Report is presented on the third sheet of the estimate. The Summary is a means to

display "bottom line values". The Summary is user customizable by modifying the existingSummary sheet.

Review the Data Tables

Let's look at the data tables which form the basis of Coster's calculations. Click on the "X" button atthe top right of the spreadsheet menu to close the spreadsheet and return to the main menu. From themain Coster menu select Material, then Plate Costs. This is a typical table. Move the cursor throughthe table and you will see costs per 100 lb for each material for various thicknesses and plate widths.Notice that many of the materials list a non-zero cost for the first thickness and the last thicknessonly. Using this information, Coster will interpolate costs for plate thicknesses and plate widths



COSTER QUICK START

< COSTER QUICK START 2 - 2 >

between the non-zero values. Remember that even though there are not many data points Coster

interpolates, so what you see as four data points is really a three-line curve sufficient to convey theinformation.

You can change the data and also add information and new materials to this table. To add new platecosts simply type in the new values (use the Insert Field option on the Edit menu of the database toadd a field to a table). Add as many new materials with corresponding plate width as you wish.New materials can be added in the cell marked by the asterisk at the bottom of the table. To add newmaterials type in the new material name or click the down arrow to select from a list of materials.Coster will sort the table by material name and then by plate width. The sorted table will bedisplayed when the table is reopened.

To view another table click the down arrow on the table drop down box for a list of tables in the

database and select another table. Customize the tables by revising and adding to the default valuesprovided with your own data.

Click on the drop down box, and select Cylinder Forming Labor. Here we see labor hours required

to form and tack cylinders and cylindrical skirts as a function of thickness and inner diameter.

Welding labor is a special case because it allows you to supply data for either weld deposition rate orwelding rate. Select Labor, Welding, Deposition Rate, Longitudinal Seam from the Main Menu.You will see weld deposition rate as a function of thickness and metallurgy. There is also amultiplier for full joint examination in this table.

Go back to the main menu by clicking the OK pushbutton or the "X" button in the top right corner of

the database. Now select the Defaults Menu. Here, you can set all default values for clips (lining,insulation), currency/units, finishing (blasting/cleaning), hydrotest, other (fabrication, labor rates,program output, tray supports), and welding (weld detail, diameter/longitudinal weld seams ratio,

fillet welds). You can also make revisions to the alias lists. The alias lists tell Coster that aparticular material can be costed using the same properties as another material. This reduces thequantity of data which must be supplied for material costs. In addition you may select whether platematerials will be cut to exact component dimensions without including waste, whether Coster willselect suitable plate sizes and incorporate a waste factor in the associated costs or whether thecylinders are purchased (formed and tacked only or formed, tacked, and welded).



USING COSTER

< USING COSTER 3 - 1 >

3USING COSTER

Vessel Coster estimates the cost of fabrication for pressure vessels. The vessels can be designedusing either COMPRESS or Vessel Modeler.

Coster contains a number of tables of costs, labor hours, and other data to calculate an estimate.Coster uses this information to automatically produce a final cost estimate in the form of anExcel-compatible workbook. The tables contain both material and labor data.

Material tables include costs of plate, formed heads, pipe, flanges, weld rod, fittings. Labor tablescontain information on the number of hours required to perform various operations involved invessel fabrication. You can customize Coster to your shop's specifications by changing or adding tothe appropriate material or labor table.

How To Use Coster

Coster is written as a true 32-bit Windows program and generally follows Windows terminology and

operating conventions. Therefore, to learn the basics of screen operation, refer to your Windowsdocumentation. This manual will address operations unique to Coster and will begin with describingthe Main Menu.

Coster Main Menu

Figure 3-1 Coster Main Menu

The Coster Main Menu bar contains the following menu items: File, Labor, Material, Defaults,Spreadsheet, Database Tree and Help.

While you are costing a vessel, you may be asked to input additional information on a "pop-up"dialog.

Coster Dialogs

Dialogs are used to provide additional information while costing a vessel and to enter default values

that will be saved and used for subsequent estimates.



USING COSTER


Keys used in Coster:

- F2 - Allows you to edit a cell within the spreadsheet.- OK pushbutton - accepts all values input and moves you to the next dialog- F3 -- accepts all values input and moves you to the next dialog (similar to the OK

pushbutton.

Coster uses the following abbreviations when referring to metallurgy:

- CS = Carbon Steel- SS = Stainless Steel- AL = Aluminum- Cu = Copper

- Cu Alloy = Copper Alloy- Ni = Nickel- Ni Alloy = Nickel Alloy- Ti = Titanium

- UHT = UHT (ferritic steels with properties enhanced by heat treatment)- Zi = Zirconium

Customizing Coster

Before using Coster, we strongly recommend you invest some time checking the values in the tablesthat are relevant to your company. Some editing of the defaults provided with Coster will benecessary because of your shop's individual circumstances. Before you change any information

presented on Coster's default tables to fit your company's requirements, please refer to “CosterTables” on page 8-6 for guidelines to follow.

Also, because labor and material costs fluctuate over time, occasional revisions will be necessary tokeep your cost information up to date.

Features

Plate Selection

When choosing stock plates to fabricate the vessel, Coster looks at the Compress material used for

the component and tries to find this material on the Plate Costs table, Structures/Rings/TraySupports table, and the Material Properties table. If the material is not found Coster will searchthrough the alias list to find an equivalent alias material that has been previously cross-referenced. If

an alias name cannot be found, Coster will display the Standard Plate Material dialog.



USING COSTER


Figure 3-2 Standard Plate Material

If the material is found on the Material Properties table but the metallurgy has not been entered forthis material then the following dialog is displayed. Select the appropriate metallurgy for thecomponent described.

Figure 3-3 Metallurgy

With the metallurgy established, Coster looks for a suitable material to fabricate each component(see “Plate Selection” on page 3-2). If Coster cannot find a stock plate size that matches both thethickness and metallurgy, then the Plate Size - User Defined dialog is displayed to enter an

appropriate user defined plate size for estimating this component. The plate size(s) used forestimating will be listed on the Bill of Materials sheet on the cost estimate. If a user defined plate



USING COSTER


size was used, the letter U will be shown to the left of the plate description on the Bill of Materials

indicating that a user defined plate was used for estimating.

Figure 3-4 Plate Material Size

In our example, Coster was unable to locate a carbon steel material, 1.1075" thick on the Stock PlateSizes table. The component being considered and its dimensions are displayed to help you choose anappropriate plate size for this component.

Enter the desired material width and length. The plate size entered here is "remembered" by Costerfor this estimate only. In other words, the plate size for this material, metallurgy, and thickness willonly have to be input once and may be used for other components in order to estimate the cost of this

particular vessel. Coster assumes that this plate size has unlimited availability. However, if you wantthis plate size to be automatically available the next time a vessel is costed, you will need to add it tothe Stock Plate Sizes table (English or Metric).

Because Coster assumes that the length is the critical dimension of the component, girth seams willnot be added unless required due to the stock plate sizes available. If girth seams have been added tothe vessel, the letter G is displayed in the Bill of Materials to the left of the Size of Plate Required toCut Each Section column. The following message will also be displayed after the x-ray dialog:

Figure 3-5 Girth Seams Required



USING COSTER


Interpolation

An important feature of Coster is interpolation. Provided a minimum amount of data are available ona table, Coster can accurately interpolate "in-between" values to use for estimating.

If there is an uncommon size or cost then Coster's interpolation capability should not be relied uponto calculate the missing value on a table. For cost structures such as these insert a record in theappropriate table(s) with corresponding prices rather than have Coster interpolate these values.These "special" costs that you add to your table should not be used as one of the data points in theinterpolations discussed above since these "specialized" costs will be reflected in the interpolatedvalue. To prevent this, cells surrounding these "specialized" costs (cells above, below, left and right)should have non-zero values.

Coster will not interpolate values for flange costs or pipe costs as these costs vary greatly dependingupon standard sizes.

If Coster cannot interpolate a value on a table because there is not enough information available you

will be prompted to manually input a value.

Plate Material Alias List

When costing a vessel, an identical match must be made between materials specified in the vesselfile and materials in the Coster tables. This may seem simple until you consider that a single materialmay be specified in many ways. For example, the material SA 516 70 could also be called A 516 70or 516 70 or SA51670. In order to match two material names, Coster removes all spaces,

hyphens (-), greater than symbols (>), less than symbols (<), and equal signs (=) from both names tosee if they are the same. Material names are not case-sensitive, which means they can be uppercaseor lowercase or a mixture of both. Therefore, Coster would identify SA 516 70 and sa51670 as the

same material. To identify the material names A 516 70 and 516 70 with SA 516 70, you can set upa cross-reference or link between these names by adding them to the alias list in the Defaults - AliasLists menu. While estimating, Coster may display a dialog as shown below to allow you tocross-reference materials (add them to the alias list) during the costing process.

In this example, Coster could not find the plate material A 516 70 (material specified in the vesselfile) in the Coster Plate Costs database table while estimating. The Standard Plate Material dialog isdisplayed.



USING COSTER


Figure 3-6 Standard Plate Material

By selecting one of the materials listed (in this example, SA 516 70), Coster cross-references thetwo materials and adds the A 516 70 material to the plate alias list. Now these two materials willalways be cross-referenced or linked together for future estimating until you delete the material fromthe alias list. The next time the vessel file uses A 516 70 material, Coster will see that it iscross-referenced to the Coster material SA 516 70. Coster will look up all costing information fromthe database tables based on the SA 516 70 material, but the estimate material name will be listed asA 516 70. This cross-reference is saved in the Alias-Plate/Structures table in the CostDB.mdbdatabase.

We refer to this cross-reference as an alias name and we differentiate between the vessel file materialand Coster material by referring to them as alias material (vessel file material) and listed material(Coster material). Therefore, the vessel material A 516 70 becomes an alias name for the Costermaterial SA 516 70. The plate listed materials are the materials from each record in the Plate Costs,Structures/Ring/Tray Supports Material Costs, and Head Costs tables. As materials are added to ordeleted from these tables, the alias materials list will be revised to reflect the changes.

Before you begin estimating vessels, update the alias names by selecting Alias Lists from theDefaults menu. From this dialog you can update plate, pipe, coupling and flange alias lists. Addmaterial names that are commonly used in your vessel designs if they are not listed in the Costerdatabase tables.

Pipe Material Alias List

The Standard Pipe material list appears when a pipe material specified in the vessel file cannot belocated in Coster's pipe cost schedule tables or the pipe alias list. This dialog works in the same wayas the plate alias list. The cross-referenced material names are saved in the Alias-Pipe table.



USING COSTER


Coupling Alias List

The Standard Coupling material list appears when a coupling material specified in the vessel filecannot be found in Coster couplings costs tables or the coupling alias list. This dialog works in thesame way as the plate alias list. The cross-referenced material names are saved in theAlias-Coupling table.

Flange Alias List

The Standard Flange material list appears when an ASME B16.5/16.47 flange material specified inthe vessel file cannot be found in Coster's flange costs tables or the flange alias list. This dialogworks in the same way as the plate alias list. The cross-referenced material names are saved in theAlias-Flange table.

Navigating and Modifying the Database Tables

Print

Select the "Print" option from the File Menu on the Database menu bar to print the current table. Thetable will be printed with the date, time and page number. You may print individual records from thetable or the complete table. To select individual records, click in the left margin of the table withyour left mouse button while holding down the Shift key to select a block of records or the Alt key toselect single records.

Insert Record

All records are added at the bottom of the database table. Enter the new information in the recordmarked by the asterisk (*) and then press Enter. Coster sorts the table using the first field of the

table. The stud costs, gasket costs, slip on, lap joint, threaded, and socket welded flange costs tablesare sorted using the first and second fields of the table. The long weld neck and blind flange coststables are sorted using the first, second, and third fields of the table. The weld neck flange coststable is sorted using the first, second, third and fourth fields of the table. The sorted table will bedisplayed when the table is reopened.

Delete Record

Place the cursor in the record to be deleted, then highlight the whole record by clicking with themouse in the left margin. Press the Delete key.

Insert Field

Select Insert Field from the Database Edit menu, enter the new field name in the "Field Name" textbox and select the field that the new field will follow from the "Add After Field" drop down box.Field names must be inserted in ascending order. Fields may be inserted only if the table is notcurrently opened by another user.



USING COSTER


Figure 3-7 Insert Field

Delete Field

Place your cursor on the field to be deleted. Select Delete Field from the Database Edit menu and

click OK. Fields may be deleted only if the table is not currently opened by another user.

Figure 3-8 Delete Field

Split View

The "as-shipped" default used to display the database tables is a "split". The split freezes the firstfield of the table so that it is always displayed as you scroll across the remaining fields within thetable. To disable the split, select "Disable Split" from the Format Menu on the Database menu bar.To enable the split again, select "Enable Split" from the Format Menu.



USING COSTER


Figure 3-9 Split Table

Revising Currency and/or Units on the Database Tables

The currency and/or units of a table may be changed to customize the values to suit your

requirements. Coster will automatically update the table according to the currency and/or unitsselected. When tables are displayed with the currency and/or units box "greyed" out this means thatyou may not revise the currency/units for these tables. Currency and/or units may be revised only ifthe table is not currently opened by another user.

Global Update

The values in the database tables may be updated using the Update Table (global) option on thedatabase Edit menu. Material costs, labor costs and labor hours may be updated according to therecords that are highlighted. You may select one record by highlighting it or you may select morethan one record or the whole table. Highlight a block of records by holding down the Shift key and

clicking the left mouse button or highlight individual records by holding down the Alt key andclicking the left mouse button. The values in the records selected will be updated using themultiplication factor entered. Some tables are updated according to fields rather than recordsbecause of the format of these tables. The fields to be updated are highlighted in the same way therecords are highlighted. This global update option is unavailable for some of the database tablessuch as the Misc Items tables.



USING COSTER


Regional Settings

The regional settings for the "as-shipped" Coster database are English (United States). If theregional settings for your computer are different then Coster will update the database to reflect thesenew regional settings. Coster will update the database only if it can be opened exclusively (no otherinstances of Coster are running on the network). If there is already another instance of Costerrunning on the network and your regional settings are different than the settings on the currentlyopened database then the Coster program will not start because of this conflict.

Database Password

You may wish to protect your database by using a password to restrict access to your database.Currently the password cannot be set within Coster but may be set in Microsoft Access. After you

have saved the database with a password Coster will prompt you for the password before theprogram will start. Once you have provided the password Coster will allow you to modify thedatabase tables and will not prompt you for the password again until you exit and restart theprogram.

Lining

If the vessel is lined the following dialog appears:

Figure 3-10 Lining

Lining Cost

Enter the cost of the lining per square foot for the density and thickness indicated.

Lining Labor

Enter the labor hours required to line an area of 100 square feet.

If linings of different densities and/or thicknesses are used on a vessel, the Lining dialog will appear

for each density/thickness variation.



USING COSTER


Insulation

This dialog is similar to the Lining dialog above.



USING COSTER




FILE MENU

< FILE MENU 4 - 1 >

4FILE MENU

The File menu allows you to perform various operations on vessel files: cost a new file, retrieve apreviously saved cost estimate, backup Coster data, repair the Coster database, or exit the program.

Figure 4-1 File Menu

Cost a Codeware File

This option allows you to cost a Codeware file that has previously been saved.

Select Cost a Codeware File from the File menu. The Codeware Vessel Files dialog appears:

Figure 4-2 COMPRESS Files

Select a file for costing (for example, Sample3). Click Open. You can exit the costing process fromany dialog by selecting the Exit pushbutton.

Once a file is selected, Coster scans all vessel components, searching for the information

(metallurgy, plate thickness, diameter) required to determine a suitable material layout.

Coster then proceeds to the User Selectable Items dialog.



FILE MENU

< FILE MENU 4 - 2 >

Figure 4-3 User Selectable Items

The components affected by the inputs on this dialog are heads, cylinders, transitions, skirts andskirt base rings. Studs and gaskets are estimated for all nozzles with blind flanges using theinformation provided on this dialog. Weld neck, long weld neck, and blind flange costs are

determined in part according to the facing selected on this dialog. Just below the studs and gasketssection a message is displayed to indicate whether the cylinders are fabricated, purchased formedand tacked only, or purchased formed, tacked, and welded.

Cylinder -- Coster displays the method used for estimating cylinders. They may befabricated in house, purchased formed and tacked only or purchased formed, tacked andwelded.

Primer and Finish Painting -- Select the type of primer or paint to be used forestimating this vessel. The primer/paint types listed are from the Painting and Primerdatabase tables. Check "Inside" and/or "Outside" to indicate how to prime or paint the

above components.

Coats of Primer/Paint -- Enter the number of primer/paint coats to be applied. If thenumber of primer/paint coats entered is zero then no priming/painting will beconsidered.

Paint and Prime Stainless Steel Materials -- The default for this checkbox is"unchecked". If "unchecked" then paint and primer applied to the vessel will include



FILE MENU

< FILE MENU 4 - 3 >

only those components made from carbon steel material. If "checked" then paint and

primer applied to the vessel will include components made from both carbon steel andstainless steel materials.

Cleaning Method -- Select the desired metal surface preparation method. This list isformed from the methods entered on the Blasting/Cleaning dialog which may be selectedfrom the Defaults - Finishing menu.

Grinding Method/Inside and Grinding Method/Outside -- Select the type of grinding tobe applied to all welds on the inside and outside of the vessel.

Stud material (used with ASME B16.5/16.47 flanges) -- Select the stud material usedfor estimating this vessel. This list of stud materials displays all the materials found on

the Stud Cost table.

Gasket material (used with ASME B16.5/16.47 flanges) -- Select the gasket materialused for estimating this vessel. If the Flange Facing selected is RF then the list of gasket

material displays all the materials found on the Gasket Cost table. If the flange facingselected is RTJ (ring type joint) and the ring type selected is R then the list of gasketmaterial displays all materials found on the Ring Joint R Cost table. If the flange facingselected is RTJ and the ring type selected is RX then the list of gasket material displaysall materials found on the Ring Joint RX Cost table.

Flange facing (used with ASME B16.5/16.47 flanges) -- Select the flange facing (RF orRTJ) used for estimating this vessel. If the flange facing selected is RF (raised face) then

the ring type is disabled. If the flange facing selected is RTJ then the ring type is active.

Ring type (used with ASME B16.5/16.47 flanges) -- Select the ring type (R or RX)

used for estimating RTJ gaskets. This selection is available only if the flange facingselected is RTJ.

Costing the Vessel

Coster considers all vessel components, attachments, and nozzles that make up the vessel. Costersearches the data tables for density, weld rod cost, impact testing, normalization, labor, and materialcosts. If Coster cannot find the information it needs and cannot interpolate a value, then you will be

prompted for more information.

If Coster cannot find the vessel material in its database tables or in the alias lists, you will be

prompted to enter an alias name for this material.

If Post Weld Heat Treatment (PWHT) is required on this vessel for any component(s) an entry forPWHT will be shown on the estimate. Coster determines that "global" PWHT is required if thefollowing components all require PWHT -- ASME B16.5/16.47 body flange, ASME Section VIIIDivision 1 Appendix 2 flange, 2:1 head, f&d head, hemi head, flat welded head, transition, cylinder.Otherwise if PWHT is required on some but not all of these components then Coster determines that"local" PWHT is required. If global PWHT is determined then Coster will also add the weight of the



FILE MENU

< FILE MENU 4 - 4 >

saddles, skirt base ring and compression ring, legs (including leg base plate and leg pad), skirts, and

vacuum rings to the weight of the welded components. If the ASME B16.5/16.47 body flangerequires PWHT then the blind weight will be added to the weight of the welded components.Similarly the weight of the pad will be added if the nozzle to which it is attached requires PWHT.Global PWHT is calculated by multiplying the weight of the welded components by the cost per 100lb user-defined default from the Fabrication dialog on the Defaults - Other menu. The total PWHTand the weight of the welded components will be displayed on the estimate. If local PWHT isrequired you will be asked to enter a total cost for PWHT during the estimating process. The weightwill not be displayed on the estimate for local PWHT.

Figure 4-4 Local PWHT

The x-ray dialog is the last dialog displayed before the estimate.

Figure 4-5 Total X-ray Cost



FILE MENU

< FILE MENU 4 - 5 >

Total X-Ray Cost -- Enter the cost of x-ray for the entire vessel. Coster calculates the

total weld lengths based on the type of weld and type of radiography (full, spot, none) forthe vessel and displays these totals as a guide when entering the total x-ray cost. This listof welding information is also displayed on the estimate at the bottom of the Bill ofMaterials sheet.

Retrieve Coster Estimate

Figure 4-6 Retrieve Coster Estimate

File name -- Enter the name of the workbook (with a .xls extension) to retrieve.

Files of type -- The type of files displayed are Microsoft Excel Files (*.xls)

Open or Cancel

Select Open to retrieve the .xls workbook. Select Cancel to return to the main menu withoutretrieving a workbook.

Backup Coster Data

Select Backup Coster Data from the File Menu to back up the CostDB.mdb and CostSS.xls files.



FILE MENU

< FILE MENU 4 - 6 >

Figure 4-7 Backup Coster Data

Select the drive and directory to back up your files. Coster will create a copy of the CostDB.mdband CostSS.xls files in the selected directory. The names of these files will be CostDBbk.mdb andCostSSbk.xls respectively. This option is only available if the database can be opened exclulsively

(no other instances of Coster are running on the network).

Repair Coster Database

This option will reduce the size of your database so you may select this option periodically tomaintain a more reasonable size for your database.

This option will also attempt to repair a database file that has been marked as possibly corrupt by anincomplete operation. This may occur due to a power outage or computer hardware problem. Thisoption will validate all tables and indexes, and any data that cannot be repaired will be discarded.An error will be displayed if the database cannot be repaired. Choose this option if your database is

behaving unpredictably.

This option is only available if the database can be opened exclusively (no other instances of Coster

are running on the network).



LABOR MENU

< LABOR MENU 5 - 1 >

5LABOR MENU

The Labor menu accesses Coster default labor tables.

Figure 5-1 Labor Menu

Fitup

The following fitup labor tables are included: cylinder/cylinder, cylinder/transition, flatwelded head (sketches (c), (e), (f), (g), (h)), formed head/cylinder (includes formedheads and flat welded head sketches (b-1), (b-2), (d))), nonradial nozzle, skirt. Thesetables contain labor hours to fit up one component to another based on componentthickness and diameter. The diameter and thickness used to read the labor hours fromthese tables will be determined as follows: cylinder/cylinder fitup will look up thethickness and diameter of the cylinder with the larger OD (if the OD's are equal then use

the first cylinder thickness and diameter), cylinder/transition will use the cylinderthickness and diameter, flat welded head will use the head thickness and head OD,formed head/cylinder will use the cylinder thickness and diameter, and skirt fitup willlook up the thickness and diameter at the top of the skirt. The nonradial nozzle fitup is a

factor based on the radial angle (degrees) which is used to increase the nozzle installationlabor hours for nonradial nozzles.

Forming

Cylinder/Straight Skirt -- The Cylinder Forming Labor table displays the labor hoursrequired to form cylinders, straight skirts and fabricated nozzles as a function ofcomponent thickness and component ID.



LABOR MENU


Transition/Conical Skirt -- The Cones and Skirts Forming Labor table displays the

labor hours required to form cones and conical skirts as a function of componentthickness and component ID.

Heads

Bevel (all heads) -- The Head Bevel Labor table contains labor hours to bevel the head.These labor hours will be included in the Forming Labor column of the estimate.

Layout (flat welded head) -- The Head Flat Layout Labor table contains labor hours tolay out flat welded heads based on head thickness and head OD.

Machining (flat welded head) -- The Head Flat Machining Labor table contains

machining labor hours for flat welded heads based on groove depth and head OD.

Vacuum Rings (layout, fitup)

The Vacuum Ring Labor table displays the labor hours required to lay out and fit up vacuum rings asa function of vessel OD.

Nozzle Installation

Figure 5-2 Nozzle Installat ion Submenu

The labor costs for nozzles are calculated using the manufacturing labor cost default from the LaborRates dialog on the Defaults - Other menu (see page 7-6).

Coupling to Vessel -- The Coupling Installation Labor table displays the labor hoursrequired to install, layout and fitup couplings as a function of coupling type, vesselthickness and coupling nominal size.



LABOR MENU


Boltup Blinds -- The Blind Flange Labor table displays the labor hours required to

attach a blind flange as a function of flange size and class. If a blind flange is notattached to a nozzle, hydrotest labor hours are calculated by using the blind flange labormultiplied by 2.

Flange to Nozzle -- There are two separate Flange to Nozzle Labor tables - fitup laborand welding labor. These tables contain flange fitup or welding labor hours as a functionof flange type (weld neck flange or other ASME B16.5/16.47 flange except long weldneck flanges and HB types), metallurgy, nozzle OD and pipe schedule. A field fornominal size has been included for informational purposes only. Fields and records mustnot be added or deleted from these tables.

Nozzle/Long Weld Neck -- The Nozzle to Shell or Head Labor table displays the labor

hours required to attach the nozzle or long weld neck (layout, fitup) to the shell or headas a function of vessel thickness and nozzle OD.

Pad to Nozzle/Long Weld Neck -- The Pad to Nozzle Labor table displays the labor

hours required to attach the pad (layout, fitup) to the nozzle or long weld neck as afunction of pad thickness and nozzle OD.

Grinding Rates (normal, flush, smooth)

The Grinding Labor table displays the grinding rates as a function of metallurgy, grinding type(normal, flush or smooth grinding) and component thickness. This table is used for cones, skirts,heads, and cylinders according to the long seam and circumferential seam weld lengths.

Fabrication

Misc (cutting, welding supports, drilling, bevelling) -- The Miscellaneous FabricationLabor table displays labor hours for various operations such as cutting, fillet and groovewelding, and drilling as a function of metallurgy and component thickness. Thesecutting and fillet welding rates are used for estimating saddles and these cutting, drilling,fillet welding, groove welding, and gusset welding rates are used for estimating skirtbase rings. The bevelling field is used to calculate labor hours for the seams oncylinders, transitions, and skirts.

Drilling -- The Drilling Labor table displays drilling labor for appendix 2 flanges.

Machining -- The Machining Labor table displays labor hours for appendix 2 flanges.

Davit

The Davit table is actually one table containing davit cost, labor hours, and weight, but within Costerit appears as if there are three separate tables (one table for davit material costs, one for davit laborhours and one for davit weight). Each field heading displays the class and the type of davitinformation -- cost, labor, or weight. Fields and records may be inserted and deleted through theEdit menu on the Coster database. When adding fields Coster automatically adds "# cost",



LABOR MENU


"# labor", or "# weight" to the class field name entered by the user to complete the field heading.

Using the data in this table Coster calculates the material cost, labor hours, and weight of each davitfor manway openings. The davit weight is listed on the Bill of Materials sheet in the estimate, andthe material costs and labor hours are displayed in the Miscellaneous section of the Vessel DetailCost sheet. The Davit cost table can be accessed through the Material menu and the Davit Labor andDavit Weight tables can be accessed through the Labor menu.

To include davits in the estimate, check the "Always Add Davits" checkbox and enter a value for"Minimum Manway Diameter Required to Add Davits" on the Fabrication tab of theDefaults - Other menu. Davits will then be estimated for all manway openings equal to or largerthan the minimum specified.

Finishing

Paint

The Paint (finishing) table contains material costs and labor hours for each paint type. As the paint

labor rate does not vary according to paint type there is only one labor rate which is located on theDefaults - Other menu Labor Rates dialog.

Paint Application Labor -- The time required to apply 1 coat of paint to 100 squarefeet of vessel surface.

Paint Cost -- The cost per gallon of the paint being used.

Paint Coverage -- The number of gallons of paint required to cover 100 square feet ofvessel surface.

Paint Standard Container Size -- If you enter a zero for standard container size,Coster will report the paint material cost based on the exact quantity of paint used. If thestandard container size entered is anything other than zero, Coster rounds the quantity ofpaint used up to the next standard container size. This is done because leftover paintcannot usually be used for the next project.

Primer

The Primer table is contains material costs and labor hours for each primer type similar to the painttable above. As the primer labor rate does not vary according to primer type there is only one laborrate which is located on the Defaults - Other menu Labor Rates dialog.

Legs

The submenu for Legs includes the following tables: Legs Labor, Legs Labor - Base Plate, and LegsLabor - Pad. The Legs Labor table contains labor hours to layout/burn, fitup, and weld legs basedon the leg major dimension. The Legs Labor - Base Plate table contains labor hours to layout andfitup the base plate based on the base plate major dimension. The Legs Labor - Pad table containslabor hours to layout and fitup the pad based on the pad major dimension. The leg, base plate, and



LABOR MENU


pad major dimensions are determined by comparing the length and width (or in the case of the leg

compare the width and depth) and using the larger dimension as the major dimension.

Platform/Ladder

The Platform/Ladder Cost and Labor table contains material costs and labor hours for platforms,railings and ladders. Since this table contains both material costs and labor hours it can be accessedfrom both the Labor and Material menus. Using the data in this table Coster calculates platform,railing, and ladder material costs, labor hours, and labor costs for display in the Miscellaneoussection of the estimate. The weights of these items are listed on the Bill of Materials in the estimate.

Saddles (fitting)

The Saddles Fitting Labor table displays labor hours to fit the saddle and wear plate as a function ofvessel OD.

Skirt Base Ring (layout)

The Base Plate Layout Labor table displays the labor hours to install the carbon steel skirt base plate.This includes labor hours to lay out and fit up the base plate as a function of base plate ID and thenumber of ring segments.

Tray Support Rings (layout, installation)

The Tray Installation Labor table displays the labor hours required to lay out and install tray support

rings as a function of vessel ID.



LABOR MENU


Welding

Figure 5-3 Welding Time Submenu

Time to Weld Submenu -- These tables (Welding Time - Circumferential Seam Weld,Welding Time - Longitudinal Seam Weld, Welding Time - Nozzle Fillet Weld andWelding Time - Nozzle Groove Weld) are not directly used by Coster for estimating butare included for users that have data for welding in minutes/ft rather than lb/hr. The

function of these tables is to allow a conversion from minutes/ft values to lb/hr values

based on the weld type, thickness, metallurgy and defaults set in the Conversion WeldDefaults dialog (see Figure 5-4). You will be asked if you want to convert these valueswhen you switch to another database table. The converted lb/hr values are saved in thecorresponding deposition rate table -- Weld Deposition Rate - Circumferential SeamWeld, Weld Deposition Rate - Longitudinal Seam Weld, Weld Deposition Rate - NozzleFillet Weld, Weld Deposition Rate - Nozzle Groove Weld. If the deposition rate tableshave been updated using the minutes/ft values, a note appears at the bottom of thedeposition rate table to identify the defaults used to convert the minutes/ft values to lb/hr.These deposition rate tables are the tables used by Coster to calculate welding. If youhave welding rates available in lb/hr, it is not necessary to enter information into these"Welding Time" tables; enter the lb/hr rates directly into the appropriate deposition rate

table.

The parameters used to convert from minutes/ft to lb/hr are contained on the ConversionWeld Detail dialog.



LABOR MENU


Figure 5-4 Conversion Weld Detail

The values on this dialog will be used only to convert the minutes/ft welding rates in the"welding time" tables to lb/hr rates in the "deposition rate" tables. The values used forestimating a vessel are saved from the Weld Detail tab of the Defaults menu. Thedefinitions of the conversion weld details and the estimating weld details are identicaland are described beginning on page 7-10. The Weld Reinforcement table contains dataindicating the height of the weld bead projecting beyond the surface of the parts being

welded. This table is used for both converting the minutes/ft values to lb/hr and also forestimating the cost of a vessel.

Welding Time

Circumferential Seams (Welding Time) -- The Welding Time - Circumferential SeamWeld table displays circumferential seam welding time in minutes/ft for single v orsingle u welding as a function of metallurgy and thickness. Also included on this table isa full rework multiplier based on the thickness (included to increase the labor hours forfull joint examination) which will be transferred from the welding time table to the welddeposition rate table when the lb/hr conversions are made.

Longitudinal Seams (Welding Time) -- The Welding Time - Longitudinal Seam Weldtable displays longitudinal seam welding time in minutes/ft for for single v or single u

welding as a function of metallurgy and thickness. Also included on this table is a fullrework multiplier based on the thickness (included to increase the labor hours for full joint examination) which will be transferred from the welding time table to the welddeposition rate table when the lb/hr conversions are made.

Nozzles (Welding Time) -- Fillet/Groove -- The Welding Time - Nozzle Fillet Weldand Welding Time - Nozzle Groove Weld tables display welding time in minutes/ft



LABOR MENU


based on metallurgy, nozzle OD, and weld thickness (nozzle groove weld) or weld leg

size (nozzle fillet weld).

Deposition Rate Submenu

Figure 5-5 Weld Deposition Rate Submenu

Circumferential Seam (Cylinder/Heads) -- The Weld DepositionRate - Circumferential Seam Weld table Deposition Rate displays the circumferential

seam weld deposition rate as a function of metallurgy and component thickness. Thereis a full rework multiplier included based on the thickness which is used duringestimating to increase the labor hours for full joint examination.

Longitudinal Seam (Cylinder) -- The Weld Deposition Rate - Longitudinal Seam Weldtable displays the longitudinal seam weld deposition rate as a function of metallurgy andcomponent thickness. There is a full rework multiplier included based on the thicknesswhich is used during estimating to increase the labor hours for full joint examination.

Nozzles -- The Weld Deposition Rate - Nozzle Fillet Weld and Weld DepositionRate - Nozzle Groove Weld tables display the weld deposition rate for manual welding

as a function of metallurgy, weld thickness and nozzle OD.

Note: If you do not have data for lb/hr values, refer to “Welding Time” on page 5-7 forinformation on converting minutes/ft values to lb/hr. These tables are used to calculatethe long seam and girth seam labor hours for skirts, cones, cylinders, flat heads, and

nozzle from plate material and to calculate the labor hours to weld nozzles.



MATERIAL MENU

< MATERIAL MENU 6 - 1 >

6MATERIAL MENU

The Material menu accesses Coster default material costs tables.

Figure 6-1 Material Menu

Couplings/Fittings Cost

The Couplings Costs table contains pricing for 3000# and 6000# couplings as a function of material

and coupling nominal size.

Cylinder Costs (purchased)

Formed and Tacked -- The Cylinder Costs (formed/tacked) table contains pricing for purchasedcylinders based on material, length and thickness and cylinder OD.

Formed, Tacked and Welded -- The Cylinder Costs (welded) table contains pricing for purchasedcylinders based on material, length and thickness and cylinder OD.



MATERIAL MENU


Flanges (ASME B16.5/16.47)

Figure 6-2 Flanges (ASME B16.5/16.47)

These tables contain flange costs for each table as follows:

a) blind and long weld neck flange costs as a function of flange size according to thematerial, class, and flange facing selected

b) slip on, lap joint, threaded and socket welded flange costs as a function of flangesize according to the material and class selected.

c) weld neck flange costs as a function of flange size according to the material, class,

bore size, and flange facing selected

Long Weld Neck -- Flange Costs, Flange Specs, Cutting Fee

There are six selections for long weld neck flanges. Each long weld neck type has a separate table

containing flange costs as a function of flange size according to the material, class, and flange facingspecified.



MATERIAL MENU


Figure 6-3 Long Weld Neck Types

For each long weld neck flange type and class there is a separate Flange Specs table containing

standard length, and cost per 1" length as a function of flange size and class to be used for weldingcalculations.

Density, weld rod cost and metallurgy will be read from the Material Properties table based on thematerial to which the LWN is attached.

Long weld neck flanges that are shorter than the standard length will be priced according to thestandard length plus a cutting fee to cut it to the required length. Long weld neck flanges that are

longer than the standard length will be priced according to the standard length plus a cost for theextra length plus a cutting fee to adjust the flange to the required length. Coster assumes that longweld neck flanges can be purchased in lengths beginning at 12 inches and incremented by 2 inch

lengths (12 inches, 14 inches, 16 inches, etc.). Calculate the extra length by subtracting the standardlength from the purchased length and multiply this extra length by the cost per 1" lengths value fromthe flange specs table.

The cutting fee used to adjust the long weld neck to the required length is read from the FlangeCutting Fee - Long Weld Neck table based on the flange nominal size and long weld neck type(standard, heavy barrel, etc.).



MATERIAL MENU


Formed Heads

Figure 6-4 Formed Heads Submenu

The head tables contain head costs based on material, head thickness and head OD.

Pipe Cost Schedule

The pipe table contains pricing based on material, pipe schedule and pipe nominal size.

Plate Costs

The Plate Costs table contains pricing for plate materials as a function of material, width andthickness.

Structures/Rings/Tray Supports Cost

The Structures/Rings/Tray Supports Material Costs table contains pricing for structures/rings/traysupports based on the type of structure/rings/tray supports.

Material Properties

The Material Properties table includes data for material density, welding rod density, welding rodcost, normalization premium, impact testing, and metallurgy.

Misc Items (user defined)

Misc Items 1 -- The Misc Items 1 table displays a list of miscellaneous items (davits,vortex breakers) and their corresponding unit weight, labor requirement, and cost that



MATERIAL MENU


may be added to the Vessel Detail Cost sheet in the Miscellaneous section of the

estimate. Additional items may be added to this table or additional "misc items" tablesmay be created if you choose to group similar items together into one table. The order ofthe columns on this table must match those in the Miscellaneous section of the VesselDetail Cost sheet and must not be changed. For more information on creating additional"misc items" tables, refer to “Insert Miscellaneous Items” on page 8-1. Miscellaneousitems that are required on all estimates should be added to the Misc Items Auto table.

Misc Items Auto -- Coster includes a Misc Items Auto table that contains material costsand labor hours for items to be included on every vessel estimated. Similar to the MiscItems 1 table, the columns on this table must match those in the Miscellaneous section ofthe Vessel Detail Cost sheet and must not be changed. More items may be added to thistable, and you may revise or delete the name plate record to suit your requirements. The

difference between this table and the Misc Items 1 table is that all items from the MiscItems Auto table will be added automatically by Coster to the miscellaneous section ofeach estimate so that these items do not need to be added manually each time.

Stock Plate Sizes

The Stock Plate Sizes table contains available plate sizes used to estimate cylinders, skirts, cones,nozzles, and pads from plate material. There are two Stock Plate Sizes tables -- one in English unitsand one in Metric units. If a vessel has been saved in metric units then Coster will read the Metricstock plate sizes table to determine a suitable plate size for fabricating components. Vessels saved inEnglish units will read the English stock plate sizes table.

Davit Material Cost

Refer to “Davit” on page 5-3 for a description of this table.

Finishing

Refer to “Finishing” on page 5-4 for a description of these tables.

Gasket Cost

The Gasket Costs table contains cost per gasket (used with ASME B16.5/16.47 flanges) based on the

gasket type, flange nominal size, and class. These costs are for gaskets with RF (raised face) flangefacing. Ring type joint gasket costs are read from the Ring Joint Cost tables according to the ringtype. Records may be added to this table and the table will be sorted according to gasket type and

flange nominal size when it is reopened. Fields may not be added to this table. To update the costson the table using the Update Table (global) option from the database Edit menu highlight therecords to be updated. Gasket type is selected from a drop down box on the User Selectable Itemsdialog and will be used for estimating all gaskets. The gasket types are selected from the gaskettypes in the Gasket Costs table. The gasket types are selected from the gasket types in the GasketCosts table. The flange facing and ring type are also selected from the User Selectable Items dialog.If there is a blind flange present then gasket costs will be estimated and added to the Miscellaneoussection of the Vessel Detail Cost sheet. No interpolation will be made for gasket costs. Gasket costs



MATERIAL MENU


are combined on the Vessel Detail Cost sheet if the gasket type and gasket cost are identical. Coster

determines the ring size according to the class, flange nominal size, flange facing, and ring typeusing an internal data chart. Gaskets are listed in the Bill of Materials and are combined if the gaskettype, flange nominal size, class, flange facing, ring type, and ring size are identical.

Platform/Ladder

Refer to “Platform/Ladder” on page 5-5 for a description of this table.

Stud Cost

The Stud Costs table contains cost per stud, including 2 hex nuts, based on the stud material, studbolt length, and stud diameter. Records may be added to this table and the table will be sorted

according to stud material and stud bolt length when it is reopened. Fields may not be added to thistable. To update the costs on the table using the Update Table (global) option from the database Editmenu highlight the records to be updated. Stud material is selected from a drop down box on theUser Selectable Items dialog and will be used for estimating all studs. The stud materials are

selected from the materials in the Stud Costs table. The flange facing and ring type are also selectedfrom the User Selectable Items dialog. If there is a blind flange present then stud costs will beestimated and added to the Miscellaneous section of the Vessel Detail Cost sheet. No interpolationwill be made for stud costs. Coster determines the number of bolt holes, stud diameter, stud boltlength and ring size according to the class, flange nominal size, flange facing, and ring type using aninternal data chart. Stud costs are combined on the Vessel Detail Cost sheet if the stud material andstud cost are identical. Studs are listed in the Bill of Materials and are combined if the stud material,flange nominal size, class, stud bolt length, stud diameter, and flange facing are identical. Weight of

source material for studs in the Bill of Materials is calculated as

stud quantity x (stud diameter / 2)^2 x x stud length x carbon steel density

Ring Type Joint R Cost

The Ring Type R Cost table contains cost per ring type joint based on material and R number (ringsize). Records may be added to this table and the table will be sorted according to stud material andstud bolt length when it is reopened. Fields may not be added to this table. To update the costs onthis table using the Update Table (global) option from the database Edit menu highlight the recordsto be updated. If there is a blind flange present and the ring type specified on the User SelectableItems dialog is RTJ then ring type joint gasket costs will be estimated and added to theMiscellaneous section of the Vessel Detail Cost sheet. No interpolation will be made for ring type joint costs. Coster determines the R number according to the class, flange nominal size, flange

facing, and ring type using an internal data chart.

Ring Type Joint RX Cost

The Ring Type RX Cost table contains cost per ring type joint based on material and RX number.Records may be added to this table and the table will be sorted according to material when it isreopened. Fields may not be added to this table. To update the costs on this table using the UpdateTable (global) option from the database Edit menu highlight the records to be updated. If there is a

π



MATERIAL MENU


blind flange present and the ring type specified on the User Selectable Items dialog is RTJ then ring

type joint gasket costs will be estimated and added to the Miscellaneous section of the Vessel DetailCost sheet. No interpolation will be made for ring type joint costs. Coster determines the RXnumber according to the class, flange nominal size, flange facing, and ring type using an internaldata chart.



MATERIAL MENU




DEFAULTS MENU

< DEFAULTS MENU 7 - 1 >

7DEFAULTS MENU

Select one of the options on the defaults menu to set user defined values. The information enteredon these dialogs will be saved and used as defaults for estimating until further revisions are made.

Alias Lists

Select Alias Lists to make changes (add/delete) to the alias lists for plate, pipe, coupling and flangematerials. The alias lists creates a cross-reference between materials contained in the Coster tablesand materials used to design the vessel. Once established, each time a material is located on a vesselduring the costing procedure, it will be matched with its "alias" on the data tables, even though theymay not be specified identically in both places (for example, the materials SA 516 70 and A 516 70).

Plate Materials

Select Plate to add, edit, or delete alias names for plate materials in the Plate Costs, Structures/ Rings/Tray Supports Material Costs, Head Costs - 2:1, Head Costs - F&D, and Head

Costs - Hemispherical tables.

Figure 7-1 Plate Cross Reference

Plate Materials - Alias Name for Selected Coster Material -- Select an alias namefrom the materials in the drop down list to correspond with the material namehighlighted in the Coster Name list. The drop down list of materials is created from theCOMPRESS or Modeler asme.mdb and user.mdb files (see "Materials" in theCOMPRESS manual).



DEFAULTS MENU


Coster Name -- This is a list of the materials from the Plate Costs, Structures/Rings/

Tray Supports Material Costs, Head Costs - 2:1, Head Costs - F&D, and HeadCosts - Hemispherical tables. Click on the material name you wish to link orcross-reference to one or more vessel alias name(s). After creating this cross-reference,each time Coster encounters one of the "alias" names, it will use the properties of thehighlighted material for estimating but will display the actual material name from thevessel file in the estimate.

Alias Name(s)

There are two ways to add alias names to this list:

1) Material names selected from the "Alias Name for Selected Coster Material" drop

down list will be added to the Alias Name(s) list and cross-referenced to thematerial name highlighted in the Coster Name list.

2) Materials selected from “Standard Plate Material” on page 3-3 during costing will

automatically be cross-referenced to the material specified and added to the aliaslist.

Add Alias/Delete Alias/Clear Alias List

Click on Add Alias to add the material name specified in the "Alias Name for Selected CosterMaterial" input box to the Alias Name(s) list.

Highlight a material to be removed from the Alias Name(s) list box. Click on Delete Alias toremove the material name specified.

The Clear Alias pushbutton will delete all names in the Alias Name(s) list box corresponding to thehighlighted material in the Coster Name list.

This list of cross-referenced plate materials is saved in the Alias - Plate/Structures table in theCostDB.mdb database file.

Pipe

The pipe alias option is similar to the plate alias option. The Coster Name list includes materialnames from the Pipe Cost Schedule database table. This list of cross-referenced pipe materials issaved in the Alias - Pipe table in the CostDB.mdb database table.

Coupling

The coupling alias option is similar to the the plate alias option. The Coster Name list includesmaterial names from the Coupling Costs table. This list of cross-referenced plate materials is savedin the Alias - Coupling table in the CostDB.mdb database file.



DEFAULTS MENU


Flange

The flange alias option is similar to the the plate alias option. The Coster Name list includesmaterial names taken from all flange cost database tables. This list of cross-referenced platematerials is saved in the Alias - Flange table in the CostDB.mdb database file.

Clips

Insulation Clips

Insulation Coverage -- The area which is held in place by one clip. Coster uses thisinformation to determine the total number of clips required to attach the insulation.

Insulation Clips -- Enter the cost of one insulation clip.

Insulation Clip Labor -- Enter the labor hours required to install one insulation clip.

Insulation is shop installed -- Indicate that all insulation is shop installed.

Insulation is field installed -- Indicate that all insulation is field installed.

Lining Clips

The Lining Clips dialog is similar to the Insulation Clips dialog.

Currency/Exchange

Select Currency/Exchange to set currency names along with their corresponding exchange rates and

currency symbol for the estimate. These settings will be used for estimating and displaying theestimate until revisions are made.



DEFAULTS MENU


Figure 7-2 Set Currency/Exchange Rate

Currency -- Enter the names of the currencies you require. The $US (base currency) isdisplayed and cannot be changed. All other currencies are user defined so any currenciesmay be entered.

Exchange Rate -- All currency is based on the United States equivalent. Enter the

exchange rate for a particular currency here. For example, an exchange rate of 1.45

beside Canadian currency shows the following relationship between Canadian andUnited States currencies.

$1 CDN X 1.45 = $1 US

If all table costs are in $US and the estimate currency selected is $CDN, Coster willconvert the values to Canadian currency based on the exchange rate specified on thisdialog.

Report Currency -- Select the currency to be used for displaying the final estimatefrom this list. The currencies specified in the Currency column automatically appear in

this list.

Defaults Menu Units -- Select the units to be used for entering the user defineddefaults on the Defaults menu.



DEFAULTS MENU


Finishing

Blasting/Cleaning

Blasting/Cleaning Method -- Enter the blasting/cleaning methods and hours requiredto clean or blast an area of 100 square feet.

These blasting/cleaning methods are listed on the User Selectable Items dialog whichappears during estimating. The labor hours entered here as user defined blasting/ cleaning defaults are used to estimate the blasting/cleaning on the estimate.

Hydrotest

Hydrotest Factor (a, b, c) -- Coster calculates hydrotest hours for the main vesselusing the following formula.

Hydrotest hours = a * ID2 * L + b * ID + c * L

where:

ID = inner diameter in feet

L = component length (axial length for cones) in feet

Enter values for a, b, and c in the hydrotest factor fields. If you enter 0 in all three fields,

hydrotest will not be considered, even for nozzles.

If the vessel design does not include blind flanges on each nozzle, the time to attach and

remove a blind flange is calculated and added to the hydrotest hours.



DEFAULTS MENU


Other

Figure 7-3 Fabrication, Defaults - Other

Fabrication

Minimum Shell Course Length -- Enter the smallest acceptable width of plate

material that can be used when piecing together a component. When a component mustbe pieced, Coster uses sections of plate whose width is equal to or larger than theminimum shell course length specified. The minimum shell course length applies toboth circumferential and longitudinal seams.

To show you how this works, let's assume that the minimum shell course length has beenspecified as 12". We are going to construct a cylinder with a 48" diameter and96" length from plate material that is 48" x 96". This would require three plates48" x 96", with a section of 6.797" x 96" left to complete the cylinder. However, this6.797" wide piece is narrower than the specified minimum shell course length (12") sothis method of fabrication would not be acceptable. Coster could instead choose a larger

plate size, for example, 84" x 96" and cut the cylinder from two pieces of plate.

Cut Width (waste from flame cutting) -- When a pad is cut, a certain amount ofmaterial is wasted. Enter the amount of wastage that will occur around the perimeter ofthe pad. This value is also used to calculate the wastage of the skirt base ring and is usedwhen Coster selects the plate sizes to fabricate components (refer to “How CosterDetermines Material Layout and Plate Requirements (Default Method)” on page 11-3).When Coster determines a suitable plate layout, all drop material (material remaining



DEFAULTS MENU


after a virgin plate has been cut) is reduced by the waste from flame cutting, and this

adjusted size is remembered so that it may be reused to fabricate other components.

Pipe Material Waste and Pipe Minimum Cut Length (for nozzles only) -- You canspecify a value for one or both of these entries. If you enter a zero for both of these itemsno waste is considered.

When a nozzle is cut from a pipe material, a certain amount of material waste isconsidered. This waste, expressed as a percentage, is added to the calculated nozzlelength if the nozzle length is greater than the minimum cut length. This length,including waste, is used to determine the nozzle material cost in the Vessel Detail Costand pipe requirements in the Bill of Materials.

The waste may also be determined by the minimum length of nozzle used. If the nozzlelength calculated is less than the minimum cut length, then the length used to determinethe nozzle material cost in the Vessel Detail Cost and pipe requirements in the Bill ofMaterials will be the minimum cut length.

Post Weld Heat Treatment (PWHT) -- Enter the cost per 100 lb for post weld heattreatment. Coster determines that global PWHT is required if the following componentsall require PWHT -- ASME B16.5/16.47 body flange, ASME Section VIII Division 1Appendix 2 flange, 2:1 head, f&d head, hemi head, flat welded head, transition, cylinder.Otherwise if PWHT is required on some but not all of these components then Costerdetermines that local PWHT is required. If global PWHT is determined then Coster willalso add the weight of the saddles, skirt base ring and compression ring, legs (including

leg base plate and leg pad), skirts, and vacuum rings to the weight of the weldedcomponents. If the ASME 16.5/16.47 body flange requires PWHT then the blind weightwill be added to the weight of the welded components. Similarly the weight of the pad

will be added if the nozzle to which it is attached requires PWHT. Global PWHT iscalculated using this cost per 100 lb according to the weight of the welded components.If local PWHT is required you will be asked to enter a total cost for the vessel during theestimating process.

Maximum Allowable Plate Length -- Enter the maximum plate length which will beused when calculating the required plate size for transitions, conical skirts and skirt baserings and also the plate length that may be entered as a user defined size. The default is

set to 480 inches.

Maximum Allowable Plate Width -- Enter the maximum plate width which will be

used when calculating the required plate size for transitions, conical skirts and skirt baserings and also the plate width that may be entered as a user defined size. The default isset to 120 inches.

Minimum Manway Diameter Required to Add Davits -- Enter the minimummanway diameter which will determine whether davits will be added in this estimate.The default is set to 16 inches. The "Always Add Davits" checkbox must also bechecked or davits will not be considered as part of the estimate.



DEFAULTS MENU


Cylinders -- Select the method which will be used to estimate cylinders -- Fabricated

in house, Purchased (formed/tacked only) or Purchased (formed/tacked/welded). Thedefault is set to "Fabricated in house".

Always Add Davits -- Check this box to add davits to manway openings greater thanor equal to the "Minimum Manway Diameter Required to Add Davits" value. If this boxis unchecked davits will not be considered. The default for this box is "checked".

Square All Sides of Plate -- Check this box to allow for squaring of each stock or user-defined plate. An allowance equal to the "Cut Width (waste from flame cutting)" will bemade before Coster selects a suitable plate size to fabricate each component. If this boxis "unchecked" then the exact dimensions of the stock or user-defined plate will be usedwhen determining the plate size for fabrication. The as-shipped default for this box is

"checked".

Labor Rates

Manufacturing Labor Rate -- Enter your shop's per hour labor rate ($/hr).

Wire Brush Labor Rate -- Enter the per hour labor rate to clean or blast an area usingthe wire brush method.

Sandblasting Labor Rate -- Enter the per hour labor rate to clean or blast an area forall types of sandblasting other than wire brush.

Primer Labor Rate -- The per hour shop charge to apply the primer.

Paint Labor Rate -- The per hour shop charge to apply the paint.

Welding Labor Rate -- Enter the currency per hour labor rate for welding. This laborrate is used to calculate welding labor costs on all components.

Program Output

Active Cost Source Database -- Select another Coster database to use for estimatingfrom this dropdown box which contains a list of the database files (*.mdb files) located

in the selected directory. The default directory is the "Coster Defaults" directory. Thename of the new database selected (including the drive and directory) will be saved inthe Coster registry settings and Coster will use this new database for estimating until a

different database has been selected. This option provides an opportunity to estimatevessels using the costs supplied from a variety of vendors. The database used forestimating a vessel is printed on the second line of the estimate on the Vessel Detail Costsheet. Select the Database Name option from the Coster Main Menu to display the nameof the database currently being used for estimating.

Note: When you install a new version of Coster the database registry setting is reset toCostDB.mdb. If you would like to use a database other than CostDB.mdb for estimating



DEFAULTS MENU


you will need to use this option to reselect your database each time you install a new

version of Coster.

Active Cost Source Drive / Active Cost Source Directory -- Select the drive anddirectory where the new database file (*.mdb file) is located.

Note: The CostSS.xls file must exist in the same directory as the new database file(*.mdb file) selected. If the CostSS.xls file is present then Coster will use the newdatabase file selected for estimating and will use the CostSS.xls file in this directory asthe template for estimating until a new database is selected in another directory. If theCostSS.xls file is not present then Coster will display an error message and will revertback to the previous database file for estimating.

Figure 7-4 Database Error Message

Print Expanded Form of Estimate -- The default for this box is "checked". Theestimate will be printed as shown on the screen which may take several pages to print. If

this box is "unchecked" Coster will condense the nozzle section of the estimate to fit allthe columns on one page when printing in landscape mode.

Display Cutting Sketch on Estimate -- The default for this box is "checked". Coster

includes a column to display the cutting sketch number on the Bill of Materials sheet andthe cutting sketch(es) used are displayed at the bottom of the Bill of Materials. Thisprovides the layout of each component fabricated from plate material. To reduce the sizeof the spreadsheet file you may choose to eliminate these cutting sketches ("uncheck"this box) from the estimate.

Design Program To Use -- The materials list used within Coster is read from the asme

and user defined databases from the Compress or Modeler program which Coster definesas the "design program". The Modeler program is the "as-shipped" default designprogram. The materials displayed from these databases are simplified using the short listselected within the design program. On the database tables you may select one of the

materials listed in the drop down list or type in a material name. On the "revise aliaslists" dialog you may only select from the list of materials displayed. The materials listused in Coster is updated after the design program is closed or when a material is addedto the user.mdb file using the "save this in the main database" option in the designprogram.



DEFAULTS MENU


Tray Supports

Select the material, structural type, and size to use for estimating tray supports. Material cost isbased on the material, structural type, and size as specified on the "Structures/Rings/Tray SupportsMaterial Cost table".

Welding

Weld Detail

Figure 7-5 Weld Detail

Type of Welding -- Select V welding or U welding to weld components.

Single V <= thickness > Double V and Single U <= thickness > Double U -- Thenumber entered here specifies the thickness of the vessel where Coster automaticallyswitches from single to double welding for estimating. For example, if you have selecteda V type weld and enter 1 for thickness then vessels with thicknesses less than or equal to1" will be welded with single V type welds and vessels with a thickness greater than 1"

will be welded with double V welds. To force all welding on a vessel to use double V(double U), enter 0 for this input. To force single V (single U), enter a large number forthickness.

Weld Gap (All Joints) -- Enter the weld gap between components. Refer to the iconwhen you click on this item:



DEFAULTS MENU


Weld Straight Section -- Enter the length. Refer to the icon displayed.

Weld Bevel Angle -- Enter the bevel angle of the component when preparing forwelding. Refer to the icon displayed.

Single V Double V

Single U Double U

Single V Double V

Single U Double U



DEFAULTS MENU


Weld Recovery -- Enter the percentage of the welding rod that will actually be usedduring welding. A value less than 100% will include weld wastage in your estimate.

Operator Weld Efficiency -- Enter the percentage of time actually spent welding by

the operator.

Bevel Angle (Nozzle Groove Welds) -- Enter the angle. Refer to the icon displayed.This input is available only when V type welding is selected.

U Groove Weld Radius -- Enter the radius of the weld type chosen. Refer to the icondisplayed. This input is available only when U type welding is selected.

Single V Double V

Single U Double U

Single V Double V



DEFAULTS MENU


Weld Reinforcement -- Click on the Weld Reinforcement button to retrieve the WeldReinforcement table which displays the height of the weld bead projecting beyond thesurface of the parts being welded.

Diameter/Longitudinal Weld Seams Ratio

Figure 7-6 Diameter/Long Weld Seams Ratio

Values entered on this dialog are considered for cylinders, fabricated nozzles, andcylindrical skirts if the corresponding Use Custom Plates Cut To Component Sizecheckbox has been selected. Pads and saddles are not affected by these selections.

Transitions, conical skirts, and skirt base rings do not use these values (see “Custom CutPlates (Alternate Material Layout)” on page 11-13).

Single U Double U



DEFAULTS MENU


Diameter (in) <= -- Numbers entered in the left column indicate a diameter range.

These diameters must be entered in ascending order.

Number of Long Seams -- Numbers entered in the right column indicate how manylong seams are required for the diameter range specified in the left column. Forexample, the number 152 displayed in the left column means that all diameters greaterthan 114 inches but less than or equal to 152 inches will require 4 long seams.Therefore, if a vessel component diameter is 120 inches, it will require 4 long seams.

The values initially displayed on the Ratio of Long Seams to Diameter dialog aredefaults supplied by Coster which may be edited. Revised values are saved in theCostDB.mdb database. When the program is loaded, if all values on this dialog are inputas zero, Coster automatically reloads the orginal default values.

Use Custom Plates Cut to Component Size -- These checkboxes tell Coster to usethe actual dimensions of each component to calculate material costs for cylinders,transitions, skirts, skirt base rings, and fabricated nozzles. No additional material cost

for drop is considered. The plate dimensions for each component are listed in the Bill ofMaterials on the estimate. Because Coster is not determining plate sizes, the number oflong seams for cylinders, cylindrical skirts, and fabricated nozzles is not known. Inorder to calculate the longitudinal weld length (length of the component multiplied bythe number of long seams), Coster reads the number of long seams for a particular vesseldiameter from the Diameter/Longitudinal Weld Seams Ratio dialog. The circumferentialweld length is calculated according to the circumferential seam length. The default forthe cylinder, transitions, skirts, and skirt base rings box is "unchecked". The default for

the fabricated nozzles box is "checked". Transitions, conical skirts, and skirt base ringsdo not use these values to calculate longitudinal seam weld length (see “Custom CutPlates (Alternate Material Layout)” on page 11-13). Pads and saddles are not affected by

these checkboxes and are listed in the Bill of Materials as usual.

Fillet Welds

Vacuum Ring Intermittent Welding -- Enter the percentage of welding required toattach the ring. For example, 100 means welded fully, whereas 60 means that 0.6 timesthe total length is welded.

Vacuum Ring/Tray Supports Weld Deposition Rate -- Enter the rate at which weldmetal is deposited while welding vacuum rings/tray supports to the shell.

Vacuum Ring Fillet Weld Size -- Enter the vacuum ring fillet weld size which is usedto calculate the vacuum ring weld volume. The default is set to 0.25 inches.

Saddle Fillet Weld Size -- Enter the saddle fillet weld size used to calculate the weldvolume for the web plate, wear plate and each rib. The default is set to 0.25 inches.

Fillet Weld Size for Vessel Internals -- Enter the fillet weld size which is used tocalculate the tray weld volume. The default is set to 0.25 inches.



DEFAULTS MENU


Saddle Welding (1 side of seam) and Saddle Welding (2 sides of seam) -- Select the

number of sides to the weld the saddle. This option is used to calculate the weld lengthand weld volume when costing saddles. The default is set to weld two sides.

Vacuum Ring Welding 1 Side and Vacuum Ring Welding 2 Sides -- Enter thenumber of sides to weld the vacuum ring. This value is used to calculate the vacuumring weld volume. The default is set to weld two sides.



DEFAULTS MENU




COSTER SPREADSHEET

< COSTER SPREADSHEET 8 - 1 >

8COSTER SPREADSHEET

General Spreadsheet Operation

Select Spreadsheet from the Coster main menu to display the Coster spreadsheet. This spreadsheetoperates as does Excel. Refer to your Excel manual for instructions. Formulas allow you to add,subtract, multiply or divide the values appearing in various cells in the worksheet. To enter aformula into a cell, begin by entering an equal (=) sign.

Regional Settings

The Coster spreadsheet estimate is compatible with regional settings in French, Italian, German,Spanish, Dutch and Brazilian Portuguese.

Printing the Estimate

If the 'printer not found' message appears when you are trying to print from the spreadsheet open the

CostSS.xls template and select 'Print' from the File menu. When the 'printer not found' messageappears click 'ok'. Resave the CostSS.xls file and this should eliminate the message.

Printing the estimate as it is displayed on your screen may take several pages to print. To condensethe nozzle section of the estimate so that all columns will fit on one page when printing in landscapemode (depending upon font size and column width) deselect the 'Print Expanded Form of Estimate'checkbox from the Progam Output dialog of the Defaults - Other menu. Coster will automaticallycondense the estimate for printing and then restore the estimate to the expanded form for display on

your computer screen.

Insert Miscellaneous Items

Coster provides this option to incorporate unique items that have not been included in the vesseldesign into the Miscellaneous section of the estimate. Open a Coster estimate file by costing avessel or opening a previously saved estimate. Select Insert Miscellaneous Items from theSpreadsheet Edit menu (this option will be "greyed out" on the menu until a Coster estimate isdisplayed). A list is displayed showing items which have been saved on a unit cost and unit laborbasis in the Misc Items table(s) in the Coster database. A few examples of these items are vortexbreakers, mist extractors, and davits. Select one or more items from the list. (To select one item,

click on the item to highlight it. To select a group of items, highlight the first item in the group andclick on the last item in the group while holding down the Shift key. To select or deselect individualitems, highlight each item while holding down the Ctrl key.) The highlighted items will be added to

the Miscellaneous section of the estimate. Formulas are included for each item (making it easy torevise quantities), and the addition of each item is reflected in the totals of the Miscellaneous sectionand also in the final vessel totals. Formatting (fonts, colors) of the inserted miscellaneous items willfollow the formatting of the other items in the Miscellaneous section of the estimate in which theseitems are added.



COSTER SPREADSHEET


These additional items are inserted on the last line of the Miscellaneous section of the

estimate. Coster automatically generates formulas in required cells for these items. To additems automatically to each estimate generated add these items to the Misc Items Auto table(see “Misc Items Auto -- Coster includes a Misc Items Auto table that contains materialcosts and labor hours for items to be included on every vessel estimated. Similar to the

Misc Items 1 table, the columns on this table must match those in the Miscellaneous section of theVessel Detail Cost sheet and must not be changed. More items may be added to this table, and youmay revise or delete the name plate record to suit your requirements. The difference between thistable and the Misc Items 1 table is that all items from the Misc Items Auto table will be addedautomatically by Coster to the miscellaneous section of each estimate so that these items do not needto be added manually each time.” on page 6-5).

Included with Coster is a sample database table (Misc Items 1) which includes miscellaneous costs.

Note: The information in the fields of this table is the same as the information displayedin the CostSS.xls template. When an item is inserted, Coster converts the units andcurrency in the new row to match the units and currency on the estimate.

When adding items to the Misc Items table(s) enter pricing information for a quantity of one. Theformulas which are added to the cost estimate multiply this pricing information by the quantity. Ifyou always want to add more than one of these items to the estimate, you may wish to enter theappropriate quantity in the quantity field of the Misc Items table(s). Otherwise if the quantity variesfor each vessel, enter a quantity of 1 in the Misc Items table(s) and change the quantity after youhave inserted the item into the estimate. You can create as many Misc Items tables as you wishcontaining these specialized items. Create new tables by selecting the Add Miscellaneous Items

Table option from the Database File menu.

Customize the Template (CostSS.xls)

From the Spreadsheet menu, open the CostSS.xls spreadsheet template. To modify the appearance(fonts, colors, underline, alignment, heading text, custom numbers, column width, justification) ofeach subsequent estimate, revise the CostSS.xls file and save your changes. Any customizing madeto the CostSS.xls file becomes the default Coster setting. Each estimate will take on this newappearance until further revisions are made.

The Coster estimate contains defined names (range names) for every numeric column. These

defined names describe the items listed in one column (excluding totals) from the first amount in thecolumn down to and including the underscore. The estimate also contains defined names assignedto each column total as well as defined names to identify the first item of each section and the first

and last row and column of the headings for each section. The following figures show the definednames that are part of the CostSS.xls template. In order for Coster to display the cost estimateaccording to your customization on the CostSS.xls template, these defined names must not berenamed and must reference the correct cell as listed in the table. If any of these names are missing,a dialog box will display the missing names so that you may add them (see instructions below), butCoster will continue to display the estimate using default headings and fonts.

There are three sheets in the CostSS.xls template:



COSTER SPREADSHEET


1) Vessel Detail Cost (displays the cost estimate)

2) Bill of Materials (displays the bill of materials, component weights, plate usage,radiography table and cutting sketches)

3) Summary (example of a customized summary).

To customize your estimate, revise the CostSS.xls template using the Coster spreadsheet orMicrosoft Excel version 7.0 and resave it. (Note: If you are using a newer version of MicrosoftExcel, the CostSS.xls template must be saved as a "Microsoft Excel 5.0/95 Workbook" forcompatibility with Coster). You may format cells any way you choose. For example, choose fonts,text color, column widths, number of decimal places, or word wrap. The text in the headings of theShell, Nozzle and Miscellaneous sections of the Vessel Detail Cost sheet may also be revised with

the exception of the last row of the heading. The last row contains the units and currency and will bedisplayed according to the units of the vessel file being costed and the currency selected withinCoster from the Currency/Exchange dialog. The formatting of each component (row) within asection will follow the same formatting as the first row of that section from the spreadsheet template.

The titles, vessel name, date and time displayed at the top of each sheet may be formatted for fontsand color, but the text is specified by Coster. Similarly the headings for the Bill of Materials, PlateUsage and Radiography sections may also be formatted, but Coster will specify the text for thesesections. Any changes made to text on the spreadsheet template that is specified by Coster will beoverwritten on each estimate.

If you delete any of the defined names, you may add them from the Coster spreadsheet as follows:

1) Select Spreadsheet from the Coster main menu (if you are not in the spreadsheetalready)

2) Open the CostSS.xls template

3) Move the cursor to the cell that you wish to name

4) Select the Define Name option from the Spreadsheet Edit menu

5) Type the defined name in the Name text box and click OK



COSTER SPREADSHEET


Figure 8-1 Define Name

There are other defined names provided on the CostSS.xls template to use as "hooks" for creating

your own customized summary. Coster creates these same defined names with each estimate. Toview the list of defined names, open the CostSS.xls template and select the Define Name option

from the Edit menu. As you scroll through the list of names, the formula in the box to the right willdisplay the corresponding sheet and cell that this name references.



COSTER SPREADSHEET


Figure 8-2 Vessel Detail Cost Sheet Defined Names

Figure 8-3 Bill of Materials Defined Names



COSTER SPREADSHEET


Figure 8-4 Summary Sheet Defined Names

Coster Tables

The tables included with Coster contain labor and material costs which may be used as provided oredited as costs for labor and material change.

Note: Tables may be edited but not deleted or the program will not run. Tables mustalways be resaved using the original "as-shipped" table name.

Most of the tables within Coster are indexed on the first field (column) but some tables are sortedusing the more than one field. For example, the weld neck flange costs table is sorted using the first,second, third and fourth fields of the table. This primary index is used to sort the table as records(rows) are added. The sorted table will be displayed after the table has been revised, closed andreopened. Because of this indexing, duplicate entries are not allowed in the group of fields used for

sorting, and blank or empty cells in this group of fields will cause an error within Coster. Theinterpolation feature requires that all values in this group of fields must be non-zero and all fieldheadings must be in ascending order.

The Material Properties table has fields for material, material density, welding roddensity, welding rod cost, normalization premium, impact testing, and metallurgy. Thesefields must remain in the "as-shipped" order so that Coster can properly interpret the data.

The "as-shipped" database tables are saved in US currency and English units. Within Coster youmay change the units and currency of these tables so that the tables may be updated according toyour preferred units and currency. The units and currency selections will be "greyed out" on tables

that Coster will not allow these changes to be made.

Coster's Estimate Spreadsheet

A saved costed vessel file is referenced in this manual as an "estimate". The top line of the estimatecontains the following information:

- Vessel Coster



COSTER SPREADSHEET


- Filename of vessel being costed

- Creation date and time

The estimate is in the same format as the CostSS.xls spreadsheet template.

The second line of the estimate displays the name of the database that was used to generate theestimate.

Shell Section - The top section of the estimate includes the heads, cylinders, transitions, and skirts.

Nozzle Section - The middle section of the estimate includes the nozzles, couplings and flanges.

Miscellaneous Section - The bottom section of the estimate includes the skirt base rings,

attachments (packed beds, trays), studs, gaskets, weld rod, paint, primer, hydrotest, post weld heattreatment, x-ray, and miscellaneous items.

Estimate Columns

As you read across a row in each section of the estimate you will find the following columns ofinformation.

Shell Section

1) Item - the component identifier as specified in the vessel file.

2) Material - the material as specified in the vessel file.

3) Quantity - the number of items for this component.

4) Finished Weight - the finished weight of the component. If identical componentsare present, this is the total weight of the identical components as indicated by theformula in the cell. The weight does not include material waste.

5) Mat'l Cost - calculated based on the finished weight. If the component isfabricated from plate material the equation in this cell displays the finished weighttimes the material cost per lb. For heads and purchased cylinders the equation is

the unit cost of the component times the quantity.

6) Surface Area - outside surface area of this component (heads, cylinders,

transitions and skirts).

7) Long Seam Labor Hrs - welding labor hours.

a) Heads, cylinders made from pipe material -- zero long seam labor hours.

b) ASME B16.5/16.47 body flanges -- flange welding labor hours.



COSTER SPREADSHEET


c) Transitions, skirts, and cylinders made from plate material -- long seam

welding labor hours calculated according to the long seam weld volume usingwelding rod density, long seam weld deposition rate, and operator weldefficiency. If the cylinders are purchased formed and tacked only then the longseam labor hours are calculated according to the long seam weld volume as abovesimilar to the 'Cut to Component Size' cylinders. If the cylinders are purchasedformed, tacked, and welded then long seam welding labor is zero.

d) Vacuum Rings -- welding labor hours calculated according to the ring weldvolume using welding rod density, ring weld depositon rate and operator weldefficiency.

8) Forming Labor Hrs

a) Cylinders made from pipe material, purchased cylinders, and ASME B16.5/ 16.47 body flanges -- zero forming labor hours.

b) Transitions, skirts, and fabricated cylinders made from platematerial -- displays forming labor hours.

c) Vacuum rings -- displays forming labor hours from the Vacuum Ring Labortable.

d) ASME B16.5/16.47 body flanges with blind attached -- displays blind laborhours.

9) Fitup Labor Hrs - fitup labor hours.

a) ASME B16.5/16.47 body flanges -- flange fitting labor hours.

10) Cutting Labor Hrs - cutting labor hours

11) Layout Labor Hrs - layout labor hours

12) Girth Seam Labor Hrs - girth seam welding labor hours.

a) Heads, cylinders, transitions, skirts -- girth seam welding labor hourscalculated according to the girth seam weld volume using welding rod density,girth seam weld deposition rate, and operator weld efficiency.

b) Vacuum Rings -- welding labor hours calculated according to the ring toshell weld volume using welding rod density, ring weld deposition rate, andoperator weld efficiency.

13) Bevel Labor Hrs - labor hours to bevel heads, cylinders, transitions and skirts.



COSTER SPREADSHEET


14) Blasting Labor Hrs - the hours required to blast the surface area specified above

for all types of blasting except wire brush.

15) Cleaning Labor Hrs - the hours required to clean the surface area specified aboveif wire brush is selected.

16) Grind Labor Hrs - the hours required to prepare the seams for welding.

17) Shell Labor Hrs - the total of long seam, forming, fitup, cutting, layout, girthseam, blasting, cleaning, grind labor hours.

18) Shell Labor Cost - the labor hours (long seam, forming, fitup, cutting, layout,girth seam, blasting, cleaning, grind) multiplied by their respective $/hr rates (for

example, long seam and girth seam labor costs are calculated using the weldinglabor rate, forming, fitup, cutting, and layout labor costs are calculated using themanufacturing labor rate, blasting cost is calculated using the sandblasting laborrate, cleaning cost is calculated using the wire brush labor rate, and grinding cost

is calculated using the manufacturing labor rate).

19) Shell Mat'l Cost - the finished weight material cost calculated above.

20) Shell Total Cost - Coster adds together the totals of Shell Labor Cost and ShellMat'l Cost above). This gives the total cost of the main components listed in thetop section of the worksheet.

Nozzle Section

1) Item - the nozzle tag as specified in the vessel file and the identifier if different

from the nozzle tag.

2) Material - the material of the nozzle as specified in the vessel file.

3) Pad Material - material used for the pad as specified in the vessel file.

4) Flange Type - the flange type is displayed in an abbreviated form as follows:

BLD - blind

BR - no flange (bare)

LJ - lap joint

LWNFB - full body long weld neck

LWNHB - heavy barrel long weld neck

LWNST - standard long weld neck



COSTER SPREADSHEET


LWNV1 - V1 variable body long weld neck



SO - slip on

SW - socket weld

TH - threaded

WN - weld neck

5) Quantity - the number of items for this component.

6) Nozzle Length - the finished length of the nozzle (waste not included).

7) Nozzle Finished Weight - the finished weight of the nozzle. If identical nozzlesare present on the vessel, this is the total weight of the identical nozzles (waste notincluded).

8) Pad Finished Weight - the finished weight of the pad. If identical nozzles arepresent on the vessel, this is the total weight of the pad from these identicalnozzles (waste not included).

9) Flange Weight - the weight of the flange. If identical nozzles are present on thevessel, this is the total weight of the flanges on these identical nozzles (waste not

included).

10) Blind Weight - the weight of the blind flange. If identical nozzles are present onthe vessel, this is the total weight of the blind flanges on these identical nozzles(waste not included).

11) Nozzle Finished Weight Mat'l Cost - fabricated nozzle material cost is calculatedbased on the finished weight of the specified material for this nozzle. The

equation displays the finished weight times the material cost per lb. Material costfor nozzles made from pipe material is calculated using the nozzle length timesthe pipe cost per ft. This pipe nozzle length is calculated according to the Pipe

Material Waste or Pipe Minimum Cut Length as entered on the Other Defaultsdialog. For appendix 2 flanges the material cost is calculated based on thefinished weight of the flange times the material cost per lb.

12) Pad Finished Weight Mat'l Cost - pad material cost is calculated based on thefinished weight of the specified material for this pad. The equation displays thefinished weight times the material cost per lb.



COSTER SPREADSHEET


13) Flange Cost - the cost of the flange.

14) Blind Cost - the cost of the blind flange.

15) Nozzle Installation Labor Hrs - the labor hours required to attach the nozzle to thevessel (layout, fitup).

16) Pad Installation Labor Hrs - the labor hours required to attach the pad to thenozzle (layout, fitup).

17) Flange Fitup Labor Hrs - the labor hours required to attach the flange. Forappendix 2 flanges the machining and drilling labor are included as part of theequation.

18) Blind Labor Hrs - the labor hours required to attach a blind flange.

19) Forming Labor Hrs - the labor hours required to form the nozzle (fabricated

nozzles).

20) Nozzle Cutting Labor Hrs - the labor hours required to cut out the hole for thenozzle. For fabricated nozzles the labor hours to cut out the nozzle from platematerial is also included and for nozzles made from pipe material the labor hoursto cut the required length of pipe is also included.

21) Pad Cutting Labor Hrs - the labor hours required to cut out the pad from plate

material.

22) Nozzle Welding Labor Hrs - the labor hours required to weld the nozzle to the

component.

23) Pad Welding Labor Hrs - the labor hours required to weld the pad to the nozzle.

24) Long Seam Welding Labor Hrs - the labor hours required to weld the long seamfor fabricated nozzles calculated according to the long seam weld volume usingwelding rod density, long seam weld deposition rate, and operator weldefficiency.

25) Flange Welding Labor Hrs - the labor hours required to weld the flange. Flangewelding labor is zero for long weld necks and studded outlet.

26) Nozzle Labor Hrs - the total of all labor hours above (nozzle installation, padinstallation, flange fitup, blind, forming, nozzle cutting, pad cutting, nozzlewelding, pad welding, long seam welding, and flange welding labor).

27) Nozzle Labor Cost - the individual itemized cost of labor for the total number oflabor hours shown in Nozzle Labor Hrs above (use welding labor rate to calculatewelding labor cost and manufacturing labor rate for all other labor costs).



COSTER SPREADSHEET


28) Nozzle Mat'l Cost - the total of all material costs above (nozzle finished weight

mat'l cost, pad finished weight mat'l cost, flange cost, and blind cost).

29) Nozzle Total Cost - Coster adds together the totals calculated for Nozzle LaborCost and Nozzle Mat'l Cost. This gives the total cost of all items listed in thenozzle (center) section of the worksheet.

Miscellaneous Section

Hydrotest hours are reported in this section. If the blind flange is not part of the vesseldesign, hydrotest hours for the flange are calculated as the labor hours to attach andremove a blind flange. Otherwise, if all blind flanges are part of the vessel design, flangehydrotest hours are zero. Hydrotest hours for the vessel are calculated using the formula

discussed earlier. Items that are included in the Misc Items Auto database table areautomatically included in the miscellaneous section of the estimate. Each cell contains aformula when it is added to the estimate. The equation is the value from the Misc ItemsAuto table times the quantity cell.

1) Item - the attachment identifier as specified in the vessel file.

2) Material - of the attachment specified in the vessel file.

3) Quantity - the number of items for identical attachments.

4) Finished Weight - the finished weight of the attachment. If identical attachments

are present, this is the total weight of the identical attachments. If "global" postweld heat treatment (PWHT) is required then the weight of the weldedcomponents is displayed in this column.

5) Finished Weight Mat'l Cost - of the specified material cost for this attachment. Ifa value for x-ray has been entered then this column contains the total x-ray cost.For skirt base rings the material cost is calculated based on the finished weight.The equation in this cell for skirt base rings displays the finished weight times thematerial cost per lb. If post weld heat treatment (PWHT) is required then thevalue entered will be displayed in this column. If "global" PWHT is entered as acost per 100 lb value then an equation of weight of the welded components times

the cost per 100 lb is displayed. If "global" PWHT is entered as a total cost thenthe value entered is displayed in this column. "Local" PWHT is always entered asa total cost which is displayed in this column.

6) Consumables Cost - totals for welding rod cost and cost of lining and insulationclips are displayed in this column.

7) Fitup Labor Hrs - fitup labor for insulation, lining, saddles, legs, legs base plate,and legs pad.

a) Insulation, lining -- labor hours per clip.



COSTER SPREADSHEET


b) Saddles -- the equation displayed in this cell is saddle fitting labor hours +

wear plate fitting labor hours.

8) Cutting Labor Hrs - cutting labor for saddles, skirt base rings, and compressionrings.

a) Saddles -- the equation displayed in this cell is rib cutting labor hours + wearplate cutting labor hours + web plate cutting labor hours + base plate cutting laborhours.

9) Layout Labor Hrs - layout labor for legs, legs base plate, legs pad, skirt baserings, and compression rings.

10) Welding Labor Hrs - welding labor for saddles, skirt base rings, compressionrings, legs, legs pad, and tray supports.

a) Saddles -- the equation displayed in this cell is rib plate welding labor hours

+ wear plate welding labor hours + web plate welding labor hours

b) Skirt Base Ring and Compression Ring -- equation displays the total ofgroove welding labor hours + fillet welding labor hours + gusset welding laborhours

c) Legs -- equation displays the total of legs to shell or pad welding hours + legsto base plate welding hours.

11) Drilling Labor Hrs - drilling labor for bolts in legs base plate, skirt base ring, andcompression ring.

12) Installation or Other Labor Hrs - installation or other labor hours for platforms,railings, ladders, insulation, lining, davits, installing tray supports, paint, primer,hydrotest, skirt base rings, and compression rings.

a) Skirt Base Ring and Compression Ring -- the hours required to blast/cleanthe surface area plus the hours required to prepare the seams for welding. Theequation in this cell displays the total of blasting labor hours + cleaning labor

hours + grinding labor hours (cleaning labor hours are calculated if wire brush isselected and blasting hours are calculated for all other types of blasting/cleaning).

13) Misc Labor Hrs - the total of all labor hours above (fitup, cutting, layout, welding,drilling, and installation/other)

14) Misc Labor Cost - the cost of labor for the total number of labor hours shown inMisc Labor Hrs above. Welding labor hours are calculated using the weldinglabor rate, paint labor hours are calculated using the paint labor rate, primer laborhours are calculated using the primer labor rate, blasting labor hours arecalculated using the sandblasting labor rate, cleaning hours are calculated using



COSTER SPREADSHEET


the wire brush labor rate, and all other labor hours are calculated using the

manufacturing labor rate.

15) Misc Mat'l Cost - the combined cost of the Finished Weight Mat'l Cost andConsumables Cost columns above.

16) Misc Total Cost - Coster adds together the totals calculated for Misc Labor Costand Misc Mat'l Cost. This gives the total cost of all items listed in themiscellaneous (bottom) section of the worksheet.

X-Ray Cost

The last row on the estimate displays the x-ray cost in the Finished Weight Mat'l Cost column for

the vessel if a positive amount is entered.

Vessel Total Costs

Total Finished Vessel Weight

Coster displays the sum of the total weights (lb) on the estimate -- Shell Total Weight (ShTotWt) +Nozzle Total Weight (NozTotWt) + Pad Total Weight (PadTotWt) + Flange Total Weight(FlangeTotWt) + Blind Total Weight (BlindTotWt) + skirt base ring weight + saddles weight + davitweight + legs weight -- as the Total Finished Vessel Weight. The skirt base ring, saddles, davits, andlegs weight are displayed by individual cell reference.

Finished Vessel Cost

Coster calculates the average $/lb cost of the total vessel based on the Total Vessel Cost divided by

the Total Finished Vessel Weight.

Total Plate Material Cost

The Total Plate Material Cost is the sum of the Stock Material Cost and User Defined Material Costfrom the Bill of Materials plate usage section (TotalStockMatlCost + TotalUserDefinedMatlCost).

Finished Weight Plate Material Cost

This is the sum of all material costs made from plate (cylinders -- excluding purchased cylinders,skirts, transitions, fabricated nozzles, pads, skirt base rings, saddles).

Unused Plate Material Cost

Coster calculates the unused plate material cost by taking the total (purchased) plate material costand subtracting the cost of the finished weight of plate components.



COSTER SPREADSHEET


Total Costs for the Vessel

Coster calculates three subtotals for labor hours in the Shell Labor Hrs, Nozzle Labor Hrs, and MiscLabor Hrs columns. These three subtotals are added together to give the total labor hours for thevessel. This total is reported as TOTAL VESSEL LABOR HOURS.

Similarly, Coster calculates three subtotals for labor cost in the Shell Labor Cost, Nozzle LaborCost, and Misc Labor Cost columns. These three subtotals are added together to give the total laborcost for the vessel. This total is reported as TOTAL VESSEL LABOR COST.

Coster calculates three subtotals for material cost in the Shell Mat'l Cost, Nozzle Mat'l Cost, andMisc Mat'l Cost columns. The sum of these three subtotals plus the unused plate material cost givethe total material cost for the vessel. This total is reported as TOTAL VESSEL MATERIAL COST.

TOTAL VESSEL LABOR COST is then combined with TOTAL VESSEL MATERIAL COST toshow the final TOTAL VESSEL COST.

Bill of Materials

A bill of materials is displayed on sheet 2 of the estimate. This lists the quantities and descriptions ofmaterials required to build the vessel.

1) Quantity - the actual component quantity required. If the component is madefrom pipe material, this quantity is the length of pipe required.

This length of pipe includes the Pipe Material Waste or Pipe Minimum Cut Length asshown on the Other Defaults dialog. In cases where pipe material is the same for morethan one nozzle, these lengths (including waste), will be added together for a combined

pipe length.

2) Material - the material specification as found in the vessel file.

3) Component - the identifier as found in the vessel file. If the component is anozzle, the nozzle tag name is displayed. If the component is a flange, the type offlange is displayed.

4) Description - the actual dimensions of the component.

5) Section Qty - how many sections (pieces) are required to assemble the

component.

6) Dimensions of Sections Req'd to Assemble Component - the size of each of thesections required to assemble the component from plate material. In the case ofpurchased cylinders this column contains the type of purchased cylinder (eitherformed and tacked or formed, tacked, and welded)



COSTER SPREADSHEET


Note: Coster calculates the rectangular plate size required to cut out the pad and

assumes that the pad will be cut from a piece of scrap material. Therefore the platequantity, size of plate required to cut each section and drop columns are left blank.

7) Plate Qty - how many pieces of plate material are required to cut the sectionsshown in 6 above.

8) Size of Plate Required to Cut Each Section - the plate size required to cut thesection of the dimension shown in 6 above. The plate sizes shown in this columnare stock plate sizes found on the Stock Plate Sizes tables (English or Metric),user defined plate sizes that you have entered while costing the vessel, or dropplates left over after cutting out a previous component.

The following list is displayed beneath the Size of Plate Required to Cut Each Sectioncolumn heading:

U(cut from user defined plate, no stock)

G(girth seams added to plate layout)

The letter U is shown in the column to the left of the plate size listed if Coster could notfind a suitable plate size in stock (from the Stock Plate Sizes table) and you entered aplate size for this component. The letter G means that additional girth seams wererequired to fabricate this component from the available plate sizes. The letters G U meanmore girth seams were added and a user defined plate size was used for this component.

9) Weight of Source Material - this column displays the component weight

10) Cutting Sketch - this column displays the number of the cutting sketch used to cut

out this component. The cutting sketches used are displayed at the bottom of theBill of Materials sheet to show the layout used for cutting.

11) Drop From - sometimes it is possible to cut smaller component sections fromleftover pieces of plate material. This column displays the identifier of thecomponent that contributed the plate remnant.



COSTER SPREADSHEET


Plate Usage (Bill of Materials)

Stock Plates Required

This is a list of the actual plates which must be purchased to fabricate the vessel, along with material

cost for each plate. These stock plates were used by Coster because the sizes were available in the

Stock Plates Sizes tables.

User Defined Plates Required

This is a list of the user specified plates sizes which must be purchased to fabricate the vessel but

could not be found in the Stock Plate Sizes tables. In this instance Coster prompts the user to

provide a suitable plate description. There is also a material cost for each plate.

Drop Material Used

This is a list of the drop material used to fabricate various components. Drop is the material thatremains that can be reused after cutting a virgin stock plate.

Drop Material Remaining

This is a list of the drop material that Coster could not reuse for this vessel, along with a

corresponding material cost for each piece. Coster assumes that the drop material is always a

rectangular piece of plate.

Scrap Material

This is a list of the material that is left over that Coster cannot use because of its odd geometry, along

with a corresponding material cost for each piece of scrap. One example of scrap is the material

remaining after a multiple segment base ring has been flame cut.

Total Unused Material Cost

This cost is calculated as the drop plates remaining material cost plus the scrap material cost.

Radiography

A table is displayed below the Bill of Materials indicating the weld type and length of weld for eachtype of radiography (full, spot, no radiography). This same table is displayed on the x-ray dialog touse as a guide for entering the x-ray cost.



COSTER SPREADSHEET


Summary (Create a Customized Report)

The third sheet of the estimate is a summary report. The summary can be modified to suit yourpreferences. At the top of the spreadsheet on the left, the active cell is displayed, along with theformula bar showing the contents of that cell. The corresponding cell in the spreadsheet displays theresult of this formula bar. As you move through the cells in the summary you will notice that theformula bar does not always contain a specific number. It sometimes contains a defined name fromthe Vessel Detail Cost sheet. By using these defined names you can create your summary toautomatically link values from the Vessel Detail Cost sheet. Formulas may be added to yoursummary in order to total various costs or add profit margins.

Note: Remember that this customization must be saved on the CostSS.xls spreadsheettemplate as this is the file Coster uses to generate each estimate.



DATABASE TREE MENU

< DATABASE TREE MENU 9 - 1 >

9DATABASE TREE MENU

The database tree menu displays the operations required to estimate each component. Through thistree you can access each database table and the default dialogs associated with each operation.Operations common to many components are listed together under the "Common Operations"heading of the database tree. The database tables and default dialogs associated with these commonoperations may be accessed through these branches of the database tree. Although the commonoperations are also listed with each individual component these common operations are marked withan asterisk (*) because the database tables and default dialogs cannot be accessed from this branchof the tree.



DATABASE TREE MENU

< DATABASE TREE MENU 9 - 2 >



HELP MENU

< HELP MENU 10 - 1 >

10HELP MENU

The help menu displays information about the Coster program.

Figure 10-1 Help Menu

About Coster

This option displays the Coster version and copyright information.

Coster Directories

This displays a list of the directories where the Coster files are located as specified duringinstallation of the program.

Database Name

Selecting this option will display the directory and name of the database that is currently being usedfor estimating vessels. This database name also appears at the top of each spreadsheet estimate.



HELP MENU

< HELP MENU 10 - 2 >



CALCULATIONS DESCRIPTION

< CALCULATIONS DESCRIPTION 11 - 1 >

11CALCULATIONS DESCRIPTION

General Calculations For All Components

The currency and units used to display the estimate are based on the units of the vessel file beingcosted and the Report Currency selection from the Currency/Exchange dialog of the Defaults menu.

The weld recovery and operator weld efficiency are read from the values entered on the WeldingDetail dialog on the Defaults - Welding menu. The manufacturing labor rate and welding labor rateare read from the values entered on the Labor Rates dialog on the Defaults - Other menu. The weldrecovery and operator weld efficiency are divided by 100 for use in the calculations below.

Unless otherwise specified, units used in the following calculations are:

angle degrees pipe cost $/ftbevel angle degrees pipe material waste %blast/clean coverage gal/100 sq ft pipe minimum cut length ft

corrosion in plate cost $/100 lbcut width in saddle fillet weld size indensity (bed, lining, insulation) lb/cubic ft saddle height indiameter in saddle welding 1 or 2 sideselevation in straight flange ingrinding rate hrs/ft surface area square feethead cost $/each thickness inheight in vacuum ring fillet weld size in

hydrotest equation values ft vacuum ring intermittent welding %impact testing % vacuum ring weld deposition rate lb/hrinsulation/lining clip labor hrs/clip vacuum ring welding 1 or 2 sides

insulation/lining clips cost $/clip volume cubic ininsulation/lining coverage sq ft/clip weight lblength in weld deposition rate lb/hrmanufacturing labor rate $/hr weld gap inmaterial density lb/cubic in weld recovery %nominal size in weld size innormalization % welding labor rate $/hrnozzle inside projection in weld rod density lb/cubic in

operator weld efficiency % width inpaint/primer application labor hrs/100 sq ft x-ray weld length ftpaint/primer coverage gal/100 sq ft

Outer diameter is usually read from the .xml file. Otherwise outer diameter is calculated as:

OD = ID + 2 * thickness.

Longitudinal and circumferential weld cross section areas and weld lengths are calculated by Costeraccording to the weld type specified based on diameter and thickness -- use OD for cylinders,Left ID for transitions and skirts, OD for nozzles, and ID for heads. The deposition rates required to





weld these seams are read from the Weld Deposition Rate - Longitudinal Seam Weld and Weld

Deposition Rate - Circumferential Seam Weld tables based on thickness and metallurgy.

The lining weight and insulation weight are provided by the COMPRESS .xml file for cylinders,transitions, heads, and skirts.

Interpolation Method Used by Coster

Coster interpolates values within one field (column) if each field belongs to a separate group as onthe Miscellaneous Fabrication Labor table (fields contain data for cutting, fillet welding, groovewelding, drilling hours, and bevelling labor) or within one record (row) if each record belongs to aseparate group as on the Plate Costs table (records contain data for different materials). We refer tothis as "single interpolation".

Coster can also interpolate between fields and records if all the information contained on a table isrelated as on the Cylinder Forming Labor table (fields contain cylinder ID and records containcylinder thickness). We refer to this as "multiple interpolation".

To interpolate values, the records and field headings must be in ascending order as shown in thefollowing examples.

Single Interpolation

Coster interpolates to find a value between two non-zero coordinates in one field or record. In thisexample Coster finds a value for weld deposition rate at a thickness of 2.75". Coster searches for the

first non-zero value in the deposition rate column above and below the 2.75" thickness. In ourexample, the first non-zero value above 2.75" is 1.6 (at 1" thickness), and the first non-zero valuebelow 2.75" is 7.4 (at 4.5" thickness). Once these two points have been located, Coster calculates

the weld deposition rate at 2.75" to be 4.5 1bs/hr as follows:

Multiple Interpolation

Coster uses multiple interpolation to determine an intermediate value between four non-zero valuesarranged in a "four-cornered" pattern. Suppose the following data were available. The following

steps show how Coster determines the labor hours required to weld a 6" diameter nozzle with a0.875" weld thickness:

Thickness Deposition Rate1 1.6

1.752.5

2.75 ?3.25

4

4.5 7.4

7.4 1.6 ) 4.5 1–( ) ⁄ 2.75 1 )– 1.6 4.5=+(×–(





1) In the first interpolation, Coster determines a value for labor hours for 4" diameterand 0.875" thickness calculated as follows.

2) The second interpolation reveals a value for labor hours for 8" diameter and0.875" thickness as follows.

3) Coster now takes the values determined in Step 1 and Step 2 above, interpolatesbetween these two points to determine the labor hours for 6" diameter and 0.875"thickness as follows.

Therefore the (interpolated) labor hours required to weld a 6" diameter nozzle with a 0.875" weldthickness is 8.512 hours.

How Coster Determines Material Layout and Plate Requirements (Default Method)

All stock plate sizes listed in the Coster database are assumed to be available in unlimited quantitiesduring the fabrication process. Stock plates are simply plates of standard size that are readilyavailable for purchase. You can change the plate sizes available to Coster by selecting Stock PlateSizes from the Material menu. Coster decides where to place the vessel weld seams and whichstock plate sizes to specify based on what may be thought of as a two stage process.

Stage (1) - The locations of the girth seams are specified by the user based on thecylinder lengths entered in COMPRESS. The only time Coster will add girth seams iswhen the user has specified a cylinder length longer than can be made from the longest

stock plate. Coster strives to minimize the number of longitudinal seams by selectingstock plate sizes that do not need to be pieced together even if this results in more scrapmaterial. The layout of conical transitions, conical skirts and skirt base rings is morecomplicated and is described in detail in a later section.

weld legsize 1 2 4 6 8 16 480.25 6 6.2 6.5 7 7.5 8

0.3750.5

0.75

0.875 8.205 ? 8.81811.251.5

22.5

3 12 13 14 15 20 30

14 6.5 ) 3 0.25–( ) ⁄ 0.875 0.25 )– 6.5 8.205=+(×–(

15 7 ) 3 0.25–( ) ⁄ 0.875 0.25 )– 7 8.818=+(×–(

8.818 8.205 ) 8 4–( ) ⁄ 6 4 )– 8.205 8.512=+(×–(





Stage (2) - Stage (1) establishes the required length and width of each plate required to

fabricate the vessel. This "required plate size" is the size that once rolled forms therequired cylinder diameter. For large diameters more than one plate may be required toform each component. The stock plate used to cut out the required plate is determinedby comparing the required plate size to all available stock plate sizes and then selectingthe stock plate (and layout) that leaves the most remaining material or "drop". If therequired plate can be cut entirely from a stock plate size then the best of cutting sketches1 through 4 is selected. If none of the stock plates is large enough then the better ofcutting sketches 5 or 6 will be used (see “Cutting Sketches” on page 11-9). If the "usesquared plates" checkbox from the Fabrication dialog on the Defaults - Other menu hasbeen "checked" (this is the "as-shipped" default) then the sides of each required platechosen for fabrication must allow for squaring of the plate -- in other words an allowanceof the "Cut Width (waste from flame cutting)" from the Fabrication dialog on the

Defaults - Other menu is made. For example, if the "Cut Width (waste from flamecutting)" is equal to 0.5" then to determine if a plate which has a width of 96" can beused to fabricate a component Coster will compare the required size to the plate width(96") minus a cutting allowance on both sides of the plate (0.5" x 2) or a 95" plate width.

Note that the specified flame cutting allowance is deducted from the drop piece size(based on the selected layout) before it is placed in the drop inventory if the "use squaredplates" checkbox on the Fabrication dialog of the Defaults - Other menu is "unchecked".Depending upon the layout used for cutting (cutting sketch), the side(s) of the drop piecemay have already been squared so this allowance is not necessary when comparing thedimensions of the drop piece to the required plate size. The flame cutting allowance willonly be considered for sides that are "not squared" when the "use squared plates" optionis "checked". Refer to the “Cutting Sketches With Drop Dimensions (includes

allowance for squaring of plate)” on page 11-10 that show the dimensions of the droppieces after allowance is made for squaring of the plate.

As stage (2) proceeds Coster accumulates all drop material in a "drop inventory". Before selecting a"virgin" stock plate Coster first examines the drop inventory to see if the required plate size can becut from an existing piece of drop material. In an attempt to maximize the use of drop materialCoster sorts the components in the vessel in the following order: cylinder, transition, skirt, andnozzle in order to select stock plates for larger components first. A consequence of this arrangementis that only drop from this vessel is available for use. The plate selection process can be summarizedas follows:

a) Sort all of the vessel components in the following order: cylinder, transition,skirt, and nozzle.

b) First see if the required plate can be cut from an existing piece of drop. In aneffort to use the most drop possible Coster will use drop if it is as good as or betterthan the required metallurgy. For example if the only difference between therequired plate and a drop piece is that the drop is normalized and the requiredplate is not normalized then Coster will use the drop. If the required plate can bemade from drop skip step c).





c) Find the stock plate size that produces the least amount (area) of drop. To do this

examine all available stock plate sizes trying cutting sketches 1 through 4. The"best" stock plate size and cutting sketch are now known. If none of the stockplates is large enough then try cutting sketches 5 and 6.

d) Cut the required plate size from the "best" stock plate size and add the drop piecesto the drop inventory. Note that the specified flame cutting allowance is deductedfrom the drop piece size (based on the selected layout) before it is placed in thedrop inventory if the "use squared plates" checkbox on the Fabrication dialog ofthe Defaults - Other menu is "unchecked". If the "use squared plates" checkboxhas been "checked" then the sides of each required plate chosen for fabricationmust allow for squaring of the plate using the "Cut Width (waste from flamecutting)" from the Fabrication dialog on the Defaults - Other menu (see “Cutting

Sketches With Drop Dimensions (includes allowance for squaring of plate)” onpage 11-10). These sketches also show which sides of the drop pieces areconsidered to be "squared". Note also that the drop material takes on thecharacteristics of the plate from which it was cut. For example if a piece of drop

is cut from normalized stock then it too is marked as normalized.

e) Repeat the process using the next required plate size (starting at step b) until all ofthe required pieces have been cut.

The material which is added to the drop inventory for possible use in fabricating another componentis assumed to be rectangular in shape. Other shapes are considered unusable and are referred to asscrap material. Examples of "scrap" are the irregular shapes remaining after cutting out pads,

transitions, conical skirts, and skirt base rings. A list of the stock plate sizes, user defined platesizes, drop material and scrap are listed on the Bill of Materials sheet on the estimate (see “StockPlates Required” on page 8-17).

When piecing together a component, assuming that the "use squared plates" checkbox is "checked"and the "Cut Width (waste from flame cutting)" is equal to 0.5", Coster selects a plate layout thatwill minimize the number of long seams and will not allow a plate width of less than the MinimumShell Course Length specified on the Defaults - Other dialog. For example, Coster may choose tofabricate a component, 61" ID (midcircumference 193.208"), 119" length, 0.5" thickness using threesections. If two full plates (96" x 120" -- actually 95" x 119" after allowing for the waste from flamecutting) are used for the first two sections then the last plate section (3.208" x 119") would be less

than the minimum shell course length (12"). Instead Coster would fabricate this component in threesections as follows (the last two sections would be divided equally) -- one section 95" x 119" andtwo sections 49.104" x 119". To test this, create a carbon steel cylinder 61" ID x 119" length x 0.5"

thickness and save it. Open the Stock Plate Sizes (English units) table. For each plate size in the0.5" thickness record type SS in the cell with the exception of 96" x 120" (type CS in this cell). Thisforces Coster to fabricate this cylinder from the 96" x 120" plate size since this size is the onlyavailable carbon steel material in 0.5" thickness. Set the "Minimum Shell Course Length" and the"Cut Width (waste from flame cutting)" on the Fabrication dialog of the Defaults - Other menu to12" and 0.5" respectively. Close the database and cost the vessel. The plate sizes listed on the Billof Materials will be the same as shown above. After testing replace the previous metallurgies in the0.5" thickness record on the Stock Plate Sizes (English units) table.





How Coster Determines The Layout of Conical Sections

Coster minimizes the welding required to fabricate transitions and conical skirts by specifying thatthe cone be made using the fewest possible number of segments. This is accomplished by takingthe cone geometry and determining what plate size would be required to fabricate it from onesegment. If there is a stock plate size large enough then this is considered to be the "best" layout.Otherwise the number of cone segments is increased until the minimum number of segments thatcan be accommodated by the stock plates is found. Once the "best" required plate size has beendetermined the stock plate size is selected per the procedure described in Stage (2) above. If morethan 12 segments are required Coster will split this cone into two separate cones of equal axiallength by adding a girth seam. The following equations are used to determine the size of the conesegments:

For φ <= π:

Cone surface length, HDL

2

--------DS

2

--------–

2

(axial length)2

+=

R DL H DL DS–( ⁄ × )=

φ Radians π DL DS–(× ) H ⁄ =





For φ> π:

where

DL = average cone diameter at the large end

Required plate length, L 2 R φ 2 ) ⁄ (sin××=

Required plate width, w R R H ) φ 2 ) ⁄ (cos×–(–=

Required plate length, L 2 R×=

Required plate width, w R 1 2 π φ ) 2 ) ) ⁄ –×((cos+(×=





DS = average cone diameter at the small end

Axial Length = cone axial length

The circumferential seam weld length is calculated according to the orientation of thetransition.

If the orientation of the transition from top to bottom is Small to Large calculate thecircumferential seam weld length using the Large OD attached to the next component:

If the orientation of the transition from top to bottom is Large to Small calculate thecircumferential seam weld length using the Small OD attached to the next component :

The cutting length is calculated as the circumferential seam weld length plus thelongitudinal seam weld length plus the length of the top end of the transition:

If the orientation of the transition from top to bottom is Small to Large calculate the topend cutting length using the Small OD:

If the orientation of the transition from top to bottom is Large to Small calculate the topend cutting length using the Large OD:

If there is only one segment then an extra cutting length of cone surface length, H, is

added because this length would be included only once in the longitudinal seam weldlength.

longitudinal seam weld length cone surface length, H=

area of cone R(2

R( H )2

) φ

2---×––=

scrap area L w area of cone–×=

circumferential seam weld lengthDL π×

number of segments------------------------------------------------=

circumferential seam weld lengthDS π×


top end cutting lengthDS π×


top end cutting lengthDL π×






If there is more than one segment then for each segment an extra cutting length of theaxial length is added

The total cutting length is calculated:

How Coster Determines The Layout of Skirt Base Rings

For each base ring Coster estimates the total cost of labor and material needed to fabricate the basering by attempting to use from one to 6 segments. Of these six arrangements Coster chooses the

most economical layout. Depending on the size of the base ring and the available stock plate sizessome layouts may not be physically possible and so may not be considered. The equations used tolayout the required base ring are described in “Two Segments to Six Segments” on page 11-61.

Cutting Sketches

Following are the cutting sketches which will be used to cut out each required plate size, where

plate width = width of the stock plate

plate length = length of the stock plate

x and y = dimensions of the required plate size

drop = rectangular plates added to drop inventory

extra cutting length cone surface length, H=

extra cutting length axial length number of segments×=

cutting length circumferential seam weld lengthlongitudinal seam weld length top end cutting length extra cutting length+ + +

=





A list of the sizes of each section used for fabrication is found on the Bill of Materials under theheading Dimensions of Sections Req'd to Assemble Component. A list of the plate sizes used to cutout each section is found on the Bill of Materials under the heading Size of Plate Required to CutEach Section.

Cutting Sketches With Drop Dimensions (includes allowance for squaring of plate)

The following cutting sketches indicate the dimensions of the drop pieces after allowance is madefor squaring of the plate.













Custom Cut Plates (Alternate Material Layout)

To bypass Coster's usual method of determining plate requirements as discussed on page 11-3 ff,check the Use Custom Plates Cut to Component Size checkbox on the Diameter/Longitudinal WeldSeams Ratio dialog from the Defaults - Welding menu.

When the Use Custom Plates Cut to Component Size checkbox is selected, Coster uses the actualdimensions of each vessel component to calculate labor and material costs. Using this method





eliminates the "drop" from being included in the material cost. This option is available for cylinders,

transitions, skirts, skirt base rings, and fabricated nozzles. The "as-shipped" default for cylinders,transitions, skirts and skirt base rings is "unchecked". The "as-shipped" default for fabricatednozzles is "checked". The dimensions are listed in the Bill of Materials as user defined plate sizes.

Fabricated Cylinders, Cylindrical Skirts and Fabricated Nozzles

For these custom plate components, the circumferential seam weld length is calculated as the girthseam weld length, and the longitudinal seam weld length is calculated according to the length of thecomponent multiplied by the number of seams (based on diameter) from the Diameter/LongitudinalWeld Seams Ratio dialog on the Defaults - Welding menu. Cutting labor is not included for thesecomponents because Coster uses a plate size of the exact dimensions required to fabricate thecomponent.

During costing, the number of long seams required for a particular diameter is looked up by Costerfrom the Diameter/Longitudinal Weld Seams Ratio dialog. If the number of long seams returnedfrom this look-up is zero, the following dialog appears. A zero value will be returned if the actual

value in the table is zero or the component diameter is larger or smaller than the largest or smallestdiameter found on the Diameter/Longitudinal Weld Seams Ratio dialog.

Figure 11-1 Long Seams Required

Enter the appropriate number of long seams to correspond with the diameter shown in the leftcolumn and click OK. Coster proceeds to calculate the longitudinal seam weld length as the vesselcomponent length multiplied by the number of long seams specified.

Transitions and Conical Skirts

Coster determines the required plate length and width using the same method as “How CosterDetermines The Layout of Conical Sections” on page 11-6 but instead of comparing the required

plate size to the stock plate sizes available, Coster compares the required plate size to the maximumallowable plate width and maximum allowable plate length dimensions (user defined defaults on theFabrication dialog of the Defaults - Other menu). As in the method described above, the number ofsegments is increased until the minimum number of segments can be accommodated on the platesize described using the maximum allowable plate width and length and if more than 12 segmentsare required Coster will split the cone into two separate cones of equal axial length by adding a girthseam.





The scrap area and circumferential and longitudinal seam weld lengths are calculated as in “How

Coster Determines The Layout of Conical Sections” on page 11-6. Scrap material cost is includedfor these custom cut components.

Segment cutting labor to cut out the individual pieces required to fabricate the component is alsoincluded but plate cutting labor (labor required to cut the required plate size from a larger stockplate) is not included since the plate size is the required size and does not need to be cut from a largerstock plate.

Skirt Base Rings

For skirt base ring custom plate components, the circumferential seam weld length is calculated asthe fillet weld length (includes welding inside and outside the skirt), and the longitudinal seam weldlength is calculated as the groove weld length (welding used to join the base ring segments).

Skirt base rings cut as one segment have no seams so the groove weld length is zero.

Coster selects the plate size and layout of the skirt base ring similar to the methods described in the

“Skirt Base Ring Calculations” on page 11-52 and in “How Coster Determines The Layout of SkirtBase Rings” on page 11-9 with the following exception. Instead of comparing the required platesize to the stock plate sizes available, Coster compares the required plate size to the maximumallowable plate width and maximum allowable plate length dimensions (user defined defaults on theFabrication dialog of the Defaults - Other menu). If the user defined maximum allowable platewidth and plate length dimensions are too small to allow Coster to create a base ring layout usingfrom 1 to 6 segments, an error message is displayed showing the plate dimensions required to lay out

the base ring in 6 segments so that you can adjust the maximum allowable plate length and widthdimensions on the Fabrication dialog of the Defaults - Other menu before estimating the vesselagain.

Segment cutting labor and scrap material cost are included for the skirt base ring as shown in the“Skirt Base Ring Calculations” on page 11-52 since the base ring must be cut from the plate sizespecified either in one piece or nested sections. Plate cutting labor is not included since the platesize is the required size and does not need to be cut from a larger stock plate.

cutting length circumferential seam weld length longitudinal seam weld length+=

fillet weld length π 2 skirt OD××=

base ring widthbase ring OD base ring ID–

2-------------------------------------------------------------------=

groove weld length number of segments base ring width×=





Purchased Cylinders

Since some shops may purchase cylinders rather than fabricating them an option is available on theFabrication dialog of the Defaults - Other menu to indicate whether the cylinders are purchasedformed and tacked only or formed, tacked, and welded. Coster includes two separate tables forpurchased cylinders -- Cylinder Costs (formed/tacked) and Cylinder Costs (welded). Pricing forpurchased cylinders will be read from these tables and fabrication hours and costs (forming, cutting)will be eliminated from the estimate. If the cylinders are purchased formed and tacked only then thelongitudinal seam weld length will be calculated according to the length of the componentmultiplied by the number of seams (based on diameter) from the Diameter/Longitudinal WeldSeams Ratio dialog on the Defaults - Welding menu.

Cylinder Calculations

Coster estimates cylinders made from pipe material according to the pipe size and pipe schedule.After determining the size and schedule Coster looks up the Pipe Cost Schedule database table tofind the material cost per foot. Using the pipe material waste or the pipe minimum cut length from

the Fabrication dialog on the Defaults - Other menu Coster calculates the total material costincluding waste for pipe (if the length of pipe is less than the pipe minimum cut length then theminimum cut length is used for estimating; otherwise the pipe material waste is used).

Cylinders fabricated from plate material are estimated using the stock plate size(s) that Costerselects to cut out the cylinder. Refer to “How Coster Determines Material Layout and PlateRequirements (Default Method)” on page 11-3 for the method that Coster uses to select plate sizes.Plate unit cost is read from the Plate Costs table. Material cost for fabricated cylinders is calculated

using the finished weight and the plate unit cost. The stock plate used for cutting out the cylinder isaccounted for in the Weight of Source Material column and in the listing of plate usage in the Bill ofMaterials. Cutting length is calculated based on the cutting layout and the cutting labor rate is read

from the Miscellaneous Fabrication Labor table. Forming labor hours for fabricated cylinders areread from the Cylinder Forming Labor table.

For purchased cylinders the material cost is read from the Cylinder Costs (formed/tacked) orCylinders Costs (welded) table. The exact dimensions of the cylinder are used to calculate weight inthe Weight of Source Material column. Cutting and forming labor are eliminated for purchasedcylinders.

For both fabricated and purchased cylinders made from pipe and plate materials, other properties(metallurgy, material density, welding rod density, normalization and impact test premiums) arefound on the Material Properties database table. Normalization and impact test premiums are added

to the material cost if required (see “Normalization and Impact Testing” on page 11-93).Circumferential seam welding and longitudinal seam welding are calculated using the welddeposition rate tables (Weld Deposition Rate - Circumferential Seam Weld and Weld DepositionRate - Longitudinal Seam Weld) based on the type of welding selected from the Weld Detail dialogon the Defaults - Welding menu. Blasting and cleaning are calculated according to the type ofblasting selected on the User Selectable Items dialog and the user defined defaults values on theBlasting/Cleaning dialog on the Defaults - Finishing menu. Grinding of the seams is calculated





from values on the Grinding table according to the selections on the User Selectable Items dialog.

Labor hours to fit up the cylinder to the attached component are read from the Fitup Labor tables.

The COMPRESS .xml file provides the following information:

- thickness- ID- OD- length- pipe nominal size and schedule- radiography of longitudinal and circumferential seams- description of attached component (material, ID, OD, thickness)- whether the material is normalized

- whether the material is impact tested- weight- material

For cylinders made from pipe material:

From the Pipe Cost Schedule table find the cost per unit length. Read the MaterialProperties table to find material density, weld rod density, weld rod unit cost,normalization and impact testing factors, and metallurgy.

For cylinders made from plate material:

Read the Plate Costs table to find plate cost. Read the Material Properties table to findmaterial density, weld rod density, weld rod unit cost, normalization and impact testingfactors, and metallurgy.

For purchased cylinders:

Read the Cylinder Costs (formed/tacked) or Cylinder Costs (welded) table to find thecylinder cost. Read the Material Properties table to find material density, weld roddensity, weld rod unit cost, normalization and impact testing factors, and metallurgy.

Material Costs

pipe material cost = length of pipe/12 x pipe cost per ft

plate weight = finished weight from COMPRESS

plate material cost = plate weight x plate cost per lb

purchased material cost = cylinder cost from table

Coster uses an internal procedure to determine the plate dimensions of each piecerequired to fabricate the cylinder and the plate size from which each of these pieces will





be cut (see “How Coster Determines Material Layout and Plate Requirements (Default

Method)” on page 11-3).

weld rod weight = (length x weld area x weld rod density) / weld recovery

weld rod material cost = weld rod weight x weld rod cost per lb

Labor Hours and Labor Costs

Forming Labor

pipe - no forming hours

plate - read from the Cylinder Forming Labor table based on thickness and cylinder ID

purchased cylinder - no forming hours

forming labor cost = forming labor hrs x manufacturing labor rate

Fitup Labor

If this cylinder is attached to another cylinder, then the fitup labor hours are read fromthe Fitup Labor - Cylinder/Cylinder table based on the thickness and diameter of thecylinder with the larger outer diameter or the thickness and diameter of this cylinderwhen the outer diameter of both cylinders is equal. Similarly, if this cylinder is attached

to a transition the fitup labor hours are read from the Fitup Labor - Cylinder/Transitiontable based on the thickness and diameter of the cylinder. If this cylinder is attached to ahead the fitup labor hours are included with the head.

fitup labor cost = fitup labor hrs x manufacturing labor rate

Cutting Labor

pipe - no cutting labor hours

plate - read the cutting rate based on the cylinder thickness and metallurgy from the

Miscellaneous Fabrication Labor table. The total cutting length is calculated accordingto the plate dimensions Coster has determined for each piece required to fabricate thecylinder.

purchased cylinder - no cutting labor hours

total cutting hourstotal cutting length

12---------------------------------------------

cutting rate

60---------------------------×=





Long Seam and Girth Seam Labor Hours

pipe - no longitudinal seam welding, only circumferential welding calculated similarlyto plate welding labor hours

plate

purchased cylinder - longitudinal seam welding is included for cylinders purchased

formed and tacked only and circumferential welding is calculated similarly to platewelding labor hours

labor cost = labor hrs x welding labor rate

Bevelling Labor

The top and bottom bevel lengths are both the "y" dimension of the required plate size(s)used to fabricate the cylinder. The extra bevel length is the "x" dimension of the requiredplate size(s) multiplied by 2 so that both sides of the seam are bevelled (this is usuallythe longitudinal seam):

For cylinders custom cut to component size the extra bevel length is calculated:

The total bevel length is:

The Item Labor Cost column on the estimate totals all the labor costs for the cylinder.

total labor cost = long seam labor cost + forming labor cost + fitting labor cost +cuttinglabor cost + girth seam labor cost + blasting /cleaning labor cost + grinding labor cost

Surface Area

labor hrslength weld area weld rod density××

weld deposition rate

operator weld efficiency----------------------------------------------------------

------------------------------------------------------------------------------------------=

extra bevel length 2 X required plate dimension×=

extra bevel length 2 X required plate dimension number of long seams××=

bevel length top bevel length bottom bevel length extra bevel length+ +=

outside surface area π OD length××

144---------------------------------------=





Transition Calculations

Transitions are estimated using the stock plate size(s) that Coster selects to cut out the transition.Refer to “How Coster Determines The Layout of Conical Sections” on page 11-6 for the method thatCoster uses to select plate sizes. Plate unit cost is read from the Plate Costs table. Material cost forthe transition is calculated using the finished weight and the plate unit cost. The stock plate used forcutting out the transition is accounted for in the Weight of Source Material column and in the listingof plate usage in the Bill of Materials. Cutting length is calculated based on the cutting layout and tocut out the required plate size from a larger stock plate and the length to cut out each segmentrequired to fabricate the transition. The cutting labor rate is read from the Miscellaneous FabricationLabor table. Forming labor hours are read from the Cones and Skirts Forming Labor table.

Other properties (metallurgy, material density, welding rod density, normalization and impact test

premiums) are found on the Material Properties database table. Normalization and impact testpremiums are added to the material cost if required (see “Normalization and Impact Testing” onpage 11-93). Circumferential seam welding and longitudinal seam welding are calculated using thedeposition rate tables (Weld Deposition Rate - Circumferential Seam Weld and Weld DepositionRate - Longitudinal Seam) based on the type of welding selected from the Weld Detail dialog on theDefaults - Welding menu. Blasting and cleaning are calculated according to the type of blastingselected on the User Selectable Items dialog and the user defined default values on the Blasting/ Cleaning dialog on the Defaults - Finishing menu. Grinding of the seams is calculated from valueson the Grinding table according to the selections on the User Selectable Items dialog. Labor hoursto fit up the transition to the attached component are read from the Fitup Labor tables.


- thickness- Small ID- Small OD- Large ID- Large OD- length (axial length)- whether the material is normalized- whether the material is impact tested

- weight- material

- orientation of transition- radiography of longitudinal and circumferential seams- description of attached component (material, ID, OD, thickness)

Determine the cone surface length, H, for calculating surface area.

inside surface area π ID length××

144-------------------------------------=





Material Costs

Read the Plate Costs table to determine plate cost. Read the Material Properties table todetermine metallurgy, material density, weld rod density, weld rod unit cost,normalization and impact testing factors.


plate cost = plate weight x plate cost per lb

Coster uses an internal procedure to determine the plate dimensions of each piece

required to fabricate the transition and the plate size from which each of these pieces willbe cut (see “Plate Selection” on page 3-2).



Forming Labor

Read forming labor hours from the Cones and Skirts Forming Labor table based on

thickness and Large ID


Fitup Labor

If this transition is attached to a cylinder, then the fitup labor hours are read from theFitup Labor - Cylinder/Transition table based on the thickness and diameter of thecylinder.


Cutting Labor

Read the cutting rate based on the transition thickness and metallurgy from theMiscellaneous Fabrication Labor table. The total cutting length is calculated accordingto the plate dimensions Coster has determined for each piece required to fabricate thetransition and the length to cut out each segment.

Cone surface length, H axial length( )2 Large ID Small ID–( )

2

2---------------------------------------------------------+=

weld rod weightlength weld area weld rod density××

weld recovery----------------------------------------------------------------------------------------------=






labor cost = labor hrs x welding labor rate

Bevelling Labor

Calculate bevel lengths where:



If the orientation of the transition from top to bottom is Small to Large calculate the topand bottom bevel length:

If the orientation of the transition from top to bottom is Large to Small calculate the topand bottom bevel length:

The extra bevel length is the cone surface length, H multiplied by 2 so that both sides ofthe seam are bevelled:


total cutting hourstotal cutting length cutting rate×

12 60×------------------------------------------------------------------------------=

labor hours length weld area weld rod density××weld deposition rate

operator weld efficiency----------------------------------------------------------

------------------------------------------------------------------------------------------=

top bevel lengthDS π×


bottom bevel lengthDL π×


top bevel lengthDL π×


bottom bevel lengthDS π×


extra bevel length 2 cone surface length, H×=





Surface Area

Vacuum Rings Calculations

Estimating vacuum rings is slightly different for files saved in Compress 5.x and Compress 6.x.

Compress 6.x allows the user to input values for weld size, welding spacing, weld length, type ofwelding (intermittent, continuous, one or two sides), and whether the rings are inside or outside the

vessel. If the weld spacing and weld length values are both zero then Coster assumes that thewelding is 100% continuous. In Compress 6.x the neutral axis for rings is calculated to take into

consideration how the ring bends when it is rolled. This neutral axis is used in Coster to calculatethe total ring circumference. These inputs are used to calculate the welding to attach the ring to theshell.

Compress 5.x rings are always outside the vessel and weld size and type of welding are determinedaccording to the user defined default settings within Coster (weld size is the value for Vacuum RingFillet Weld Size and type of welding is made up of two values -- Vacuum Ring Intermittent Welding(percent to weld) and Vacuum Ring Welding (1 side or 2 sides)). These vacuum ring default settingsare found on the Weld Detail dialog of the Defaults - Welding menu and are used to calculate the

welding to attach the ring to the shell.

Compress 6.x and Compress 5.x files

According to the material, structural type and size of the vacuum ring, Coster looks up the $/lbmaterial cost from the Structures/Rings/Tray Supports Material Costs table. The material cost forvacuum rings is calculated using the finished weight and normalization and impact test premiumsare added if required (see “Normalization and Impact Testing” on page 11-93). Metallurgy, weldingrod density, weld rod unit cost, and normalization and impact test premiums are read from theMaterial Properties table. The vacuum ring weld deposition rate used to calculate butt welding laborhours is a user defined default value on the Weld Detail dialog of the Defaults - Welding menu.

Coster assumes there is one butt weld used to join the rings for every 10 feet of shell circumference.An extra butt weld is added for any remainder. The weld gap used in the calculation is the maximumof the user defined default weld gap (Weld Detail dialog on the Defaults - Welding menu) and 1/8

inches. Forming labor hours for vacuum rings are read from the Vacuum Ring Labor table.


- cross section area


outside surface area0.5 π cone surface length, H×× Large OD + Small OD( )×

144

-----------------------------------------------------------------------------------------------------------------------------------------------=

inside surface area0.5 π cone surface length, H× Large ID+Small ID( )×

144---------------------------------------------------------------------------------------------------------------------------------=





- density

- inside shell corrosion allowance- outside shell corrosion allowance- vacuum ring ID (ring ID) -- this is equal to the shell OD- vacuum ring OD- whether the material is normalized- whether the material is impact tested- description of attached component (material, ID, OD, thickness)- whether the rings are inside or outside the vessel- weld configuration (intermittent or continuous and welding 1 or 2 sides)- vacuum ring fillet weld size (leg size)- weld spacing- weld length

- ring width- ring depth- neutral axis for rings in the x direction- weight

- vacuum ring material- vacuum ring description (size and type of vacuum ring -- flat bar, equal leg angle,

unequal leg angle, I beam/wide flange, structural tee, user defined)

Other parameters are:

- vacuum ring weld deposition rate (ring weld deposition rate)

Calculations for vacuum rings for vessels designed using Compress 5.x and the VesselModeler are different than for vessels designed using Compress 6.x. The Compress 6.xvessel design contains additional information that is used in the calculations.

COMPRESS 5.x and Vessel Modeler

Calculations for Compress 5.x and Vessel Modeler vessels use the Coster values forvacuum ring fillet weld size, vacuum ring welding 1 or 2 sides, and vacuum ringintermittent welding from the Weld Detail dialog on the Defaults - Welding menu.

Calculate the ring to shell weld volume based on the leg size, total ringcircumference, welding on one or two sides and the percent of welding (intermittent

or 100%).

total ring circumference π shell OD×=

ring to shell weld volume

leg size2

2-------------------- sides to weld total ring circumference intermittent welding×××

100---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------=





COMPRESS 6.x

Compress 6.x vessels provide additional information for rings. The Coster values fromthe Fillet Welds dialog on the Defaults - Welding menu for vacuum ring fillet weld size,vacuum ring welding 1 or 2 sides, and vacuum ring intermittent welding will not be usedsince these values are provided within the Compress 6.x vessel design.

Calculate the total ring circumference.

Calculate the percentage of welding required. If the weld length and the weld spacingentered are both zero then Coster assumes that the welding is 100% continuous.(percent to weld = 1)

Calculate the ring to shell weld volume using the total ring circumference and percent toweld according to the type of welding selected in the Compress 6.x vessel design.

In-Line Intermittent and Staggered Intermittent

sides to weld = 2

Continuous One Side, Intermittent Other Side

total ring circumference π ring ID 2 neutral axis for rings )×+(×=

percent to weldweld length

weld length + weld spacing

------------------------------------------------------------------=

ring to shell weld volume =

leg size 2

2---------------------- sides to weld total ring circumference percent to weld×××

continuous side weld volumeleg size 2

2---------------------- total ring circumference×=

intermittent side weld volume =

leg size2

2---------------------- total ring circumference percent to weld××

ring to shell weld volume =

continuous side weld volume + intermittent side weld volume





Continuous both sides

sides to weld = 2

Material Costs

Read Structures/Rings/Tray Supports Material Costs table to find the ring cost per lb forthe material, ring type and size. Read the Material Properties table to find metallurgy,material density, weld rod density, weld rod unit cost, normalization and impact testingfactors.

weight = finished weight from Compress

material cost = weight x structure cost per lb



To calculate the number of butt welds for the ring we assume that there is one butt weldfor every 10 feet (or part of a foot) of outside shell circumference. Coster assumes that

the vacuum rings are purchased in 10 foot lengths.

ring butt welds = total ring circumference / 12 / 10

Because of the way rings are formed the weld gap will always be at least 0.125 in. Tocalculate the ring butt weld volume Coster uses the maximum of either the weld gap or0.125 in.

ring labor cost = ring labor hrs x welding labor rate

Read the ring forming hours from the Vacuum Ring Labor table according to theShell OD.

ring to shell weld volumeleg size

2

2

---------------------- sides to weld total ring circumference××=

weld rod weight ring butt weld volume ring to shell weld volume )+(weld rod density weld recovery ⁄ ×

=

ring butt weld volume cross section area maximum(weld gap or 0.125)ring butt welds×

×=

ring labor hrs = ring butt weld volume weld rod density×ring weld deposition rate operator weld efficiency×------------------------------------------------------------------------------------------------------------------------------





forming cost = ring forming labor hrs x manufacturing labor rate

girth seam cost = girth labor hrs x welding labor rate

2:1 Heads, F&D Heads, Hemispherical Heads Calculations

Coster assumes that all heads are purchased. The head cost is found on the corresponding HeadCosts table based on the head nominal thickness and material specification. If Coster cannot read orinterpolate a head cost from the Head Costs tables then you will be asked to provide a cost.

Metallurgy, material density, welding rod density, welding rod unit cost, and normalization and

impact test premiums are read from the Material Properties table. Normalization and impact testpremiums are added to the material cost if required (see “Normalization and Impact Testing” on

page 11-93). Labor hours to bevel the head are read from the Head Bevel Labor table.Circumferential seam welding is calculated using the Weld Deposition Rate - Circumferential SeamWeld table based on the type of welding selected from the Weld Detail dialog on theDefaults - Welding menu. Blasting and cleaning are calculated according to the type of blastingselected on the User Selectable Items dialog and the user defined default values on the Blasting/ Cleaning dialog on the Defaults - Finishing menu. Grinding of the seams is calculated from valueson the Grinding table according to the selections on the User Selectable Items dialog.


- thickness- ID- whether the material is normalized- whether the material is impact tested- material- description of attached component (material, ID, OD, thickness and whether it is

attached on the left or right side of the head)- weight- lined head volume in US gallons (the lining volume is subtracted from the head

volume)- straight flange length

Material Costs

Read the Material Properties table to find metallurgy, material density, weld rod density,weld rod unit cost, normalization premium, impact testing factors.

Read the head costs table (2:1, F&D, Hemispherical) to find the head cost based on thehead OD, head nominal thickness, and material.

girth labor hrsring to shell weld volume weld rod density×

ring weld deposition rate operator weld efficiency×----------------------------------------------------------------------------------------------------------------------------=







Fitup Labor

If this head is attached to a cylinder or another nozzle, then the fitup labor hours are readfrom the Fitup Labor - Head/Cylinder table based on the thickness and diameter of thecylinder or nozzle.


Head Bevel Labor Hours

The labor hours to bevel the head are read from the Head Bevel Labor table based on thestraight flange thickness and the outer diameter. The head bevel labor hours are reportedas part of the forming labor hours.

head bevel labor cost = head bevel labor hrs x manufacturing labor rate


Longitudinal labor costs are zero for heads. Coster uses the mid-circumference as the

weld length for heads.

girth seam cost = girth seam labor hrs x welding labor rate

Surface Area for 2:1 Heads

Surface Area for F&D Heads

weld rod weightlength weld area× weld rod density×

weld recovery------------------------------------------------------------------------------------------=

girth seam labor hrs weld area weld length× weld rod density )weld deposition rate operator weld efficiency ⁄ ⁄

×(=

outside surface area1.084 OD

2× ) π OD straight flange length)××(+(

144----------------------------------------------------------------------------------------------------------------------------=

inside surface area1.084 ID2× ) π ID straight flange length )××(+(

144------------------------------------------------------------------------------------------------------------------------=

outside surface area0.9286 OD

2× ) π OD straight flange length )××(+(

144-------------------------------------------------------------------------------------------------------------------------------=





Surface Area for Hemispherical Heads

Flat Heads Calculations

Coster estimates material costs, fitup and welding labor for flat head sketches (b-1), (b-2), (c), (d),(e), (f), (g) and (h).

Metallurgy, material density, welding rod density, welding rod unit cost, and normalization andimpact test premiums are read from the Material Properties table. Normalization and impact testpremiums are added to the material cost if required (see “Normalization and Impact Testing” onpage 11-93). Bevelling of the flat head and hydrotest are not considered. Blasting and cleaning arecalculated according to the type of blasting selected on the User Selectable Items dialog and the userdefined default values on the Blasting/Cleaning dialog on the Defaults - Finishing menu. Grindingof the seams is calculated from values on the Grinding table according to the selections on the UserSelectable Items dialog. Paint and primer are calculated according to the selections on the userSelectable Items dialog.


- thickness- OD- whether the material is normalized- whether the material is impact tested- material- flat head sketch- description of attached component (material, ID, OD, thickness and whether it is

attached on the left or right side of the head)

- weight

Other parameters are

- waste from flame cutting- bevel angle (nozzle groove welds) (nozzle weld angle)- weld gap

inside surface area0.9286 ID

2× ) π ID straight flange length )××(+(

144---------------------------------------------------------------------------------------------------------------------------=

outside surface areaπ OD2 2 ) ⁄ (× ) π OD straight flange length )××(+(

144------------------------------------------------------------------------------------------------------------------------------=

inside surface areaπ ID

22 ) ⁄ (× ) π ID straight flange length)××(+(

144--------------------------------------------------------------------------------------------------------------------------=





Material Costs

Read the Plate Costs table to determine plate cost. Read the Material Properties table todetermine metallurgy, material density, weld rod density, weld rod unit cost,normalization and impact testing factors.



Coster assumes that there is plate material available for cutting out the flat head. Thesize that Coster displays on the Bill of Materials is a square with dimensions of the flathead OD plus 2 times the waste from flame cutting. The scrap material for the flat head

is based on this plate size.


Cutting Labor

Read the cutting rate based on the flat head thickness and metallurgy from theMiscellaneous Fabrication Labor table. The cutting length is calculated below

depending upon whether or not the head is seamless.

Cutting length for seamless flat head

Cutting length for flat head (Coster assumes that there is one seam in the center)

plate width OD 2 flame cutting waste )×+(=

plate length OD 2 flame cutting waste )×+(=

area of flat head πOD

2--------

×2

=

scrap material plate width plate length area of flat head–×=

total cutting length π OD×=

total cutting length π OD ) 2 OD )×(+×(=

total cutting hourstotal cutting length

12---------------------------------------------

cutting rate

60---------------------------×=





Fitup, Layout, and Machining Labor

Fitup labor hours for flat head sketches (c), (e), (f), (g) and (h) are read from the HeadFlat Fitup Labor table based on the flat head OD and thickness. Fitup labor hours for flathead sketches (b-1), (b-2) and (d) are read from the Fitup Labor - Head/Cylinder tablebased on the attached component OD and attached component thickness. Read thelayout labor hours from the Head Flat Fitup Labor table and the machining labor hoursfrom the Head Flat Machining Labor table for all flat head sketches based on the flathead OD and thickness. Fitup, layout, and machining labor costs are calculated using themanufacturing labor rate.

labor cost = labor hrs x manufacturing labor rate

Welding Labor

local shell thickness = thickness of attached component from Compress .xml file

The fillet weld length, fillet weld area, groove weld length, and groove weld area arecalculated according to the flat head sketch as shown below.

a) Sketches (b-1), (b-2), (d)

If there is an attached component (cylinder, 2:1 head or f&d head) then the groove weldarea is calculated as follows similar to the nozzle v groove weld where the groove size isthe local shell thickness. Otherwise the groove weld area and groove weld length areboth zero.

fillet weld length 0=

fillet weld area 0=

fillet weld hours 0=

Area A 0.5 local shell thickness2

× nozzle weld angle )(tan×=

Area B weld gap local shell thickness×=

groove weld area Area A Area B+=

θ nozzle bevel angle=





Read the girth seam weld deposition rate from the Weld DepositionRate - Circumferential Seam Weld table based on the local shell thickness andmetallurgy.

b) Sketches (c), (e) and (f)

The fillet weld length is multiplied by 2 to include two fillet welds (double fillet lapattachment weld).

Read the fillet welding rate from the Miscellaneous Fabrication Labor table based on the

local shell thickness and metallurgy.

c) Sketch (g)

groove weld length π OD×=

groove weld hours groove weld area groove weld length weld rod density )

girth seam weld deposition rate operator weld efficiency ⁄ ⁄

××((=

fillet weld length π OD 2××=

fillet weld arealocal shell thickness

2

2--------------------------------------------------=

fillet weld hours fillet weld length 12 ) fillet welding rate× ⁄ (=

groove weld length 0=

groove weld area 0=

groove weld hours 0=

fillet weld length 0=

fillet weld area 0=





The groove weld area is calculated as follows similar to the nozzle v groove weld wherethe groove size is the flat head thickness. This is a full penetration groove attachment

weld at the head circumference.

Read the groove welding rate from the Miscellaneous Fabrication Labor table based on

the flat head thickness and metallurgy.

d) Sketch (h)

This is a full penetration shell to head attachment weld with cover fillet weld (only one

fillet weld in this case).

The groove weld area is calculated as follows similar to the nozzle v groove weld wherethe groove size is the local shell thickness:

fillet weld hours 0=

Area A 0.5 flat head thickness2


Area B weld gap flat head thickness×=



groove weld hours groove weld length 12 ) groove welding rate× ⁄ (=

fillet weld length π OD×=

minimum thickness minimum flat head thickness or local shell thickness )(=

fillet weld areaminimum thickness

2

2-------------------------------------------------=

Area A 0.5 local shell thickness2


Area B weld gap local shell thickness×=







Read the fillet welding rate and the groove welding rate from the Miscellaneous

Fabrication Labor table based on the local shell thickness and metallurgy.

Long Seam Labor Hours

If there is not a head longitudinal joint then the long seam labor hours are zero.Otherwise, if there is a head longitudinal joint calculate the longitudinal seam weldinglabor. Read the longitudinal seam weld deposition rate from the Weld DepositionRate - Longitudinal Seam Weld labor table based on the metallurgy and the flat headthickness.

Coster uses the flat head OD as the weld length.

Surface Area for Flat Heads

The fillet weld volume and groove weld volume are calculated based on the area and lengthcalculated above.

fillet weld hours fillet weld length 12 ) fillet welding rate× ⁄ (=

groove weld hours groove weld length 12 ) groove welding rate× ⁄ (=

long seam labor hrs weld area weld length weld rod density )weld deposition rate operator weld efficiency ⁄ ⁄

××(=

area of flat head πOD

2--------

×2

=

area of flat head edge π OD flat head thickness××=

outside surface area area of flat head area of flat head edge) 144 ⁄ +(=

exposed inside head diameter OD 2( flat head thickness )×–=

inside surface area π exposed inside head diameter2

× 4 ) 144 ⁄ ⁄ (=

fillet weld volume fillet weld area fillet weld length×=

groove weld volume groove weld area groove weld length×=

weld rod weightfillet weld volume groove weld volume ) weld rod density×+(

weld recovery-------------------------------------------------------------------------------------------------------------------------------------------------------=





Body Flange Calculations

ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2


- flange ID- flange OD- length- flange length, e- thickness- description of attached component (material, ID, OD, thickness and whether the

attached component is made from a plate of pipe material -- if made from pipematerial then the pipe schedule and nominal size are provided)

- whether there is a hub present- hub thickness, G0- hub length- whether it is an ASME B16.5/16.47 or ASME Section VIII Division 1

Appendix 2 flange- number of bolts- bolt diameter- groove weld size- upper fillet weld size- lower fillet weld size- lap fillet weld size

- lap thickness- whether there is a blind attachedflange weight- blind weight (if there is a blind attached)- flange type (WN, SO, TH, SW, LJ, ring type integral, ring type full face gasket,

ring type loose, weld neck integral, slip on full face gasket, slip on loose, slip onintegral, lap joint loose, split loose, reverse integral, reverse loose)

- class- flange material- flange nominal size

This calculation does not apply to bare pipe, long weld necks or couplings. Hydrotest

hours are not considered for ASME B16.5/16.47 or ASME Section VIII Division 1Appendix 2 body flanges.

If the attached component is a pipe material, look up the appropriate Pipe Cost Scheduletable for metallurgy.

weld rod material cost weld rod weight weld rod cost per lb×=





Material Costs

Read the Material Properties table to find the metallurgy and weld rod unit cost based onthe flange material.

ASME B16.5/16.47 flange:

Read the flange cost from the appropriate flange table based on the flange material,flange nominal size and class (for weld neck type the bore size is also required). Theflange cost is reported in the material cost column of the estimate.

ASME Section VIII Division 1 Appendix 2 flange:

Read the plate cost from the Plate Cost table based on the flange material, flange OD,and flange thickness.

If there is an ASME B16.5/16.47 blind attached it is reported as a separate item in theshell section of the estimate. Read the blind cost from the blind cost table based on theflange material, class, flange facing and flange nominal size. The blind cost is reportedin the material cost column of the estimate. If there is a blind attached to the ASMESection VIII Division 1 Appendix 2 flange, it will be estimated as a separatecomponent -- bolted cover.


ASME B16.5/16.47 flange labor:

Read the Flange To Nozzle - Fitup Labor table to find labor hours to fit up the flangeto the nozzle based on the flange type (weld neck flange or other ASME B16.5/16.47flange), metallurgy, OD and pipe schedule (see “Flange Cost/Flange Labor” on page11-73 for lookup method). The fitup labor cost is calculated using the manufacturinglabor rate.

flange fitup labor cost = flange fitup labor hrs x manufacturing labor rate

Read the Flange To Nozzle - Welding Labor table to find labor hours to weld theflange to the nozzle based on the flange type (weld neck flange or other ASME

B16.5/16.47 flange), metallurgy, OD and pipe schedule (see “Flange Cost/FlangeLabor” on page 11-73 for lookup method). Read the girth seam weld deposition ratefrom the Weld Deposition Rate - Circumferential Seam Weld table based on thethickness and metallurgy. The welding labor hours are reported in the long seamlabor column of the estimate and the welding labor cost is calculated using thewelding labor rate.

flange welding labor cost = flange welding labor hrs x welding labor rate

material cost plate cost per lb flange weight×=





weld rod weight = girth weld deposition rate x flange welding labor hrs

weld rod cost = weld rod weight x weld rod cost per lb

If there is an ASME B16.5/16.47 blind attached, read the blind labor hours from theBlind Flange Labor table based on the class and the flange nominal size. Otherwisethe blind labor hours are zero. The blind labor is reported in the forming labor hourscolumn of the estimate and the blind labor cost is calculated using the manufacturinglabor rate.

ASME Section VIII Division 1 Appendix 2 flange labor:

Read the machining labor hours from the Machining Labor table based on flange

type, hub detail and flange ID.

Read the drilling per minute rate from the Drilling Labor table based on flangematerial and bolt nominal size.

ASME Section VIII Division 1 Appendix 2 flange welding:

Ring Type Integral

no circumfrential butt weld present

Slip On Integral

no cirumferential butt weld present

Calculate the total weld length for ring type integral and slip on integral flange:

drilling labor hours drilling per minute rate flange thickness 60number of bolts×

⁄ ×=

groove weld length π flange ID groove weld size+( )×=

upper fillet weld length π flange ID upper fillet weld size–( )×=

lower fillet weld length π flange ID lower fillet weld size+( )×=

groove weld length π flange ID hub thickness, G0 groove weld size–+( )×=

upper fillet weld length π flange ID upper fillet weld size+( )×=

lower fillet weld length π flange ID hub thickness, G0lower fillet weld size–

+()

×=





Read the fillet welding rate and the groove welding rate from the MiscellaneousFabrication Labor table based on metallurgy and weld size to calculate the upperfillet weld, lower fillet weld and groove weld hours for ring type integral and slip onintegral flange:

Calculate the welding rod weight as follows:

Ring Type Full Face Gasket, Ring Type Loose, Slip On Full Face Gasket, Slip OnLoose

no circumferential butt weld present


total weld length groove weld length upper fillet weld lengthlower fillet weld length

++

=

fillet weld hours fillet weld rate fillet weld length 12 ⁄ ( )×=

groove weld hours groove weld rate groove weld length 12 ⁄ ( )×=

groove weld area groove weld size( )2

2 ⁄ =


upper fillet weld area upper fillet weld size( )2

2 ⁄ =

upper fillet weld volume upper fillet weld area upper fillet weld length×=

lower fillet weld area lower fillet weld size( )2

2 ⁄ =

lower fillet weld volume lower fillet weld area lower fillet weld length×=

flange welding rod weight groove weld volume upper fillet weld volumelower fillet weld volume

++

() welding rod density× weld recovery ⁄ =




2 ⁄ =






Calculate the total weld length for ring type full face gasket, ring type loose, slip onfull face gasket and slip on loose flange.

Read the fillet welding rate from the Miscellaneous Fabrication Labor table based onmetallurgy and weld size to calculate the upper fillet weld and lower fillet weld hoursfor ring type full face gasket, ring type loose, slip on full face gasket and slip onloose flange:

Weld Neck Integral

no fillet welds present

If there is a component attached calculate the circumferential seam area using the

flange ID and hub thickness, G0.

Reverse Integral


If there is a component attached calculate the circumferential seam area using theflange OD and hub thickness, G0.

Reverse Loose




2 ⁄ =


flange welding rod weight upper fillet weld volumelower fillet weld volume+

(

) welding rod density× weld recovery ⁄

=

total weld length upper fillet weld length lower fillet weld length+=


circumferential seam weld length π flange ID hub thickness, G0+( )×=

circumferential seam weld length π flange OD hub thickness, G0–( )×=

circumferential seam weld length π flange OD hub thickness, G0+( )×=





Read the circumfential weld deposition rate from the Welding

Time - Circumferential Seam Weld table based on the hub thickness, G0, weld typeand metallurgy.

Calculate welding rod weight as follows:

Lap Joint Loose, Split Loose

There is no welding at all unless a welded lap is specified. If it is a welded lap thenthe following welds are present:


Read the fillet welding rate based on metallurgy and lap fillet weld size and thegroove welding rate based on metallurgy and lap thickness from the MiscellaneousFabrication Labor table to calculate the fillet weld and groove weld hours for lap joint loose and split loose flange:

Surface Area

circumferential seam volume circumferential seam areacircumferential seam weld length×

=

flange welding rod weight circumferential seam volumewelding rod density× weld recovery ⁄

=

groove weld length π flange ID×=

groove weld area lap thickness )(2

2 ⁄ =

fillet weld length π flange ID×=

total weld length groove weld length fillet weld length+=


upper fillet weld area lap thickness( )2

2 ⁄ =

upper fillet weld volume upper fillet weld area fillet weld length×=

flange welding rod weight groove weld volume upper fillet weld volume+( )welding rod density× weld recovery ⁄

=

weld hours weld rate weld length 12 ⁄ ( )×=





ASME B16.5/16.47 flange:

ASME Section VIII Division 1 Appendix 2 flange:

Surface area for weld neck integral, lap joint loose, split loose, and reverse loose:

Surface area for all other types (ring type integral, ring type full face gasket, ring typeloose, slip on full face gasket, slip on loose, slip on integral, reverse integral:

Packed Bed Calculations

For packed beds only the weight is reported on the estimate.


- weight

Platform/Ladder and Top Head Platform Calculations

Coster reports the square footage of the platform and the total platform weight which includes theweight of the platform, railing and ladder. The cage weight is included in the ladder weight. Costeralso reports the platform, railing, and ladder material costs, labor hours and labor costs using thelookups from the Platform/Ladder Cost and Labor table. Due to the format of this table nointerpolation will be made.


- platform weight (includes railing and ladder weight)

- platform length- platform width

- railing linear weight (lb/ft)- description of attached component (material, ID, OD, thickness)- ladder weight per linear ft (ladder weight also includes the weight of the cage)- grating weight- platform distance to datum- ladder distance to datum

Square Footage and Weight

outside surface area π flange OD flange length××( ) 144 ⁄ =

inside surface area π flange ID flange length××( ) 144 ⁄ =

inside surface area π flange ID flange length××( ) 144 ⁄ =

inside surface area π flange ID flange length, e××( ) 144 ⁄ =





Coster calculates the square footage of the platform and the total weight, which includes

platform weight, railing weight, and ladder weight.

The ladder weight includes the cage weight as part of the lb/linear ft cost.

Platform, Railing, Ladder Material Cost and Labor Hours

The material cost per lb and labor hrs per lb for the platform, railing and ladder are readfrom the Platform/Ladder Cost and Labor table. The material cost is displayed in theMaterial Cost column and the labor hours are displayed in the Install or Other Laborcolumn of the estimate.

platform material cost = platform weight x platform cost per lb

platform labor hours = platform weight x platform labor hours per lb

railing material cost = railing weight x railing cost per lb

railing labor hours = railing weight x railing labor hours per lb

ladder material cost = ladder weight x ladder cost per lb

ladder labor hours = ladder weight x ladder labor hours per lb

Tray Support Ring Calculations

Coster estimates tray supports labor using the Tray Installation Labor table and calculates the weight

for trays and tray supports. The tray support material, structural type and size is set on the TraySupports dialog on the Defaults - Other menu and using the cost per lb value from the Structures/ Rings/Tray Supports Material Cost table based on the material, structural type, and tray support sizeCoster estimates the material cost of the tray supports. The properties (metallurgy, material density,

ladder length abs platform distance to datum ladder distance to datum–( )( ) 12 ⁄ =

ladder weight ladder length ladder weight per linear ft×=

railing length 2 platform length platform width )+(×=

railing weight railing length 12 railing linear weight× ⁄ =

platform weight platform weight railing weight– ladder weight–=

platform square footage platform weightweight of one sq ft of platform grating--------------------------------------------------------------------------------------------=





weld rod density, weld rod unit cost) are for the tray supports and are read from the Material

Properties table. Since the material cost for trays is so variable, the cost is a manual entry.


- number of trays- tray elevation of bottom tray- space between trays- tray diameter- tray weight per area (sq ft)- tray support weight


- vacuum ring weld deposition rate (ring weld deposition rate)- fillet weld size for vessel internals (leg size)- tray support material

- structural type- size

Material Costs

Read the Structures/Rings/Tray Supports Material Cost table to find the structure costper lb based on the material, structural type and size.

material cost = tray support weight per tray x structure cost per lb

Read the Material Properties table to find the metallurgy, weld rod density and weld rodunit cost of the tray support material.

Calculate the tray support weld volume. The volume is for welding both the top andbottom of the tray supports.

leg size

shell surface

leg size

equal leg angle





weld weight = weld rod density x tray support weld volume



girth labor hrs = weld weight / ring weld deposition rate / operator weld efficiency

girth seam cost = girth labor hrs x welding labor rate

Read the Tray Installation Labor table to find the tray support ring installation laborhours based on the vessel ID.

installation labor cost = installation labor hrs x manufacturing labor rate

Weight

Calculate the cross sectional area of each tray.

Calculate the total weight (tray and tray support weight).

total weight = (tray weight per sq ft x cross section area) + tray support weight

Insulation/Lining Calculations

The weight, thickness, and density for insulation and lining are reported on the estimate. Coster alsodisplays whether the insulation/lining is field installed or shop installed. If field installed then

material cost is reported as zero. If shop installed the material cost is calculated using the cost persq ft provided by the user during the costing process. To specify the type of installation (field orshop) for insulation/lining set the user defined default on the Insulation or Lining dialog on theDefaults - Clips menu. The number of clips is calculated with the user defined Insulation/LiningCoverage default value from the Insulation or Lining dialog on the Defaults - Clips menu. Similarlythe material cost for clips and the labor hours per clip are calculated with the user defined Insulation/ Lining Clips ($/clip) and Insulation/Lining Clip Labor (hrs/clip) default values.


tray support weld volumeleg size

2

2-------------------- π tray diameter 2×××=

weld rod weight weld weightweld recovery----------------------------------=

cross section area π tray diameter2

× 4 144 ⁄ ⁄ =





- thickness

- density- weight

Other parameters are:

- insulation/lining coverage (sq ft coverage per clip)- insulation/lining clips (clip cost each)- insulation/lining clip labor (labor per clip)

Material Costs

Calculate the insulation/lining material cost and the total clips cost. The cost per sq ft of

the insulation/lining will be manually input if the insulation/lining is shop installed.Otherwise the material cost will be zero.

material cost = surface area x cost per sq ft

The total clip cost is displayed in the consumables cost column of the miscellaneoussection of the estimate.

total clip cost = number of clips x clip cost each


The labor hrs per 100 sq ft will be manually input during the estimate if the insulation/ lining is shop installed. Otherwise the labor hrs to install the insulation/lining will bezero. Calculate labor hours.

labor hrs = (surface area / 100) x labor hrs per 100 sq ft

labor cost = labor hrs x manufacturing labor rate

Calculate the number of clips required to install the insulation (Coster rounds the numberof clips to the next full clip) and calculate the labor hours to install the clips.

number of clips = surface area / sq ft coverage per clip

labor hrs to install clips = number of clips x labor per clip

labor cost to install clips = labor hrs to install clips x manufacturing labor rate

surface area weight density ⁄ ( ) thickness 12 ⁄ ( ) ⁄ =





Saddles Calculations

The saddle quantity on the estimate is always reported as 2. Coster calculates the weight of the wearplate, base plate, web plate, and ribs according to the size of each component. Coster assumes thatthe saddle width from the Compress .xml file is equal to the width of the end ribs and the width ofthe inside ribs is the saddle width minus the web thickness.

Metallurgy, material density, welding rod density, and welding rod unit cost are read from theMaterial Properties table. The plate unit cost for the web plate, wear plate if present, base plate, andribs is read from the Plate Costs table.

The plate dimensions for each saddle component are shown on the Bill of Materials sheet and arelisted as user defined plate sizes in the plate usage section. To determine these dimensions Coster

assumes that there is one waste from flame cutting added to the width and length of each plate cutfor the base plate, wear plate and web plate. Coster assumes that these plates are cut out from thecorner of a stock plate so the waste from flame cutting is added to only two sides of the rectangle.Coster assumes that the ribs are sheared so there is no waste from flame cutting added to these plate

sizes. Scrap material for the web plate is calculated and included in the plate usage section of theBill of Materials. Normalization and impact test premiums are not considered for saddlecomponents.

The weld size for fillet welding on the saddles is read from the Saddle Fillet Weld Size value on theFillet Welds dialog of the Defaults - Welding menu. Labor hours to fit up the saddle and wear plateif present are read from the Saddles Fitting Labor table. The Miscellaneous Fabrication Labor tableprovides the cutting rate and fillet welding rate for each component.

The COMPRESS .xml file provides the following information

- saddle width- saddle material waste (saddle waste)- shell OD at left saddle -- left saddle diameter (Shell OD)- overall saddle height from base plate to vessel long axis- number of ribs- whether wear plate is present- wear plate contact angle (wear plate angle)- wear plate width

- wear plate thicknessbase plate thickness- rib thickness

- web plate thicknessbase plate width (as viewed from the side of the vessel)- base plate length (around the vessel as viewed from the end of the vessel)- saddle contact angle (θ)- whether centered web or edge web (saddle type)- material- weight





The quantity for saddles displayed on the estimate is always 2.


- saddle welding (1 or 2 sides of seam) (saddle sides to weld)- saddle fillet weld size (saddle leg size)

shell radius Shell OD 2 ⁄ =





Calculate the web plate height.

web plate height =

(overall saddle height-base plate thickness)-(shell radius x sin (90- / 2))

Calculate the wear plate arc length.

wear plate arc length = shell radius x wear plate angle

Calculate the wear plate weight if present.

wear plate length = wear plate angle x (shell radius + 0.5 x wear plate thickness)

wear plate weight = wear plate width x wear plate length x wear plate thickness x

material density

Calculate the base plate weight.

base plate weight = base plate length x base plate width x base plate thickness x materialdensity

If there are ribs present then calculate the rib width and the distance between end ribs (rib distance).

inside rib width = saddle width - web plate thickness

outside rib width = saddle width

rib distance = (Shell OD + 2 x wear plate thickness) x sin ( / 2)

For each pair of ribs, and center rib if present, Coster calculates the rib width, rib weight, rib height,total rib weight, total rib cutting length, and total rib weld length. The saddle welding (1 side ofseam or 2 sides of seam) entry from the Fillet Welds dialog on the Defaults - Welding menu is usedto calculate the total rib weld length.

θ

θ





rib weight = rib height x rib width x rib thickness x material density

Calculate the web plate length, web plate arc length, web plate weld length, and wear plate weldlength.

web plate length = base plate length - (4 x rib thickness)

Coster uses 4 times the rib thickness to calculate the web plate length in the equationabove to account for a fillet weld on the outside of the end rib on each side.

web plate arc length = shell radius x

web plate weld length = (web plate length + web plate arc length + (2 x web plateheight)) x saddle sides to weld

wear plate weld length = wear plate arc length x 2 + wear plate width x 2

Calculate the web plate scrap area and the web plate weight.

web plate top scrap area = 0.5 x (shell radius + wear plate thickness) ^2 x ( - Sin( ))

If the web plate length is greater than the rib distance then calculate extra scrap material

for the two areas outside the ribs. Otherwise the web plate side scrap area is zero.

web plate side scrap area = outside rib height x (web plate length - rib distance)

total web plate scrap area = web plate top scrap area + web plate side scrap area

θ

θ θ

web plate top scrap area

web plate sidescrap area





web plate weight = (web plate length x web plate height - web plate scrap area) x web

plate thickness x material density

Welding is calculated as a fillet weld using the saddle fillet weld size default as the leg size.Calculate the total weld volume by adding together the web plate weld volume, wear plate weldvolume, and the total rib weld volume.

total weld volume = web plate weld volume + wear plate weld volume + total rib weldvolume

Material Costs

Read the Plate Costs table to find web plate cost, base plate cost, rib cost and wear platecost. Divide each of the plate costs by 100 to get the plate cost per lb. Read the MaterialProperties table to find metallurgy, material density, weld rod density, and weld rod unitcost.

total base plate cost = (base plate weight x base plate cost per lb) + ((base plate weight xbase plate cost per lb) x (saddle waste / 100))

total wear plate cost = (wear plate weight x wear plate cost per lb) + (( wear plate weightx wear plate cost per lb) x (saddle waste / 100 ))

saddle fitting cost = saddle fitting time x manufacturing labor rate

wear plate fitting cost = wear plate fitting time x manufacturing labor rate

rib cutting cost = rib cutting hrs x manufacturing labor rate

web plate cutting cost = web plate cutting hrs x manufacturing labor rate

base plate cutting cost = base plate cutting hrs x manufacturing labor rate

wear plate cutting cost = wear plate cutting hrs x manufacturing labor rate

weld rod weight = (total weld volume x weld rod density) / weld recovery

web plate weld volumesaddle leg size

2

2------------------------------------- web plate weld length×=

wear plate weld volumesaddle leg size

2

2------------------------------------- wear plate weld length×=

total rib weld volumesaddle leg size

2

2------------------------------------- total rib weld length×=







Read the Saddles Fitting Labor table to find the saddle fitting time and the wear platefitting time based on the Shell OD.

If there is no wear plate present then the total fitting time is equal to the saddle fittingtime.

total fitting time = saddle fitting time + wear plate fitting time

Read the Miscellaneous Fabrication Labor table to find the cutting rate (for ribs, web

plate, base plate, wear plate if present), and fillet welding rate based on thickness andmetallurgy.

rib cutting hrs = ((total rib cutting length /12) x rib cutting rate) / 60

web plate cutting length = web plate length + (web plate height x 2) + web plate arclength

web plate cutting hrs = ((web plate cutting length /12) x web plate cutting rate) /60

base plate cutting length = (base plate width + base plate length) x 2

base plate cutting hrs = ((base plate cutting length / 12) x base plate cutting rate) /60

wear plate cutting length = (wear plate arc length + wear plate width) x 2

wear plate cutting hrs = ((wear plate cutting length /12) x wear plate cutting rate) /60

web plate weld hrs = fillet welding rate x (web plate weld length / 12)

wear plate weld hrs = fillet welding rate x (wear plate weld length / 12)

rib weld hrs = fillet welding rate x (total rib weld length / 12)

total rib weld hrs = rib weld hrs / operator weld efficiency

total wear plate weld hrs = wear plate weld hrs / operator weld efficiency

total web plate weld hrs = web plate weld hrs / operator weld efficiency

total welding hrs = total rib weld hrs + toal wear plate weld hrs + total web plate weld hrs

total welding labor cost = total welding hrs x welding labor rate





Surface Area

Calculate the surface area for base plate, web plate and ribs to estimate blasting,cleaning, painting, and priming. The wear plate is not included as it becomes part of thecomponent to which it is attached and is therefore included in the blasting, cleaning,painting and priming estimate for that component.

Base Plate

Web Plate

Ribs

Skirt Base Ring Calculations

Coster estimates the cost of the skirt base ring using a trial and error method to find the lowest totalcost for both labor and material. Depending on the size of the base ring and the available stock platesizes from the database table (see “How Coster Determines The Layout of Skirt Base Rings” onpage 11-9) Coster determines the labor and material costs required to fabricate the base ring in one,two, three, four, five, and six segments. Coster selects a suitable plate for cutting while minimizingthe scrap produced by comparing the required plate area to the stock plate area. Coster will use droppieces first if suitable. Normalization and impact testing are not considered for skirt base rings. Ifthere are no suitable stock plates to fabricate the base ring in any of the one to six segment layoutsthen Coster will display a plate size that will allow fabrication of the base ring in six segments. Youwill be asked to provide a user defined plate size using the suggested dimensions (or largerdimensions) to fabricate the base ring. Using this user defined plate size Coster repeats the process

to find the layout that produces the lowest total cost. On the estimate Coster reports the base ringlayout that generated the lowest total cost.

If possible Coster will reuse any rectangular plates (drop pieces) that remain after cutting out thebase ring and will list the unused drop pieces on the bill of materials sheet. All other leftover piecesremaining after the base ring has been cut out will be considered scrap and will not be reused tofabricate any remaining components. This scrap is listed by weight on the Bill of Materials sheet.

outside SAbase plate length base plate width) base plate length base plate thickness )

base plate width base plate thickness ) ) 2××(+×(+×((=

144 ⁄

outside SAweb plate length web plate height web plate scrap area ) 2 )×–

web plate arc length web plate thickness ) ) 144 ⁄ ×(+

×(((=

outside SA

rib height rib width ) rib height( rib thickness×+× ) rib width rib thickness) ) 2××(+((

144----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------=





The Miscellaneous Fabrication Labor table provides the cutting rate, fillet welding rate (for welding

gussets and base to skirt), groove welding rate (for welding the base ring segments together) anddrilling rate per hole. The weld length to weld the base ring to the skirt includes welding both insideand outside the skirt.

The base ring surface area includes both the top and bottom of the base ring and the inner and outersurface of the base ring.

The gusset fillet weld size is determined using the minimum of the gusset thickness and the skirtthickness. Similarly the fillet weld size (base to skirt weld size) is determined using the minimum ofthe base ring thickness and the skirt thickness.

Blasting/Cleaning is calculated according to the type of blasting selected on the User Selectable

Items dialog and the user defined default values on the Blasting/Cleaning dialog on theDefaults - Finishing menu. Grinding is calculated for both the top and bottom of the groove weld ofthe skirt base ring based on the skirt base ring thickness.

The total gusset weight, total gusset weld length, and gusset surface area are determined accordingto the base ring configuration.

a) single base ring with gussets -- Coster assumes triangular gussets and the gussetweld length includes welding on both sides of each gusset. Also included in theweld length is the extra length (gusset height) if the skirt is flared. The number ofgussets is calculated as two times the number of bolts.

b) single base ring with external chairs -- Coster assumes a rectangular shape for thetop plate. The number of chairs is equal to the number of bolts. Similar to thesingle base ring with gussets the weld length includes welding on both sides of

each gusset and also includes the extra weld length due to a flared skirt. Tocalculate the weld length for the top chair Coster assumes that the overhang isequal to the gusset thickness.

c) centered bolting chair -- The weld length includes welding on both sides of thechair.

d) double base ring -- The weld length includes any extra length due to a flared skirt.

Coster lists two entries on the estimate for double base rings -- one entry for thebase ring and a second entry for the compression ring. The first entry for basering follows the skirt base ring and double base ring section calculations below to

determine costs for the base ring and the gussets. The compression ring entryfollows the skirt base ring and single base ring with no gussets sectioncalculations below to determine costs for the compression ring. To calculate thecompression ring information using the formulas below substitute thecompression ring dimensions in place of the base ring dimensions.






- base plate material

- bolt material- description of attached skirt (material, ID, OD, thickness, angle)- base plate OD (Base OD)- base plate ID (Base ID)- base plate thicknessbase ring weight- bolt circle- number of bolts- base configuration- whether gussets are present- gusset inside separation- gusset height (vertical)

- gusset thickness (vertical)- compression ring/plate width out from skirt OD- compression plate/ring thickness

Read the Plate Costs table for plate cost. Read the Material Properties table to find metallurgy,material density, weld rod density, and weld rod unit cost.

Calculate the base ring weld length. Multiply by two to include welding both the inside and theoutside of the skirt.

base ring weld length = 2 x (Skirt OD x )

Calculate the base ring surface area. Multiply by two to include the top and bottom of the ring.

Calculate the total gusset weight, total gusset weld length, and gusset surface area based on the typeof base plate configuration (single base ring with gussets, single base ring with external chairs,double base ring, centered bolting chair, single base ring with no gussets). Welding of gussets isdone on both sides.

Single Base Ring With Gussets

Coster assumes triangular gussets. Calculate the number of gussets.

number of gussets = 2 x number of bolts

π

base ring surface area 2 π 4 ⁄ ) Base OD(×

2

(× Base ID

2

)π base plate thickness Base OD Base ID)+(××+

–=





Calculate the gusset base, gusset face area, gusset volume, and gusset weight.

gusset base = (Base OD - Skirt OD) / 2

gusset face area = 0.5 x gusset base x gusset height

gusset volume = gusset face area x gusset thickness

gusset weight = gusset volume x material density

Calculate the gusset skirt side to consider the extra length for a flared skirt (for a straight

skirt the gusset skirt side is equal to the vertical gusset height).

gusset skirt side = gusset height / Cos (skirt angle)

Calculate the gusset weld length and multiply by two to include welding on both sides ofone gusset.

gusset weld length = 2 x (gusset base + gusset skirt side)

total gusset weight = number of gussets x gusset weight

total gusset weld length = number of gussets x gusset weld length

Calculate the total gusset surface area.

Calculate the total surface area by multiplying by the number of gussets.

total gusset surface area = number of gussets x (2 x gusset face area + gusset open side)

Single Base Ring With External Chairs

Coster assumes a rectangular shape for the top plate and that the number of chairs isequal to the number of bolts.

number of chairs = number of bolts

gusset open side gusset height2

gusset base2

+ gusset thickness×=







gusset base = (Base OD - Skirt OD) /2

gusset face area = ((gusset base + compression ring width) / 2 ) x gusset height



Calculate the gusset skirt side to consider the extra length for a flared skirt (for a straight

skirt the gusset skirt side is equal to the vertical gusset height).

gusset skirt side = gusset height x cos (skirt angle)


gusset weld length = 2 x (gusset base + gusset skirt side + compression ring width)

In calculating the top chair length, Coster assumes that the overhang is equal to thegusset thickness for welding purposes.

top chair length = gusset inside separation + 4 x gusset thickness

top chair thickness = compression plate thickness

top chair volume = compression ring width x top chair length x top chair thickness

top chair weight = top chair volume x material density

top chair weld length = top chair length + gusset inside separation

total gusset weight = number of gussets x gusset weight + top chair weight x number ofchairs





toal gusset weld length = number of gussets x gusset weld length + top chair weld length

x number of chairs

Double Base Ring

Calculate the base ring entry on the estimate following the formulas below whichdetermine the gusset information. Repeat the skirt base ring calculations section for thecompression ring entry on the estimate following the single base ring with no gussetsformulas and substituting the compression ring dimensions in place of the base ringdimensions.



gusset base = (Base OD - Skirt OD) / 2

gusset face area = (( gusset base + compression ring width) /2) x gusset height



Calculate the gusset skirt side to consider the extra height for a flared skirt (for a straightskirt the gusset skirt side is equal to the vertical gusset height).

gusset skirt side = gusset height x cos (skirt angle)


gusset weld length = 2 x (gusset base + gusset skirt side + compression ring width)

total gusset weight = number of gussets x gusset weight

total gusset weld length = number of gussets x gusset weld length

total gusset surface area = number of gussets x (2 x gusset face area)

gusset open side gusset base top chair width )–(2

gusset height2

+=

total gusset surface area number of chairs 4 gusset face area )2 gusset open side(× gusset thickness top chair width top chair length)×+ )×+

×((×=





Centered Bolting Chair

number of chairs = number of bolts

chair base = (Base OD - Base ID) / 2

inside arc radius = gusset inside separation /2

outside height = gusset height + gusset thickness

outside width = gusset inside separation + 2 x gusset thickness

outside arc radius = outside width /2

Calculate the chair volume and the chair to skirt weld length.

arc length = ( x inside arc radius) / 2

arc volume = arc length x gusset thickness x chair base

straight length = gusset height - inside arc radius

straight length = gusset height - inside arc radius

straight volume = straight length x gusset thickness x chair base

chair volume = (arc volume + straight volume) x 2

chair to skirt weld length = (arc length + straight length) x 2

Calculate the chair weight and chair weld length based on the chair volume and chair toskirt weld length calculated above. The chair weld length is multiplied by two to includewelding on both sides.

chair weight = chair volume x material density

chair weld length = 4 x chair base + chair to skirt weld length x 2

total gusset weight = number of chairs x chair weight

total gusset weld length = number of chairs x chair weld length

total gusset surface area = number of chairs x (2 (chair to skirt weld length x chair base)+ 2 x (chair to skirt weld length x gusset thickness))

π





Single Base Ring With No Gussets

total gusset weight = 0

total gusset weld length = 0

total gusset surface area = 0

The total gusset weight, total gusset weld length, and total gusset surface area have now beencalculated according to the base ring configuration.

Base Ring Calculations For All Ring Configurations

Calculate the total base ring weight.

total base ring weight = base ring weight + total gusset weight

Coster determines the gusset fillet weld size as the minimum of the gusset thickness and the skirtthickness.

gusset fillet weld size = minimum (gusset thickness or skirt thickness)

gusset weld area = gusset fillet weld size 2 / 2

Calculate the base ring weld area. Coster determines the base ring fillet weld size as the minimum

of the base ring thickness and the skirt thickness.

base ring fillet weld size = minimum (base plate thickness or skirt thickness)

base ring weld area = base ring fillet weld size 2 / 2

Read the cutting rate from the Miscellaneous Fabrication Labor table based on the base platethickness and metallurgy and calculate the cutting hours.

Read the fillet welding rate from the Miscellaneous Fabrication Labor table based on the fillet weldsize and metallurgy and calculate the fillet weld length and fillet welding hours.

fillet weld length = x 2 x (Skirt ID + (2 x skirt thickness))

fillet weld hrs = fillet weld rate x (fillet weld length / 12)

If the base ring configuration is Single Base Ring No Gussets then the gusset welding hrs is zero.Otherwise, read the gusset welding rate from the Miscellaneous Fabrication Labor table based on thegusset thickness and metallurgy and calculate the gusset welding hours.

gusset weld hrs = gusset welding rate x (total gusset weld length /12)

π





Read the drilling rate from the Miscellaneous Fabrication Labor table based on the base plate

thickness and metallurgy and calculate the drilling hours.

drilling hrs = drilling rate x number of bolts

Calculate the inside radius and base ring width for use in the calculations below.

inside radius = Base ID / 2

base ring width = (Base OD - Base ID) / 2

Calculate the area of the base ring to use when calculating scrap material.

area of base ring = x ((Base OD / 2) 2 - (Base ID /2) 2 )

Calculate the width of the base ring including the waste from flame cutting from the Fabricationdialog on the Defaults - Other menu.

base ring burn out width = base ring width + waste from flame cutting

Coster makes six groups of calculations to find the total cost (labor and material) of the base ringbased on the number of segments in which the base ring is divided (one segment up to six segments).Coster chooses the layout of the base ring for the estimate according to the lowest total cost.

a) One Segment

Calculate the required plate length and required plate width to lay out the base ring usinga rectangular piece of material. If there is only one segment, Coster uses Base OD forthe required dimensions.

required plate length = Base OD

required plate width = plate length

cut length = x (Base ID + Base OD)

cutting hrs = ((cutting length / 12) x cutting rate) / 60)

plate cutting hrs

The groove weld length and groove welding hours are zero.

Read the labor hours to layout the base ring from the Base Plate Layout Labor tableaccording to the base ring ID and the number of segments (one segment).

π

π





Using the required plate length and width calculated, Coster determines suitable plate

size(s) (stock plate width and stock plate length) from which to cut the base ring from theStock Plate Sizes table or user defined plate sizes entered (see “Plate Selection” on page3-2).

material weight = required plate length x required plate width x base plate thickness xmaterial density

material cost = material weight x plate cost per lb

welding labor hrs = fillet weld hrs + gusset weld hrs + groove weld hrs

other labor hrs = cutting hrs + layout hrs + drilling hrs

total labor hrs = welding labor hrs + other labor hrs

total labor cost = (welding labor hrs x welding labor rate) + (other labor hrs x

manufacturing labor rate)

total cost = material cost + total labor cost

scrap area = stock plate width x stock plate length - area of base ring

b) Two Segments to Six Segments

The following calculations will be made for base rings from two to six segments. In theequations below we will use a variable called segments to represent the number ofsegments (2 to 6). To determine the minimum required dimension (length and width) for

a plate containing circular ring segments of a base ring it is easiest to orient the ring withthe vertical x = 0 bisecting one of the ring segments as shown in the figure below withthree ring segments.





By orienting the ring so that one of the segments is bisected by the vertical Costercalculates the angle theta.

Calculate the required plate height and width.

θ 90 180 segments ) ⁄ (–=

x inside radius θ )(cos×=

yi inside radius θ )(sin×=

φ x inside radius base ring burn out width ) )+( ⁄ (acos=

yo inside radius base ring burn out width ) φ )(sin×+(=

k yo yi–=





required plate length = (segments x k) + b

required plate width = 2 x (inside radius + base ring burn out width) x cos ( )

Calculate the plate cutting length according to the plate dimensions Coster hasdetermined for each piece required to fabricate the skirt base ring (cutting the stock plate

to the required plate size). Calculate the segment cutting labor to cut out the individualpieces that make up the skirt base ring.

segment cutting length = x (Base ID + Base OD) + (2 x segments x base ring width)

segment cutting hours = segment cutting length / 12 x cutting rate / 60

Calculate the welding labor.

groove weld length = segments x base ring width

Read the groove welding rate from the Miscellaneous Fabrication Labor table.

groove weld hrs = groove weld rate x (groove weld length / 12)

Read the labor hours to layout the base ring from the Base Plate Layout Labor tableaccording to the base ring ID and the number of segments (2 to 6).

The required plate dimensions vary according to the number of segments for the skirtbase ring. Coster determines suitable plate size(s) (stock plate width and stock platelength) from which to cut the base ring from the Stock Plate Sizes table or user definedplate sizes entered (see “Plate Selection” on page 3-2).

material weight = required plate length x required plate width x base plate thickness xmaterial density

material cost = material weight x plate cost per lb

welding labor hrs = fillet weld hrs + gusset weld hrs + groove weld hrs

other labor hrs = cutting hrs + layout hrs + drilling hrs

total labor hrs = welding labor hrs + other labor hrs

b inside radius base ring burn out width ) yo–+(=

θ

plate cutting hours plate cutting length 12 cutting rate 60 ⁄ × ⁄ =

π

total cutting hours plate cutting hours segment cutting hours+=





total labor cost = (welding labor hrs x welding labor rate) + (other labor hrs x

manufacturing lab rate)

total cost = material cost + total labor cost

scrap area = stock plate width x stock plate length - area of base ring

Calculations After Determining the Number of Segments for the Skirt Base Ring

Coster has determined the number of segments, plate sizes, labor hours, labor costs, and materialcosts for the base ring.

base ring weld volume = base ring weld length x base ring weld area

gusset weld volume = total gusset weld length x gusset weld area

Calculate the groove weld area similar to the long seam calculation for a cylinder using the base

thickness and the base OD.

groove weld volume = groove weld length x groove weld area

weld rod weight = (base ring weld volume + gusset weld volume + groove weld volume)x weld rod density / weld recovery


outside surface area = (base ring surface area + gusset surface area) / 144

Skirt Calculations

Skirts are estimated using the stock plate size(s) that Coster selects to cut out the skirt. Refer to“How Coster Determines The Layout of Conical Sections” on page 11-6 (conical skirts) and “HowCoster Determines Material Layout and Plate Requirements (Default Method)” on page 11-3(straight skirts) for the methods that Coster uses to select plate sizes. Plate unit cost is read from thePlate Costs table. Material cost for the skirt is calculated using the finished weight and the plate unitcost.

The stock plate used for cutting out the skirt is accounted for in the Weight of Source Materialcolumn and in the listing of plate usage in the Bill of Materials. Cutting length is calculated based

on the cutting layout to cut out the required plate size from a larger stock plate. For conical skirtsthere is an extra cutting length added to include cutting out each segment required to fabricate theskirt. The cutting labor rate is read from the Miscellaneous Fabrication Labor table. Forming laborhours for cylindrical skirts are read from the Cylinder Forming Labor table. Forming labor hours forconical skirts are read from the Cones and Skirts Forming Labor table.

Other properties (metallurgy, material density, welding rod density, normalization and impact testpremiums) are found on the Material Properties table. Normalization and impact test premiums are





added to the material cost if required (see “Normalization and Impact Testing” on page 11-93).

Circumferential seam welding and longitudinal seam welding are calculated using the depositionrate tables (Weld Deposition Rate - Circumferential Seam Weld and Weld DepositionRate - Longitudinal Seam Weld) based on the type of welding selected from the Weld Detail dialogon the Defaults - Welding menu. Blasting/Cleaning is calculated according to the type of blastingselected on the User Selectable Items dialog and the user defined default values on the Blasting/ Cleaning dialog on the Defaults - Finishing menu. Grinding of the seams is calculated from valueson the Grinding table according to the selections on the User Selectable Items dialog. Labor hoursto fit up the skirt to the attached component are read from the Fitup Labor tables.


- top inner diameter

- top outer diameter- bottom inner diameter- bottom outer diameter- cone angle

- weight of the skirt- skirt thickness- description of attached component (material, ID, OD, thickness)- length- material used for the skirt- starting elevation- ending elevation

Large ID = Maximum (top outer diameter, bottom outer diameter)

Small ID = Minimum (top outer diameter, bottom outer diameter)

Determine the slant length to use when calculating surface area:

Large IDSmall ID

slant length

length

theta

slant length length2

Large ID Small ID ) 2 )2

⁄ –((+=





Material Costs

Read the Plate Costs table to determine plate cost. Read the Material Properties table todetermine metallurgy, material density, weld rod density, and weld rod unit cost.

plate weight = plate length x plate width x plate thickness x plate material density


Coster uses an internal procedure to determine the plate dimensions of each piecerequired to fabricate the skirt and the plate size from which each of these pieces will becut (see “Plate Selection” on page 3-2).


Forming Labor

Read forming labor hours for cylindrical skirts from the Cylinder Forming Labor tableand read forming labor hours for conical skirts from the Cones and Skirts Forming Labortable based on thickness and Large ID


Fitup Labor

The fitup labor hours for skirts are read from the Fitup Labor - Skirt table based on the

thickness and diameter of the top of the skirt.


Cutting Labor

Read the cutting rate based on the skirt thickness and material from the MiscellaneousFabrication Labor table. The total cutting length is calculated according to the platedimensions Coster has determined for each piece required to fabricate the skirt and thelength to cut out each segment.

weld rod weight length weld area weld rod density ) weld recovery ⁄ ××(=

weld rod material cost weld rod weight weld rod cost per lb×=

total cutting hourstotal cutting length cutting rate×

12 60×--------------------------------------------------------------------------------=






Bevelling Labor

a) Cylindrical Skirts:

The top and bottom bevel lengths are both the "y" dimension of the required plate size(s)used to fabricate the skirt. The extra bevel length is the "x" dimension of the requiredplate size(s) multiplied by 2 so that both sides of the seam are bevelled (this is usuallythe longitudinal seam):

For skirts custom cut to component size the extra bevel length is calculated:


b) Conical Skirts

Calculate bevel lengths where:



If the orientation of the skirt from top to bottom is Small to Large calculate the top andbottom bevel length:

labor hrslength weld area weld rod density××

weld deposition rate operator weld efficiency×--------------------------------------------------------------------------------------------------------------------=

labor cost labor hrs welding labor rate×=

extra bevel length 2 X required plate dimension×=

extra bevel length 2 X required plate dimension number of long seams××=


top bevel length DS π×number of segments------------------------------------------------=

bottom bevel lengthDL π×






If the orientation of the skirt from top to bottom is Large to Small calculate the top and

bottom bevel length:

The extra bevel length is the slant length multiplied by 2 so that both sides of the seamare bevelled:


Surface Area

Nozzle Calculations


- nozzle thickness- ID (Nozzle ID)- OD (Nozzle OD)- nozzle material- whether nozzle material is normalized- whether nozzle material is impact tested- nozzle length

- nozzle quantity- nozzle weight (includes pad weight)- nozzle tag- nozzle starting elevation- nozzle ending elevation- nozzle inside projection- nozzle configuration- whether it is radial or hillside

top bevel lengthDL π×


bottom bevel lengthDS π×


extra bevel length 2 slant length×=


outside surface area0.5 π slant length×× Large OD + Small OD( )×

144------------------------------------------------------------------------------------------------------------------------=

inside surface area0.5 π slant length× Large ID Small ID+( )××( )

144----------------------------------------------------------------------------------------------------------------------=





- orientation angle (radial angle)

- tipping angle (tilt angledegrees)

- radial distance- whether it is a pipe- pipe schedule -- 5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 160, Std, XST, XXS- pipe nominal size- whether it is a coupling- type of coupling -- 3000#, 6000#- coupling nominal size- description of attached component (shell material, Shell ID, Shell OD, shell

thickness, radiography)- pad material- pad thickness- pad width

- whether pad normalized- whether pad impact tested- flange code (ASME B16.5/16.47 or ASME Section VIII Division 1 Appendix 2)- flange type -- welding neck (WN), slip on (SO), threaded (TH), socket weld

(SW), lap joint (LJ), standard long weld neck (LwnST), heavy barrel long weldneck (LwnHB), full body long weld neck (LwnFB), variable body v1 long weldneck (LwnV1), variable body v2 long weld neck (LwnV2), variable body v3 longweld neck (LwnV3), ring type integral, ring type full face gasket, ring type loose,weld neck integral, slip on full face gasket, slip on loose, slip on integral, lap jointloose, split loose, reverse integral, reverse loose

- class -- no flange, 75#, 150#, 300#, 400#, 600#, 900#, 1500#, 2500#

- flange material- flange weight- flange nominal size

- flange ID- flange OD- raised face OD- raised face height- number of bolts- bolt diameter- bolt length- bolt material- bolt circle

- gasket ID- gasket OD

- long weld neck size- whether there is a blind attached- blind weight- pad to nozzle groove weld size (upper groove weld thickness)- nozzle to shell groove weld size (lower groove weld thickness)- inner fillet weld size (inner fillet weld thickness)- outer fillet weld size (outer fillet weld thickness)- lower fillet weld size (lower fillet weld thickness)






- waste from flame cutting- bevel angle (nozzle groove welds) (nozzle weld angle)- weld gap

Calculate the pad OD.

Calculate the pad weight.

Calculate the nozzle weight.

Calculate the lwn weight.

Properties and Material Costs

Coster uses the material density, welding rod density, and welding rod cost of theshell to which the nozzle is attached for all nozzles. Read the Material Propertiestable to find the shell metallurgy, shell material density, shell weld rod density andshell weld rod unit cost of the material to which the nozzle is attached.

Long Weld Neck (lwn)

Read the Material Properties table to find the metallurgy of the long weld neckflange material.

Pad ID Nozzle OD=

Pad OD Pad ID 2 Pad Width×( )+=

area of pad π pad OD 2 ⁄ ( )2

pad ID 2 ⁄ ( )2

–( )×=

pad weight area of pad pad thickness pad density××=

nozzle weight nozzle weight pad weight–=

lwn weight nozzle weight( pad weight )– flange weight+=

lwn length nozzle length=

theta atn nozzle OD 2 shell ID 2 ⁄ ⁄ ⁄ ( )=

extra length for radial nozzle shell ID 2 1 cos theta( )–( )× ⁄ =





For nozzle configuration types 1 and 2 adjust the lwn length:

For nozzle configuration types 3 and 4 adjust the lwn length:

Pipe

Read the Pipe Cost Schedule table to find the pipe cost per ft based on the pipe

material, pipe schedule and pipe nominal size. Coster will not interpolate values forPipe Costs as the costs vary greatly depending upon standard sizes. Read theMaterial Properties table to find the metallurgy, normalization premium and impacttesting factors.

Coupling

Read the Coupling Costs table to find the coupling cost based on the couplingmaterial, type of coupling, and coupling nominal size. Read the CouplingInstallation Labor table to find the installation labor hours based on type of coupling,vessel thickness and coupling nominal size. Read the Material Properties table tofind the metallurgy, normalization premium and impact testing factors.

Plate

Read the Plate Costs table to find the plate cost based on the plate material, platewidth, and plate thickness. Read the Material Properties table to find the metallurgy,normalization premium and impact testing factors.

Studded Outlet

Coster asks the user to enter a material cost for the studded outlet which is displayedin the flange cost column of the estimate. The labor hours to install the studded

outlet are calculated similarly to nozzles using the shell weld rod density to calculatewelding.

Calculate the total nozzle length.

Custom Integral Forging

lwn length lwn length shell thickness extra length for radia nozzleflange length

+ ++

=

lwn length lwn length shell thickness inside projectionextra length for radial nozzle flange length

+ ++ +

=

nozzle cut lengthnozzle weight

π Nozzle OD2

Nozzle ID2

–( ) density××

4-----------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------=





Coster asks the user to enter a material cost for the custom integral forging.

Installation labor hours are calculated similarly to nozzles using the shell density asthe material density. Flange welding labor hours are zero.

length = total nozzle length from outside edge of vessel to outside end of flange

Flange Cost, Flange Labor, Blind Cost, Blind Labor, and Hydrotest Labor

Calculate the material costs and labor based on the type of flange and flange facing (either raisedface (RF) or ring type joint (RTJ). Coster will not interpolate values for Flange Costs as the costsvary greatly depending upon standard sizes.

1) No flange attachedflange cost = 0

flange labor = 0blind cost = 0blind labor = 0hydrotest labor = 0

2) Couplingflange cost = 0flange labor = 0blind cost =0blind labor = 0hydrotest labor = 0

3) Long Weld Neck

Flange Cost and Flange Labor

flange labor = 0

There is a separate long weld neck flange costs table and a separate long weld neckflange specs table for each flange type. Read the appropriate LWN Flange Coststable to find the standard length flange cost based on the flange material, class,flange facing and long weld neck size. Read the appropriate LWN Flange Specstable to find the standard length and multiplication factor for cost per one inch

lengths (cost per 1 inch length) based on the LWN size. This multiplication factor isused to calculate the cost of a long weld neck which is shorter or longer than thestandard length.

Coster uses the nozzle OD for calculations. Calculate the long weld neck cost basedon the standard length from the LWN Flange Specs table.

finished length length inside projection shell thickness+ +=





If the long weld neck length is shorter or longer than the standard length, calculate

the cost as shown below.

i) shorter than standard length

cost calculation

ii) longer than standard length

cost calculation

Find the next purchased length beginning at 12 inches and incrementing by 2 inchlengths (12 inches, 14 inches, etc.).

Blind Flange/Hydrotest

If there is a blind attached, then hydrotest labor = 0 and the blind material cost and

blind labor hours are calculated as follows.

Read the Blind Flange Labor table to find the blind labor hours according to theLWN size and class.

Read the Blind Flange Cost table to find the blind flange cost based on flangematerial, class, flange facing and LWN size.

4) ASME Section VIII Division 1 Appendix 2 flange:

Read the plate cost from the Plate Cost table based on the flange material, flange OD,

and flange thickness.

5) All other Flange Types

Flange Cost/Flange Labor

long weld neck cost standard length cost cutting fee+=

extra length next purchased length required long weld neck length–=

extra cost extra length cost per 1 inch length×=

long weld neck cost standard length cost extra cost cutting fee+ +=

material cost plate cost per lb flange weight×=





There are flange cost tables for each flange type. Read the appropriate Flange Costs

table to find flange cost based on flange material, class and flange nominal size (forweld neck flanges the cost is also determined by bore size and flange facing).

There are two flange labor tables - fitup labor and welding labor. Read theappropriate Flange To Nozzle labor table to find labor hours to fitup and weld theflange to the nozzle based on the flange type (weld neck flange or other ASMEB16.5/16.47 flange), metallurgy, nozzle OD and pipe schedule. Since these tables donot consider heavy barrel weld neck flanges, the flange labor for these types is zero.

To determine flange labor hours Coster reads an internal table (this table cannot beviewed in Coster) called Standard Pipe Thickness to find the pipe schedule for thespecified nozzle OD and thickness. This table contains nozzle thickness as afunction of nozzle OD and pipe schedule and the fields in this table match the fields

in the flange labor hours tables. Using this information Coster will determine theflange fitup and welding labor hours from the fitup and welding flange tables. Themethod that Coster uses to calculate flange fitup labor hours for scheduled andnon-scheduled nozzles is shown below.

Scheduled Nozzles

Example: SA 106B Seamless, nozzle ID of 5.761 inches, nozzle thickness of 0.432inches with a weld neck flange.

Coster reads the Standard Pipe Thickness table to find the corresponding pipe

schedule (Sch 80) for the specified nozzle OD of 6.625 inches and thickness of 0.432inches.

Using the specified nozzle OD (6.625 inches) and pipe schedule (Sch 80) Costerreads the flange labor hours (2.1 hours) for a carbon steel (CS) weld neck flangefrom the Flange to Nozzle - Fitup Labor table. If the flange fitup labor hours readfrom the table are zero or if the record for 6.625 inch nozzle OD has been deletedfrom the table then Coster will interpolate a value for the specified nozzle OD withinthe pipe schedule field.

Non-Scheduled Nozzles

Example: SA 516 70, nozzle ID of 5.75 inches, nozzle thickness of 0.625 incheswith a weld neck flange

Coster reads the Standard Pipe Thickness table to determine four points to use forinterpolating flange fitup labor hours for the specified nozzle OD and thickness.

Step 1: Coster reads the Standard Pipe Thickness table. Using the specified nozzleOD (7 inches) and thickness (0.625 inches), Coster finds the closest smaller nozzle

flange labor hrs fitup flange labor hrs welding flange labor hrs+=





OD (6.625 inches) and the closest smaller thickness (0.562 inches) and closest larger

thickness (0.906 inches) for this smaller nozzle OD.

Using the pipe schedule that corresponds to the smaller thickness (Sch 120) and thelarger thickness (Sch 160) for the smaller nozzle OD, Coster reads the flange fituplabor hours for a carbon steel (CS) weld neck flange from the Flange toNozzle - Fitup Labor table. If either of these labor hours is zero, Coster asks you toenter the flange fitup labor hours. The flange fitup labor hours read from the fituplabor table for 6.625 inch nozzle OD are 3.2 hours for Sch 120 and 4.3 hours for Sch160. Using these fitup labor hours and their corresponding thickness, Coster caninterpolate fitup labor hours for the specified thickness.

Interpolation for 6.625 inch nozzle: Flange Fitup Labor Hours

Smaller thickness 0.562 inches 3.2 (read from table)Specified thickness 0.625 inches 3.402 (interpolated value)Larger thickness 0.906 inches 4.3 (read from table)

Step 2: Similar to Step 1 above Coster determines fitup labor hours for the specifiedthickness for the larger nozzle OD (8.625 inches).

Using the specified nozzle OD (7 inches) and thickness (0.625 inches), Coster findsthe closest larger nozzle OD (8.625 inches) and the closest smaller thickness (0.593inches) and closest larger thickness (0.718 inches) for this larger nozzle OD.

Using the pipe schedule that corresponds to the smaller thickness (Sch 100) and the

larger thickness (Sch 120) for the larger nozzle OD, Coster reads the flange fituplabor hours for a carbon steel (CS) weld neck flange from the Flange toNozzle - Fitup Labor table. If either of these labor hours is zero, Coster asks you to

enter the flange fitup labor hours. The flange fitup labor hours read from the fituplabor table for 8.625 inch nozzle OD are 3.8 hours for Sch 100 and 5.1 hours for Sch120. Using these fitup labor hours and their corresponding thickness, Coster caninterpolate fitup labor hours for the specified thickness.

Interpolation for 8.625 inch nozzle: Flange Fitup Labor HoursSmaller thickness 0.593 inches 3.8 (read from table)Specified thickness 0.625 inches 4.133 (interpolated value)

Larger thickness 0.718 inches 5.1 (read from table)

Now Coster has fitup labor hours for the specified thickness (0.625 inches) for both

the smaller OD (6.625 inches) and larger nozzle OD (8.625 inches).

Step 3: Using these fitup labor hours, Coster can interpolate between the smaller andlarger nozzle OD to find the flange fitup labor hours for the specified nozzle OD andthickness.

Interpolation for 7 inch nozzle OD: Flange Fitup Labor HoursSmaller OD 6.625 inches 3.402 (interpolated value from above)





Specified OD 7 inches 3.571 (interpolated value)

Larger OD 8.625 inches 4.133 (interpolated value from above)

The flange welding labor hours will be calculated using the same method as theflange fitup labor hours.

Blind Flange/Hydrotest

If there is a blind attached, then the hydrotest labor = 0 and the blind material costand blind labor hours are calculated as follows.

Read the Blind Flange Labor table to find the blind labor hours according to theflange nominal size and class.

Read the Blind Flange Cost table to find the blind flange cost based on flangematerial, class, flange facing and flange nominal size.

Material Cost

Coster does not report a pipe material cost for long weld necks. For couplings the material cost isthe cost that was read from the coupling costs table. For nozzles from plate or pipe material, thematerial cost is calculated as follows.

1) Pipe

Calculate the pipe material waste based on the nozzle cut length.

The waste factor for pipe is calculated according to the pipe minimum cut length or thepipe material waste set from the Fabrication dialog on the Defaults - Other menu.

If the pipe length is less than the minimum cut length then Coster increases the pipelength to the minimum length for estimating. In this case the pipe material waste is notconsidered.

If the pipe length is more than the minimum cut length then Coster adds the pipe materialwaste for estimating.

2) Plate

Coster uses an internal procedure to determine the plate dimensions needed to form thenozzle and also the plate size from which the nozzle will be cut (see “Plate Selection” onpage 3-2).

pipe length nozzle cut length=

pipe material cost adjusted pipe length(( ) 12 ) ⁄ pipe cost per ft×=





Read the forming labor hours from the Cylinder Forming Labor table.

Read the nozzle cutting rate based on the nozzle thickness and metallurgy from the MiscellaneousFabrication Labor table. The total nozzle cutting length is calculated according to the platedimensions Coster has determined for each piece required to fabricate the nozzle. Read the shellcutting rate (to cut the hole in the shell for the nozzle) based on the shell thickness and metallurgy.

For radial nozzles the nozzle extra welding length is zero.

Read the Nozzle to Shell or Head Labor table for labor hours to attach the nozzle for types other thancoupling (coupling installation labor is read from tables above) based on the shell thickness andnozzle OD.

Hillside (Nonradial) Nozzles

Coster calculates the extra welding length required for hillside nozzles on cylinders, transitions andheads to increase the welding labor.

Rs = shell outer radius for cylinder or hemispherical head= dish radius for F&D head

= transition outer radius at nozzle center line for transition= head outer radius for 2:1 ellipsoidal head

plate weight finished weight from Compress=

plate material cost plate weight plate cost per lb×=

long seam labor hrs long seam weld area long seam weld length shell weld rod density××long seam weld deposition rate operator weld efficiency×

------------------------------------------------------------------------------------------------------------------------------------------------------------------------=

total nozzle cutting hours total nozzle cutting length nozzle cutting rate×12 60×

-----------------------------------------------------------------------------------------------------------------=

cutting length for hole in shell π nozzle OD extra welding lengthnozzle+×=

total shell cutting hourscutting length for hole in shell shell cutting rate×

12 60×----------------------------------------------------------------------------------------------------------------------=

total cutting hours total nozzle cutting hours total shell cutting hours+=

Rs 0.5 attached component OD×=

X1 nozzle offset nozzle outer radius–=





Nozzle attached to 2:1 ellipsoidal head

Nozzle attached to cylinder, transition, F&D head, hemispherical head

Calculations for all hillside nozzles

Calculate the length of the slot (ellipse perimeter) based on the nozzle major and minoraxes calculated above.

If there is a pad present then calculate the extra welding length for the pad.

Calculate the length of the slot (ellipse perimeter) based on the pad major and minor axescalculated above.

X2 nozzle offset nozzle outer radius+=

Y1 0.5 Rs× max 1 X1

2

Rs ⁄

2

0 ),–(×=

Y2 0.5 Rs× max 1 X22

Rs ⁄ 2

0 ),–(×=

Y1 max Rs Rs× X1–( X1 0 ),×=

Y2 max Rs Rs× X2–( X2 0 ),×=

chord length X1 X2 )2

– Y1 Y2 )2

–(+(=

major axisnozzle chord length 2 ⁄ =

minor axisnozzle nozzle outer radius=

ellipse perimeternozzle

2 π minor axisnozzle 4 major axisnozzle minor axisnozzle )–(×+××=

extra welding lengthnozzle ellipse perimeternozzle π nozzle OD×–=

major axispa d chord length 2 ⁄ pad width+=

minor axispa d nozzle outer radius pad width+=





Read the Fitup Labor - Nonradial Nozzles table to find the labor multiplication factor based on the

radial angle. This same multiplication factor is used to adjust the pad labor. The nozzle installationlabor hours and pad installation labor hours are multiplied by this nonradial labor factor to accountfor extra labor involved for a nonradial nozzle.

Calculations for tilted nozzles located on a cylinder

radial angle in radians (from Compress)

Calculate the length of the slot (ellipse perimeter) based on the nozzle major and minoraxes calculated above.

Read the Fitup Labor - Nonradial Nozzles table to find the labor multiplication factor based on theradial angle. The nozzle installation labor hours are multiplied by this nonradial labor factor toaccount for extra labor involved for a tilted nozzle.

If there is a pad present then a multiplication factor is calculated to add extra labor hours for cuttingand welding of the pad. The multiplier is calculated using the tilted nozzle welding length and thenozzle OD.

ellipse perimeterpad 2 π minor axispad( 4 major axispa d minor axispa d )–(×+××=

extra welding lengthpad ellipse perimeterpad π pad OD×–=

nozzle installation labor hours labor hours nonradial labor factor×=

pad installation labor hours labor hours nonradial labor factor×=

minor axisnozzle OD 2 ⁄ =

tilt angleradians tilt angledegrees π 180 ⁄ ×=

major axisnozzle minor axisnozzle abs tilt angleradians(( ) )cos ⁄ =

ellipse perimeternozzle

2 π minor axisnozzle 4 major axisnozzle minor axisnozzle )–(×+××=

tilted welding lengthnozzle ellipse perimeternozzle=

nozzle installation labor hours labor hours nonradial labor factor×=

pad multiplier for cutting and welding tilted welding lengthnozzle π OD×( ) ⁄ =





Pad Calculations

If there is a pad present calculate the following. Nozzle configurations 1, 3, 5, 6, 7 do not have apad. Nozzle configurations 2, 4, 8 have a pad.

Coster uses the metallurgy, material density, welding rod density, and welding rod cost of the shell towhich the nozzle is attached for pads. Read the Material Properties table to find the shell metallurgy,shell material density, shell weld rod density and shell weld rod unit cost of the material to which thenozzle and pad are attached.

Read the Plate Costs table to find the pad plate cost. Read the Material Properties table to find padnormalization premium and pad impact testing factors.

Read the Pad to Nozzle Labor table to find the labor hours to attach the pad to the nozzle based onthe pad thickness and nozzle OD. The pad installation labor hours are adjusted for nonradial nozzlesbased on the nonradial nozzle labor factor. This is the same factor from the Fitup Labor - NonradialNozzles table that Coster looked up for the nozzle. For radial nozzles the nonradial nozzle labor

factor is one.

Read the pad cutting rate from the Miscellaneous Fabrication Labor table based on the pad thicknessand metallurgy.

Calculate the pad cutting length (cutting around the outside and inside of the pad). Coster assumesthat there is a plate available for cutting out the pad so Coster does not include cutting out the platefrom a larger piece of stock. For radial nozzles the nozzle extra welding length and pad extra

welding length are both zero.

Calculate the pad material cost.

Calculate the plate size required from which to cut out the pad.

pad installation labor hours labor hours nonradial nozzle labor factor×=

pad cutting length pad OD π ) pad ID π )

extra welding lengthnozzle extra welding lengthpad+ +

×(+×(=

pad cutting hourspad cutting length pad cutting rate×

12 60×---------------------------------------------------------------------------------------=

pad weight finished weight from Compress=

pad material cost pad weight pad plate cost per lb×=

pad plate width nozzle OD 2 pad width×+=





Calculate the pad plate length for hillside or radial nozzles as follows if the nozzle isattached to a cylinder, transition, 2:1 ellipsoidal head, F&D head, hemispherical head.

The calculation for F&D heads is an approximation because the knuckle radius is not

considered. Calculate the pad plate length for radial nozzles as follows if the nozzle isattached to another nozzle (nozzles attached to another nozzle cannot be hillside).

Hillside Nozzles

Radial Nozzles

Nozzle Weld Calculations

Calculate the nozzle welding hours based on the weld types available according to nozzleconfiguration. For radial nozzles the nozzle extra welding length and pad extra welding length areboth zero.

Configuration Weld Types Type 1 (no pad) lower groove weld, inner fillet weld Type 2 (with pad) upper groove weld, lower groove weld, inner fillet weld, outer fillet weld Type 3 (no pad) lower groove weld, inner fillet weld, lower fillet weld Type 4 (with pad) upper groove weld, lower groove weld, inner fillet weld, outer fillet weld,

lower fillet weld Type 5 (no pad) inner fillet weld Type 6 (no pad) lower groove weld, inner fillet weld Type 7 (no pad) inner fillet weld Type 8 (with pad) inner fillet weld, outer fillet weld

Groove weld areas are calculated as follows:

For nozzle configuration 6 there is no weld gap considered. Therefore Area B = 0

For all other nozzle configurations calculate Area B.

shell radius shell OD 2 ⁄ =

pad plate length 2 pad width shell radius major axis shell radius ) ) ⁄ (asin×+(×=

pad plate length 2 pad width shell radius nozzle OD shell OD ) ) ⁄ (asin×+(×=

Area A 0.5 groove size2


Area B weld gap groove size×=

nozzle v groove weld Area A Area B+=





Calculate the pad to nozzle groove weld area (upper groove weld area) using the above methodbased on pad thickness, upper groove weld thickness, and nozzle configuration.

Calculate the nozzle to shell groove weld area (lower groove weld area) using the above methodbased on shell thickness, lower groove weld thickness, and nozzle configuration.

Calculate the inner fillet weld area, outer fillet weld area, and lower fillet weld area.

Set the hub diameter equal to the Pad OD for calculations of nozzle configuration 6.

Calculate the pad to nozzle groove weld volume (upper groove weld volume).

Configuration 6 calculations

Configuration 1, 2, 3, 4, 5, 7, 8, 9, 10 calculations

Calculations for all nozzle configurations

θ nozzle bevel angle=

fillet weld area fillet weld thickness2

2 ⁄ =

upper groove weld volume

upper groove weld area π( nozzle OD×× extra welding lengthnozzle )+=

lower groove weld volume lower groove weld area π nozzle ID××=

inner fillet weld volume inner fillet weld area π hub diameter××=

inner fillet weld volume

inner fillet weld area π( nozzle OD extra welding lengthnozzle+×× )=

lower groove weld volume

lower groove weld area π( nozzle OD×× extra welding lengthnozzle )+=





For groove welds read the Weld Deposition Rate - Nozzle Groove Weld table to find the depositionrate based on metallurgy, weld thickness and nozzle OD. For fillet welds read the Weld DepositionRate - Nozzle Fillet Weld table to find the deposition rate based on metallurgy, weld leg size andnozzle OD (for the outer fillet weld Coster uses the Pad OD and metallurgy instead of the nozzle OD

and metallurgy to find the deposition rate).

Calculate the welding labor hours for each type of weld using the welding rod density of the shell

material for welding the nozzle and pad.

Weld length for x-ray purposes is considered only for a welding neck flange with a nozzle ODgreater than 10.75 inches or for nozzle wall thickness greater than 1.125 inches and for nozzlegroove welds. The number of nozzles is also reported on the x-ray dialog as a guide when spot x-rayis selected.

For each pad to nozzle groove weld or nozzle to shell groove weld calculate the weld length and addtogether to find the total nozzle groove weld length for x-ray purposes.

Calculate the nozzle and pad installation labor cost, flange labor cost, blind labor cost and forminglabor cost using the manufacturing labor rate. Calculate the long seam, flange, nozzle and padwelding labor costs using the welding labor rate.

outer fillet weld volume

outer fillet weld area π( PadOD extra welding lengthpa d+×× )=

lower fillet weld volume

lower fillet weld area π( nozzle OD extra welding lengthnozzle )+××=

total weld volume upper groove weld volume lower groove weld volumeinner fillet weld volume outer fillet weld volume lower fillet weld volume

++ + +

=

welding labor hrs weld volume shell weld rod densityweld deposition rate operator weld efficiency ⁄ ⁄

×=

total nozzle weld length nozzle OD π×=

x-ray nozzle groove weld lengthx-ray nozzle groove weld length nozzle OD π )×(+=

total nozzle weld length total nozzle weld length x-ray nozzle groove weld length+=

labor cost labor hrs manufacturing labor rate×=

weld rod weight total weld volume long seam volume )shell weld rod density weld recovery ⁄ ×

+(=





ASME Section VIII Division 1 Appendix 2 flange labor:

Read the machining labor hours from the Machining Labor table based on flange


Read the drilling per minute rate from the Drilling Labor table based on flangematerial and bolt nominal size.

ASME Section VIII Division 1 Appendix 2 flange welding:

Ring Type Integral

no circumfrential butt weld present

Slip On Integral

no cirumferential butt weld present

Calculate the total weld length for ring type integral and slip on integral flange:

Read the fillet welding rate and the groove welding rate from the MiscellaneousFabrication Labor table based on metallurgy and weld size to calculate the upperfillet weld, lower fillet weld and groove weld hours for ring type integral and slip onintegral flange:

weld rod material cost weld rod weight shell weld rod cost per lb×=

drilling labor hours drilling per minute rate flange thickness 60number of bolts×

⁄ ×=

groove weld length π flange ID groove weld size+( )×=



groove weld length π flange ID hub thickness, G0 groove weld size–+( )×=

upper fillet weld length π flange ID upper fillet weld size+( )×=

lower fillet weld length π flange ID hub thickness, G0lower fillet weld size–

+()

×=

total weld length groove weld length upper fillet weld lengthlower fillet weld length

++

=






Ring Type Full Face Gasket, Ring Type Loose, Slip On Full Face Gasket, Slip OnLoose

no circumferential butt weld present



groove weld hours groove weld rate groove weld length 12 ⁄ ( )×=

groove weld area groove weld size( )2

2 ⁄ =



2 ⁄ =


lower fillet weld area lower fillet weld size( )

2

2 ⁄ =


flange welding rod weight groove weld volume upper fillet weld volumelower fillet weld volume

++





2 ⁄ =



2 ⁄ =


flange welding rod weight upper fillet weld volumelower fillet weld volume+






Calculate the total weld length for ring type full face gasket, ring type loose, slip on

full face gasket and slip on loose flange.

Read the fillet welding rate from the Miscellaneous Fabrication Labor table based onmetallurgy and weld size to calculate the upper fillet weld and lower fillet weld hoursfor ring type full face gasket, ring type loose, slip on full face gasket and slip onloose flange:

Weld Neck Integral


If there is a component attached calculate the circumferential seam area using theflange ID and hub thickness, G0.

Reverse Integral



Reverse Loose



Read the circumfential weld deposition rate from the WeldingTime - Circumferential Seam Weld table based on the hub thickness, G0, weld typeand metallurgy.

total weld length upper fillet weld length lower fillet weld length+=


circumferential seam weld length π flange ID hub thickness, G0+( )×=

circumferential seam weld length π flange OD hub thickness, G0–( )×=

circumferential seam weld length π flange OD hub thickness, G0+( )×=

circumferential seam volume circumferential seam areacircumferential seam weld length×

=





Calculate welding rod weight as follows:

Lap Joint Loose, Split Loose

There is no welding at all unless a welded lap is specified. If it is a welded lap thenthe following welds are present:


Read the fillet welding rate based on metallurgy and lap fillet weld size and thegroove welding rate based on metallurgy and lap thickness from the MiscellaneousFabrication Labor table to calculate the fillet weld and groove weld hours for lap joint loose and split loose flange:

Leg Calculations

The fillet weld size for welding the legs to the shell and and base plate is determined from the .xmlfile. If this value is zero then Coster assumes a fillet weld size of 0.375 inches. This weld size isalso used to look up the base plate fillet weld rate from the Miscellaneous Fabrication Labor table.The fillet weld size for welding the pad to the shell is also determined from the .xml file. If this

value is zero then Coster assumes a fillet weld size of 0.375 inches.

flange welding rod weight circumferential seam volumewelding rod density× weld recovery ⁄

=

groove weld length π flange ID×=

groove weld area lap thickness )(2

2 ⁄ =

fillet weld length π flange ID×=

total weld length groove weld length fillet weld length+=


upper fillet weld area lap thickness( )2

2 ⁄ =

upper fillet weld volume upper fillet weld area fillet weld length×=

flange welding rod weight groove weld volume upper fillet weld volume+( )welding rod density× weld recovery ⁄

=

weld hours weld rate weld length 12 ⁄ ( )×=





Leg section width and Leg section length always refer to the same dimension no matter which way

the wide flange is attached to the vessel.

Determine the leg major dimension by using the larger of the Leg section width and the Leg sectionlength. Similarly determine the base plate and pad major dimensions by comparing the width andlength of each.

The leg material cost is determined by the structural cost per lb read from the Structures/Rings/TraySupports Material Cost table based on the leg material, type and size. Find the metallurgy, weldingrod density, and welding rod unit cost from the Material Properties table for the vessel material andthe leg material.

Look up the labor hours for layout and fitup for the pad and base plate on the Legs Labor - Pad andLegs Labor - Base Plate tables based on the pad major dimension and base plate major dimension.Also look up the labor hours to layout/burn, fitup, and weld the legs based on the leg majordimension.

Use the pad material welding rod density and pad material welding rod unit cost to calculate weld

rod weight and weld rod cost to attach the legs to the pad. Use the vessel material welding roddensity and vessel material welding rod unit cost to calculate weld rod weight and weld rod cost toattach the legs to the vessel.

If the base plate is present Coster assumes the material for the leg base plate to be SA 36. Read thebase plate material unit cost from the Plate Costs table and read the base plate metallurgy, materialdensity, welding rod density, and welding rod unit cost from the Material Properties table. The baseplate weight is the finished weight but the base plate material cost is calculated to include wastefrom flame cutting on all sides of the base plate. Find the cutting rate and drilling labor for the legsfrom the Miscellaneous Fabrication Labor table based on the base plate thickness and metallurgy.The fillet welding rate is also read from the Miscellaneous Fabrication Labor table and the welding

rod weight and welding rod cost to attach the legs to the base plate is calculated using the base platewelding rod density and welding rod unit cost.

The pad welding is calculated similarly. Coster assumes the material to be SA 36 for the leg pad.


- Leg overall length





- Leg base to girth weld seam length

- Leg weight (total of all legs including the base plate weight and pad weight)- Number of legs- Leg section width- Leg section length- Base plate length- Base plate width- Base plate thickness- whether or not a pad is present- Pad length- Pad width- Pad thickness- Leg structural type

- Size (if leg type is pipe then size includes pipe schedule)- Leg fillet weld size- Pad fillet weld size- Number of bolts per leg

- Vessel material of the component to which the legs are attached

Coster assumes the following for estimating legs:

- Base plate material = SA 36- Pad material = SA 36- If the leg fillet weld size from the .xml file is zero then the leg fillet weld size is

set to 0.375 inches.

- If the pad fillet weld size from the .xml file is zero then the pad fillet weld size isset to 0.375 inches.

Legs

Read the Material Properties table to determine normalization and impact testing factors. Read theStructures/Rings/Tray Supports Material Costs table to find the leg cost per lb based on the legmaterial, structural type and size.

If leg type is pipe then:

Calculate the weight per leg:

pipe OD leg section width=

weight per leg leg weight number of legs ⁄ ( ) base plate weight– pad weight–=

leg material cost per ft leg cost per lb weight per leg leg overall length 12 ) ⁄ ( ⁄ ×=

leg material cost leg overall length 12 ) leg material cost per ft× ⁄ (=





Read the Legs Labor table to find the layout/burn hours, fitup hours and welding hours based on the

leg major dimension.

The leg labor hours are displayed as an equation (shown below) in the Fabrication labor hours

column of the Coster estimate.

The leg welding labor hours are displayed as an equation (shown below) in the Finishing labor hourscolumn of the Coster estimate.

Weld Rod Calculations

Calculate leg weld length according to the leg structural type.

a) equal leg angle, leg in

b) equal leg angle, leg out or wide flange, flange in

c) wide flange, flange out

Calculate the leg fillet weld volume

Read the Material Properties table to determine metallurgy, weld rod density and weld rod unit costbased on the vessel material to which the legs are attached.

layout/burn labor cost layout/burn labor hours manufacturing labor rate×=

fitup labor cost fitup labor hours manufacturing labor rate×=

welding labor cost welding labor hours welding labor rate×=

fabrication labor hours layout hours fitup hours ) leg quantity×+(=

finishing labor hours leg to vessel or pad welding hoursleg to base plate welding hours ) leg quantity×+

(=

leg weld length leg overall length leg base to girth weld seam length) 2 )

2 leg section length×+

×–((=

leg weld length leg overall length leg base to girth weld seam length) 2 )leg section length+

×–((=

leg weld length leg overall length leg base to girth weld seam length) 2 )leg section width 2 )×(+

×–((=

leg fillet weld volume leg fillet weld size2

2 leg weld length× ⁄ =





To calculate the weld rod weight, Coster uses the pad weld rod density and pad weld rod unit cost if

the leg is welded to the pad. If the leg is welded to the vessel Coster uses the vessel weld rod densityand the vessel weld rod unit cost.

Calculate the leg to base plate weld length based on the leg structural type.

a) equal leg angle, leg in, equal leg angle, leg out, wide flange, flange in, and wideflange, flange out (multiply each section by 2 to weld the inside and outside of theleg

b) user defined -- You are asked to enter the "user defined leg width" where itattaches to the base plate. Coster assumes that the weld length is a square basedon this user defined leg width.

c) pipe

Calculate weld rod weight and weld rod cost based on the weld rod density and weld rod unit cost of

the base plate material.

Base Plate

Read the Plate Costs table to determine plate cost. Read the Material Properties table to determinemetallurgy, material density, normalization and impact testing factors.

Read the Legs Labor - Base Plate table to find the layout hours and fitup hours based on the baseplate major dimension.

leg weld rod weight leg fillet weld volume weld rod density×=

leg weld rod cost leg weld rod weight weld rod cost per lb×=

leg to base plate weld length leg section width 2 ) leg section length 2 )×(+×(=

leg to base plate weld length user defined leg width 4×=

leg to base plate weld length π pipe OD×=

leg to base plate fillet weld volume

base plate fillet weld size2

2 ) leg to base plate weld length× ⁄ (=

leg to base plate weld rod weightleg to base plate fillet weld volume base plate weld rod density×=

leg to base plate weld rod costleg to base plate weld rod weight base plate weld rod unit cost×=





Calculate the base plate weight including waste. Add waste from flame cutting to the material

dimensions. This weight will be used to calculate material cost and is the weight displayed in theBill Of Materials. Coster also calculates the actual base plate weight which is displayed in the

weight column of the Vessel Detail Cost.

Read the Miscellaneous Fabrication Labor table to find the cutting rate and drilling hours based onthe base plate thickness and metallurgy.

Welding of the leg to the base plate is included with the legs.

Pad

Read the Plate Costs table to determine plate cost. Read the Material Properties table to determinemetallurgy, material density, weld rod density, weld rod unit cost, normalization and impact testing

factors.

Read the Legs Labor - Pad table to find the layout hours and fitup hours based on the pad major

dimension.

layout labor cost layout labor hours manufacturing labor rate×=

fitup labor cost fitup labor hours manufacturing labor rate×=

base plate weight including wastebase plate length( 2 waste from flame cutting ) )×(+

base plate width(× 2 waste from flame cutting ) ) base plate thicknessbase plate material density×

××(+=

actual base plate weight base plate length base plate widthbase plate thickness base plate density××

×=

base plate material cost base plate weight including waste base plate cost per lb×=

base plate cutting length base plate length base plate width ) 2×+(=

base plate cutting hrs base plate cutting length 12 )base plate cutting rate ) 60 ) ⁄ ×

⁄ ((=

base plate drilling hrs drilling hrs number of bolts per leg×=

layout labor cost layout labor hrs manufacturing labor rate×=

fitup labor cost fitup labor hrs manufacturing labor rate×=





Calculate the pad weight including waste. Add waste from flame cutting to the material dimensions.

This weight will be used to calculate material cost and is the weight displayed in the Bill OfMaterials. Coster also calculates the actual pad weight which is displayed in the weight column ofthe Vessel Detail Cost.

Read the Miscellaneous Fabrication Labor table to find the cutting rate based on the pad thickness

and pad metallurgy, and the fillet welding rate based on the pad fillet weld size and pad metallurgy.

Calculate the pad to vessel welding hours.

Calculate weld rod weight and weld rod cost based on the weld rod density and weld rod unit cost ofthe vessel material.

Normalization and Impact Testing

Normalization premium and impact testing are not considered for estimating trays, skirts and skirtbase rings. Normalization and impact testing factors are applied to the material cost if they arespecified for cylinders (made from pipe, fabricated, or purchased), transitions, skirts, vacuum rings,heads (flat welded or formed), nozzles, and pads. These extra costs are displayed on the estimate aspart of the material cost equation as follows:

pad weight including waste pad length( 2 waste from flame cutting ) )×(+pad width(× 2 waste from flame cutting ) ) pad thickness

pad material density×××(+

=

actual pad weight pad length pad width pad thickness pad material density×××=

pad material cost pad weight including waste pad material cost per lb×=

pad cutting length pad length pad width ) 2×+(=

pad cutting hrs pad cutting length 12 ) pad cutting rate ) 60 ) ⁄ × ⁄ ((=

pad weld length pad cutting length=

pad to vessel welding hrs pad fillet welding rate pad weld length 12 ) ⁄ (×=

pad fillet weld volume pad fillet weld size2

2 ) pad weld length× ⁄ (=

pad weld rod weight pad fillet weld volume vessel weld rod density×=

pad weld rod cost pad weld rod weight vessel weld rod cost per lb×=





Heads

If the head costs are read or interpolated from the corresponding head cost tables then theequation on the estimate shows the normalization and/or impact testing percentages

added to the head cost. If, however, the head cost is manually entered while costing thevessel then we assume that the head cost entered already includes extra costs fornormalization and/or impact testing and therefore these percentages are not reflected inthe equation for head material cost on the estimate.

Cylinders

Fabricated cylinders or cylinders made from pipe material will include normalizationand/or impact testing factors in the equation on the estimate. For purchased cylindersextra costs for normalization and/or impact testing will be added to the equation on the

estimate if the cylinder costs are read or interpolated from the cylinder costs tables. Ifthe user manually enters the cylinder cost while costing the vessel then we assume that

the cost entered includes any extra costs for normalization and/or impact testing so theseextra percentages are not reflected in the equation for cylinder material cost on theestimate.

Nozzles

Nozzles made from pipe material do not add extra costs for normalization and/or impacttesting. Fabricated nozzles add extra costs for normalization and/or impact testing intothe equation on the estimate. If the user manually enters the nozzle cost while costing

the vessel then we assume that the cost entered includes any extra costs fornormalization and/or impact testing so these extra percentages are not reflected in the

equation for nozzle material cost on the estimate.

ASME B16.5/16.47 Body Flanges

We assume that normalization and impact testing factors have already been included inthese costs according to the material specification so these extra percentages are notreflected in the equation for ASME B16.5/16.47 and ASME Section VIII Division 1Appendix 2 body flange material costs on the estimate.

Davit Calculations

If the "Always Add Davits" box is checked then davits will be considered for manway

openings with a manway nominal size greater than or equal to the "Minimum ManwayDiameter Required to Add Davits" value. The manway nominal size and the class areused to look up the cost, labor, and weight of the davit from the corresponding davittable. To determine the manway nominal size Coster uses the pipe nominal size (pipematerial) or the inner diameter (fabricated nozzle) of the manway and compares this size

total material cost material cost= material cost normalization percent )material cost impact testing percent)×(+

×(+





to the manway diameters listed on the davit table. Coster selects the manway diameter

from the davit table which is equal to or larger than the pipe nominal size or innerdiameter (if the pipe nominal size or inner diameter lies within the range of manwaydiameters listed on the table) and uses this manway nominal size to determine the davitcost, labor, and weight. Davits are listed separately in the Miscellaneous section of theestimate and the weight of each davit is listed in the Bill of Materials.

Grinding Calculations

Grinding is calculated according to the selections on the User Selectable Items dialog forcylinders, transitions, heads, skirt base rings, and skirts. For skirt base rings the grooveweld length calculated for grinding is multiplied by two to include smooth grinding onboth the top and bottom of the groove weld (the base ring weld length and total gusset

weld length are not considered for grinding because they are fillet welds which do notrequire grinding). The grinding rates are read from the Grinding Labor table based onmetallurgy, thickness, and type of grinding (normal, flush, smooth). The inside andoutside grinding rates are calculated and combined for a total grinding rate. Grinding is

not considered for ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2body flanges.

Blasting/Cleaning Calculations

Blasting/Cleaning is calculated based on the selection on the User Selectable Items dialog forcylinders, transitions, heads, skirt base rings, skirts (blasting/cleaning is always calculated for boththe inside and outside of the skirts if blasting/cleaning is selected), and saddles. Blasting/Cleaning isnot considered for ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2 bodyflanges. If the method chosen is "wire brush" then the labor hours will be displayed under the"cleaning labor" column on the estimate. All other methods chosen will be displayed under the

"blasting labor" column on the estimate.

inside grinding rate grinding rate=

outside grinding rate grinding rate=

total grinding rate inside grinding rate outside grinding rate+=

grinding labor hrs total weld length 12 ⁄ total grinding rate×=

grinding labor cost grinding labor hrs manufacturing labor rate×=

blasting/cleaning labor hrs outside surface area 100 ) blasting hrs per 100 sq ft× ⁄ (=

blasting/cleaning labor cost blasting/cleaning labor hrs blasting labor cost per hr×=





Paint/Primer Calculations

Paint and primer type, quantities, labor hours, and labor costs are calculated according to theselections on the User Selectable Items dialog for cylinders, transitions, heads, skirt base rings, skirts(paint/primer is always calculated for both the inside and outside of the skirts if paint/primer isselected), and saddles. Cylinders, transitions, and heads use the inside surface area in the equationsbelow to calculate painting and priming on the inside of these components. Paint and primer are notconsidered for ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2 body flanges.Coverage per 100 sq ft, cost per container, application labor hrs and standard container size are readfrom the Paint or Primer database tables according to the paint/primer type selected. Labor cost perhr is read from the Labor Rates dialog on the Defaults - Other menu.

Hydrotest Calculations

Coster calculates hydrotest at the end of the costing procedure using the formula fromthe Hydrotest dialog on the Defaults - Hydrotest menu for cylinders, transitions, 2:1ellipsoidal heads, F&D heads, and hemispherical heads. Hydrotest hours are reported in

the miscellanous section of the estimate. The diameter value in this formula is aweighted average calculated as follows. For transitions Coster calculates an average ID

to replace ID in the formula below. For heads Coster calculates a hydrotest length toreplace the length in the formula below. In addition to these hydrotest hours, Costercalculates hydrotest hours nozzles when no blind flange is attached (if a blind is attachedthen hydrotest hours are zero). To calculate hydrotest hours for nozzles read the blindlabor hours from the Blind Labor table based on the class and the flange nominal size orlong weld neck size. Multiply these blind labor hours by two to determine the hydrotesthours. Coster estimates the hydrotest hours as the labor hours to attach and remove ablind. At this time Coster does not take into consideration the cost of water to fill thetank or the drying time. Coster does not consider hydrotest for ASME B16.5/16.47 or

ASME Section VIII Division 1 Appendix 2 body flanges.

Hydrotest Length for Heads (2:1 ellipsoidal, F&D, Hemispherical)

The length of a head for hydrotest purposes is calculated through a comparison of thehead volume compared to the length of a cylinder with an equal volume.

quantity outside surface area 100 ) coverage per 100 sq ft number of coats×× ⁄ (=

material cost quantity cost per container×=

labor hrs outside surface area 100 ) application labor hrs number of coats×× ⁄ (=

labor cost labor hrs labor cost per hr×=

ID weighted average Σ ID length ) total length ⁄ ×(=





Convert the head volume from US gallons to cubic inches

To turn off hydrotest calculations, set each of the Hydrotest Factors a, b, and c on theHydrotest dialog of the Defaults menu to zero.

Post Weld Heat Treatment (PWHT)

If Post Weld Heat Treatment (PWHT) is required on this vessel for any component(s) anentry for PWHT will be shown on the estimate. Coster determines that "global" PWHT

is required if the following components all require PWHT -- ASME B16.5/16.47 bodyflange ASME Section VIII Division 1 Appendix 2 body flange, 2:1 head, f&d head,hemi head, flat welded head, transition, cylinder. Otherwise if PWHT is required onsome but not all of these components then Coster determines that "local" PWHT isrequired. If global PWHT is determined then Coster will also add the weight of thesaddles, skirt base ring and compression ring, legs (including leg base plate and leg pad),skirts, and vacuum rings to the weight of the welded components. If the ASME B16.5/ 16.47 or ASME Section VIII Division 1 Appendix 2 body flange requires PWHT thenthe blind weight will be added to the weight of the welded components. Similarly theweight of the pad will be added if the nozzle to which it is attached requires PWHT.Global PWHT is calculated by multiplying the weight of the welded components by thecost per 100 lb user-defined default from the Fabrication dialog on the Defaults - Other

menu. The total PWHT and the weight of the welded components will be displayed onthe estimate. If local PWHT is required you will be asked to enter a total cost for PWHTduring the estimating process. The weight will not be displayed on the estimate for localPWHT.

X-Ray Calculations

Coster keeps track of the weld lengths for the x-ray dialog according to the weld typeand radiography specified on the vessel for cylinders, transitions, heads, and nozzles.X-ray is not considered for estimating skirts.

Welding Calculations

One feature of Coster is the ability to automatically switch from single side welding to double sideaccording to the thickness of the component. The "as-shipped" thickness default is set to0.75 inches on the Weld Detail dialog of the Defaults - Welding menu. This means that if you havespecified V welding for estimating, Coster forces all components with a thickness less than or equalto 0.75 inches to be calculated using single V welding and all components with a thickness greaterthan 0.75 inches to be calculated using double V welding. Enter a value in the thickness default

volume of cylinder π 4 ) cylinder length ID2

×× ⁄ (=

cubic inches head volume US gal head volume 231×=

hydrotest length cubic inches head volume π 4 ) ⁄ ID2

×( ⁄ =





input box labelled "Use single weld <= thickness Use double weld > thickness" according to the

type of welding you require. If you would like all components to use a single V weld then select Vwelding and set the thickness default to a very large thickness. To force all welding to be double Vselect V welding and set the thickness default to zero. This feature operates similarly when Uwelding is selected.



APPENDIX A

< APPENDIX A 12 - 1 >

12APPENDIX A

Coster Database Tables

Coster uses libraries of cost and other data to calculate an estimate. These libraries are stored asdatabase tables and the final cost estimate is produced in an Excel-compatible format. Some tablesinclude abbreviations which used by Coster for metallurgy:

- CS = Carbon Steel- SS = Stainless Steel- AL = Aluminum- Cu = Copper- Cu Alloy = Cooper Alloy

- Ni = Nickel- Ni Alloy = Nickel Alloy- Ti = Titanium- UHT = UHT (ferritic steels with properties enhanced by heat treatment)

- Zi = Zirconium

The following is a summary of the database tables provided with your Coster program:

Base Plate Layout Labor -- labor hours to install (layout/fitup) skirt base plate as afunction of base plate ID and the number of ring segments.

Blind Flange Labor -- labor hours to attach a blind flange as a function of class

and flange size. These hours (multiplied by 2) are used to calculate the hydrotestlabor hours for nozzles.

Cones and Skirts Forming -- labor hours to form cones/conical skirts as a functionof cone/conical skirt thickness and large end ID.

Coupling Costs -- pricing for 3000# and 6000# couplings as a function ofcoupling material and coupling nominal size .

Coupling Installation Labor -- labor hours (layout/fitup) to install 3000# and6000# couplings as a function of vessel thickness and coupling nominal size.

Cylinder Costs (formed/tacked) -- pricing for cylinders (formed and tacked) as afunction of material, length, thickness, and OD.

Cylinder Costs (welded) -- pricing for cylinders (formed, tacked, and welded) as afunction of material, length, thickness, and OD.

Cylinder Forming Labor -- labor hours to form cylinders/cylindrical skirts as afunction of cylinder/cylindrical skirt thickness and ID.

Davit Cost -- material cost as a function of manway diameter and class.



APPENDIX A


Davit Labor -- labor hours as a function of manway diameter and class.

Davit Weight -- davit weight as a function of manway diameter and class.

Drilling -- drilling labor for appendix 2 flanges as a function of material and boltnominal size.

Fitup Labor (cylinder/cylinder) -- labor hours to fit up cylinder to cylinder as afunction of cylinder thickness and cylinder OD (if the OD is not the same for bothcylinders then use the thickness and OD of the cylinder with the larger OD).

Fitup Labor (cylinder/transition) -- labor hours to fit up cylinder to transition as afunction of cylinder thickness and cylinder OD.

Fitup Labor (head/cylinder) -- labor hours to fit up head to cylinder as a functionof cylinder thickness and cylinder OD. This includes formed heads and flatwelded heads sketch (b-1), (b-2), (d).

Fitup Labor (nonradial nozzles) -- fitup labor multiplication factor as a functionof radial angle.

Fitup Labor (skirt) -- fitup labor hours as a function of thickness and top skirt OD.

Flange Costs -- pricing for flanges. Slip on, lap joint, threaded and socket weldedflange costs are based on material and class as a function of flange size. Long

weld neck and blind flange costs are based on material, class, and facing as afunction of flange size. Weld neck flange costs are based on material, class, boresize (to fit pipe schedule listed), and flange facing as a function of flange size.

Flange Cutting Fee (LWN) -- pricing for cutting long weld neck flanges to therequired length as a function of flange type and flange size.

Flange Specs (LWN) -- displays standard length and cost per 1" lengths as afunction of flange size and class.

Flange to Nozzle - Fitup Labor -- labor hours to fitup flange to nozzle based on

pipe schedule as a function of flange type, metallurgy, and nozzle OD (nominalsize is also included for informational purposes only). Fields must not be addedor deleted from these tables.

Flange to Nozzle - Welding Labor -- labor hours for welding the flange to nozzlebased on pipe schedule as a function of flange type, metallurgy, and nozzle OD(nominal size is also included for informational purposes only). Fields must notbe added or deleted from these tables.

Gasket Cost -- cost per gasket as a function of gasket type, flange nominal size,and class (used with ASME B16.5/16.47 flanges).



APPENDIX A


Grinding Labor -- grinding labor rates as a function of metallurgy, grinding type

(normal, flush, smooth), and component thickness.

Head Bevel Labor -- labor hours to bevel heads as a function of head thicknessand head OD.

Head Costs -- pricing for heads as a function of material, head nominal thicknessand head OD.

Head Flat Fitup Labor -- labor hours to fitup flat welded heads -- sketch (c), (e),(f), (g), (h) -- as a function of head nominal thickness and head OD.

Head Flat Layout Labor -- labor hours to lay out flat welded heads as a function

of head nominal thickness and head OD.

Head Flat Machining Labor -- machining labor (minutes/ft) for flat welded headsas a function of groove depth and head OD.

Legs Labor -- labor hours (layout/burn, fitup, welding) for legs as a function ofmajor dimension (larger of the leg section width and length).

Legs Labor - Base Plate -- labor hours (layout, fitup) for leg base plate as afunction of major dimension (larger of the leg base plate width and length).

Legs Labor - Pad -- labor hours (layout, fitup) for leg pad as a function of major

dimension (larger of the leg pad width and length).

Machining Labor -- labor hours for appendix 2 flanges as a function of flange


Material Properties -- includes material density, welding rod density, welding rodcost, normalization premium, impact test and metallurgy for a specified material.

Misc Items 1 -- miscellaneous items to be added to the Miscellaneous section onthe Vessel Detail Cost sheet in the estimate. Includes material, quantity, weight,material cost, consumables cost, fitup labor, cutting labor, layout labor, welding

labor, drilling labor, and installation or other labor.

Misc Items Auto -- miscellaneous items that Coster will add automatically to the

Miscellaneous section on the Vessel Detail Cost sheet in the estimate. Includesmaterial, quantity, weight, material cost, consumables cost, fitup labor, cuttinglabor, layout labor, welding labor, drilling labor, and installation or other labor.

Miscellaneous Fabrication Labor -- miscellaneous fabrication operations as afunction of metallurgy and component thickness (includes cutting, fillet welding,groove welding drilling and bevelling).



APPENDIX A


Nozzle to Shell or Head Labor -- labor hours to attach nozzle to shell or head

(layout, fitup) as a function of vessel thickness and nozzle OD.

Pad to Nozzle Labor -- labor hours to install pad to nozzle (layout, fitup) as afunction of pad thickness and nozzle OD.

Painting (finish) -- includes application labor, paint cost, coverage, and standardcontainer size for each paint type.

Pipe Cost Schedule -- pricing for pipe according to pipe material and pipeschedule as a function of pipe nominal size.

Plate Costs -- pricing for plate as a function of plate material, plate width, and

plate thickness.

Platform/Ladder Cost and Labor -- material cost and labor hours for platforms,railings, and ladders.

Primer -- includes application labor, primer cost, coverage, and standardcontainer size for each primer type.

Ring Joint R Cost -- unit cost as a function of material and R number (used withASME B16.5/16.47 flanges).

Ring Joint RX Cost -- unit cost as a function of material and RX number (used

with ASME B16.5/16.47 flanges).

Saddles Fitting Labor -- labor hours to fit the saddle and wear plate as a function

of vessel OD.

Stock Plate Sizes (English Units or Metric Units) -- list of standard plate sizesavailable for cutting components. Includes available metallurgy for standardplate sizes as a function of plate thickness and plate dimensions -- width andlength.

Structures/Rings/Tray Supports Material Costs -- pricing for structures/rings/tray

supports as a function of material, type, and size.

Stud Cost -- stud cost (including 2 hex nuts) as a function of stud material, stud

bolt length and stud diameter (used with ASME B16.5/16.47 flanges).

Tray Installation Labor -- labor hours to install tray support rings (layout) as afunction of vessel ID.

Vacuum Ring Labor -- labor hours to roll and fit up vacuum rings as function ofvessel OD.



APPENDIX A


Weld Deposition Rate - Circumferential Seam Weld -- weld deposition rate (lb/

hour) as a function of component thickness and metallurgy. There is also a fullrework multiplier which is used to increase the labor hours for full jointexamination. This multiplier varies according to thickness.

Weld Deposition Rate - Longitudinal Seam Weld -- weld deposition rate (lb/hour)as a function of component thickness and metallurgy. There is also a full reworkmultiplier which is used to increase the labor hours for full joint examination.This multiplier varies according to thickness.

Weld Deposition Rate - Nozzle Fillet Weld -- fillet weld deposition rate (lb/hour)for manual welding as a function of metallurgy, weld leg size, and nozzle OD.For outer fillet welds, the deposition rate is based on the pad OD (in).

Weld Deposition Rate - Nozzle Groove Weld -- groove weld deposition rate (lb/ hour) for manual welding as a function of metallurgy, weld thickness and nozzleOD.

Weld Reinforcement -- weld bead reinforcement -- height of the weld beadprojecting beyond the surface of the parts being joined as a function of componentmaterial thickness and the type of seam.

Welding Time - Circumferential Seam Weld -- This table contains min/ft weldingrates based on thickness, metallurgy and weld type. The values from this table areconverted to lb/hour weld deposition rates and are used to populate the Weld

Deposition Rate - Circumferential Seam Weld table which is used during thecosting process to calculate welding labor hours. There is also a full reworkmultiplier based on the thickness (included to increase the labor hours for full

joint examination) which will be transferred from the welding time table to theweld deposition rate table when the lb/hour conversions are made. The WeldingTime - Circumferential Seam Weld table is NOT used during the costing process.It is available only as a conversion tool for users who have labor hours based onwelding time rather than weld deposition rate.

Welding Time - Longitudinal Seam Weld -- This table contains min/ft weldingrates based on thickness, metallurgy, and weld type. The values from this table

are converted to lb/hour weld deposition rates and are used to populate the WeldDeposition Rate - Longitudinal Seam Weld table which is used during the costingprocess to calculate welding labor hours. There is also a full rework multiplier

based on the thickness (included to increase the labor hours for full jointexamination) which will be transferred from the welding time table to the welddeposition rate table when the lb/hour conversions are made. The WeldingTime - Longitudinal Seam Weld table is NOT used during the costing process. Itis available only as a conversion tool for users who have labor hours based onwelding time rather than weld deposition rate.



APPENDIX A


Welding Time - Nozzle Fillet Weld -- This table contains min/ft welding rates as a

function of metallurgy, weld leg size, and nozzle OD. The values from this tableare converted to lb/hour weld deposition rates and are used to populate the WeldDeposition Rate - Nozzle Fillet Weld table which is used during the costingprocess to calculate welding labor hours. The Welding Time - Nozzle Fillet Weldtable is NOT used during the costing process. It is available only as a conversiontool for users who have labor hours based on welding time rather than welddeposition rate.

Welding Time - Nozzle Groove Weld -- This table contains min/ft welding ratesas a function of metallurgy, weld thickness, and nozzle OD. The values from thistable are converted to lb/hour weld deposition rates and are used to populate theWeld Deposition Rate - Nozzle Groove Weld table which is used during the

costing process to calculate welding labor hours. The Welding Time - NozzleGroove Weld table is NOT used during the costing process. It is available only asa conversion tool for users who have labor hours based on welding time ratherthan weld deposition rate.



INDEX

< INDEX - i >

13INDEX

2 to 1 HEAD

calculations 11-27ALIAS

add names 7-2

clear alias list 7-2

coupling materials 3-7, 7-2

delete names 7-2

flange materials 3-7, 7-3

lists 7-1

matching material names 3-5

material 3-2, 3-6

name 3-6

pipe materials 3-6, 7-2

plate materials 3-5, 7-1

APPENDIX 2 FLANGE

calculations, body flange 11-35

ASME B16.5/16.47 FLANGE 6-2

calculations, body flange 11-35

hydrotest, body flange 11-35

impact testing, body flange 11-94

labor hours/costs, body flange 11-36

material cost, body flange 11-36

normalization, body flange 11-94

ATTACHMENTS 8-7

BACKUP COSTER DATA 4-5

BACKUP FILES

directory 4-6

BASE PLATE

labor hours 5-5

legs 11-91

BEVELcylinder 11-19, 11-22

skirt 11-67

BEVEL ANGLE

nozzle groove welds 7-12

BEVEL LABOR

heads 5-2, 11-27, 11-28

BILL OF MATERIALS 7-7, 7-14, 8-15

cutting sketch 8-16

plate sizes 11-14

plate usage 8-17

radiography 8-17

weight of source material 8-16

BLASTING 7-5

calculations 11-95BLASTING/CLEANING

cylinder 11-16

heads 11-27, 11-29

method 4-3

skirt 11-65

skirt base ring 11-53

transition 11-20

BLINDcost 8-11

flange 8-11

flange table 5-3

labor hours 8-11

long weld neck 11-73

nozzles 11-72

BOLTUP BLINDS 5-3

BUTT WELDING

vacuum rings 11-23

CALCULATIONS

appendix 2 body flange 11-35

asme b16.5/16.47 body flange 11-35

blasting/ cleaning 11-95

cylinder 11-16

cylinder, purchased 11-16

davits 11-94

grinding 11-95

heads 11-27, 11-29

hydrotest 11-96

impact testing 11-93

insulation/lining 11-44

legs 11-87

normalization 11-93

nozzles 11-68

packed bed 11-41

pads 11-80

paint 11-96

platform /ladder/top head platform 11-41

primer 11-96pwht 11-97

saddles 11-46

skirt 11-64


transition 11-20

tray support 11-42

vacuum rings 11-23

welding 11-10, 11-97

x-ray 11-97

CENTERED BOLTING CHAIR


CIRCUMFERENTIAL SEAM WELDING

see also girth seam labor

skirt 11-65transition 11-20

CLEANING 7-5

calculations 11-95

method 4-3

CODEWARE

vessel file 4-1



INDEX

< INDEX - ii >

COLUMN

estimate 8-7

misc section 8-12

nozzle section 8-9

shell section 8-7COMPATIBILITY

vessel files 1-1

COMPONENT

bill of materials 8-15

COMPRESS 3-1

files compatible with Coster 1-1

CONSUMABLES

cost 8-12

CONVERSIONS

currency 8-2

units 8-2

COPYRIGHT iCOSTER

official material 3-6quick start 2-1

spreadsheet template file (CostSS.xls) 8-2

COSTS

finished vessel 8-14

finished weight plate material 8-14

total plate material 8-14

total vessel costs 8-15

unused plate material 8-14

vessel totals 8-14

COUPLING 6-1, 8-7

alias 7-1

alias list 3-7

alias names 7-2

layout/fitup

5-2

to vessel 5-2

CROSS REFERENCE

material names 3-6

CURRENCY 7-3, 7-4, 8-3

database tables 8-6

estimate 11-1

revising on tables 3-9

CUSTOM

cut plate materials 7-14

plate layout, conical skirts 11-14

plate layout, cylinders 11-14

plate layout, nozzles 11-14

plate layout, skirt base rings 11-15

plate layout, skirts 11-14

plate layout, transitions 11-14

CUSTOMIZE

Coster 3-1

Coster template (CostSS.xls) 8-2

cutting plate material 11-13

database tables 3-2

misc items 8-2

report 8-18

CUT WIDTH 7-6

CUTTING 8-13

alternate layout 11-13

conical sections 11-6cylinder 11-18

labor hours (nozzle) 8-11

labor hours (pad) 8-11

labor, head 11-30

labor, skirt 11-66

labor, transition 11-21

length, custom cut transitions and conical skirts 11-15

length, cylinder 11-16

length, skirt 11-64

long weld neck 6-2, 6-3

plate layout 11-3

sketches 11-9

skirt base rings 11-9skirt base rings, custom cut 11-15

transition 11-20

CUTTING SKETCH


display on estimate 7-9

CYLINDER

bevelling 11-19, 11-22

blasting/cleaning 11-16

calculations 11-16

custom cut plates 7-14

cutting 11-18

cutting length 11-16

fitup labor 11-17, 11-18

forming

11-18

girth seam labor 11-19

grinding 11-16

impact test 11-16


long seam labor 11-19

material cost 11-16, 11-17

method for estimating 7-8

normalization 11-16, 11-94

pipe 11-16, 11-17

plate 11-16, 11-17

properties 11-16

purchased 11-16, 11-17

surface area 11-19

welding 11-16

DATABASEsee also tables

backup file (CostDbBk.mdb) 4-6

changing database 7-8, 7-9

current database for estimating 10-1

global update 3-9

password 3-10



INDEX

< INDEX - iii >

regional settings 3-10

revising currency 3-9

revising units 3-9

DATABASE TREE 9-1

DAVITS 5-3add 7-8

calculations 11-94

material cost 6-5

minimum manway diameter 7-7

user defined default 5-4

DEFAULTS

active cost source database 7-8

active cost source directory 7-9

active cost source drive 7-9

alias lists dialog 7-1

always add davits 7-8, 11-94

bevel angle (nozzle groove welds) 7-12


blasting/cleaning dialog 7-5clip labor, insulation 7-3

clip labor, insulation/lining 11-44

clips 7-3

clips, insulation 7-3

clips, insulation/lining 11-44

coupling alias materials 7-2

coverage, insulation 7-3

coverage, insulation/lining 11-44

currency 7-4

currency/exchange dialog 7-3

custom plates 7-14

cylinder 7-8

defined names 8-2

design program to use for materials list

7-9

diameter 7-14

diameter/longitudinal weld seams ratio dialog 7-13

display cutting sketch on estimate 7-9

exchange rate 7-4

fabrication 7-6

field installed insulation 7-3

field installed, insulation 7-3

fillet weld 7-14

fillet weld size for vessel internals 7-14

finishing 7-5

flange alias materials 7-3

hydrotest dialog 7-5

hydrotest factors 7-5

insulation clips dialog 7-3

labor rate 7-8

labor tables 5-1

lining 7-3

lining clips dialog 7-3

manufacturing labor rate 7-8

material tables 6-1

maximum allowable plate length 7-7

maximum allowable plate width 7-7

menu 2-2, 7-1

menu units 7-4

min. manway diameter to add davits 7-7, 11-94

minimum shell course length 7-6number of long seams 7-14, 11-14

operator weld efficiency 7-12

other defaults dialog 7-6

paint application labor 5-4

paint cost 5-4

paint coverage 5-4

paint labor rate 7-8

paint standard container size 5-4

pipe alias materials 7-2

pipe material waste 7-7

pipe minimum cut length 7-7

plate alias materials 7-1

plate layout 11-3

post weld heat treatment 7-7primer labor rate 7-8

print expanded form of estimate 7-9

program output 7-8

report currency 7-4

saddle fillet weld size 7-14, 11-46

saddle welding 7-15

sandblasting labor rate 7-8

set user defined 7-1

shop installed insulation 7-3

shop installed, insulation 7-3

square all sides of plate 7-8

switch from single to double welding 7-10

tables 3-2

tray supports

7-10

tray supports deposition rate 7-14

type of welding 7-10

u groove weld radius 7-12

use custom plates cut to component size 11-13

vacuum ring fillet weld size 7-14

vacuum ring intermittent welding 7-14, 11-23

vacuum ring weld deposition rate 7-14

vacuum ring welding 7-15, 11-23

waste from flame cutting 7-6

weld bevel angle 7-11

weld detail dialog 7-10

weld gap 7-10

weld recovery 7-12

weld straight section 7-11

welding 7-10

welding labor rate 7-8

wire brush labor rate 7-8

DEFINED NAMES

see also range names

adding 8-3

view list 8-4



INDEX

< INDEX - iv >

DESCRIPTION


DESIGN PROGRAM

materials list 7-9

DIALOGSpurpose 3-1

DIAMETER/LONGITUDINAL WELD SEAMS RATIO 7-13

DOUBLE BASE RING


DRILLING 8-13

DROP FROM


ERROR MESSAGE

key not found 1-1

printer not found 8-1

uninstalling 1-2

ESTIMATE

add misc items 8-1bill of materials 2-1, 8-15

columns 8-7

currency 7-4, 8-3, 11-1

customize template 8-18

cutting sketches 2-1

drop material remaining 8-17

drop material used 8-17

Excel compatible 3-1

finished vessel cost 8-14

finished weight plate material cost 8-14

format cells 8-3

girth seams added 3-4

headings 8-3, 8-6

miscellaneous section

8-12

nozzle section 8-9

plate usage 2-1, 8-17

print expanded form 7-9

printing 8-1

radiography 8-17

radiography table 2-1


scrap material 8-17

sections 2-1

shell section 8-7

spreadsheet 8-6

spreadsheet operation 8-1

starting 2-1

stock plates required 8-17

summary report 2-1, 8-18

total cost 2-1

total finished vessel weight 8-14

total plate material cost 8-14

total unused material cost 8-17

total vessel costs 8-15

units 8-3, 11-1

unused plate material cost 8-14

user defined plates required 8-17

version 8-3

vessel total costs 8-14

x-ray cost 8-14ESTIMATING METHOD

skirt base ring 11-52, 11-60

EXCEL

version compatibility with Coster 8-3

EXCHANGE RATE 7-3, 7-4

F&D HEAD

calculations 11-27

F3 2-1

FABRICATION 7-6

FACING

flange 4-3

FEATURES

backup Coster data 4-5

bill of materials 2-1cost a Codeware file 4-1

coupling alias list 3-7

customize summary report 2-1

delete field 3-8

delete record 3-7

flange alias list 3-7

insert field 3-7

insert record 3-7

interpolation 2-1, 8-6

pipe alias list 3-6

plate alias list 3-5

plate selection 3-2

print database table 3-7

repair Coster database

4-6

retrieve Coster estimate 4-5

split database view 3-8

summary report 2-1

user defined defaults 2-2

vessel detail cost 2-1

FIELD

delete 3-8

insert 3-7

FIELD INSTALLED


FILE MENU 4-1

add miscellaneous items (database) 8-2

backup Coster data 4-5

cost a Codeware file 4-1

repair Coster database 4-6

retrieve Coster estimate 4-5

FILES

.xls 4-5

backup (database/template) 4-6

compatible with Coster 1-1

compatible with Coster (.xml output) 1-1



INDEX

< INDEX - v >

CostDbBk.mdb 4-6

Coster directories 10-1

CostSS.xls 8-2

CostSsBk.xls 4-6

sample vessel 4-1sample1 2-1

FILLET WELD 7-14

legs 11-87

saddle 7-14, 11-46

skirt base ring 11-53, 11-59

vacuum ring 7-14

vessel internals 7-14

FINISHING 5-4, 6-5, 7-5

paint 5-4

primer 5-4

FITTINGS 6-1

FITUP LABOR 5-1, 8-12

cylinder 11-18

flange to nozzle 5-3heads 11-28, 11-31

non-scheduled nozzles 11-74

scheduled nozzles 11-74

skirt 11-66

transition 11-21

FLAME CUTTING WASTE 7-6

FLANGE

alias 7-1

alias list 3-7

alias names 7-3

cost 8-11

cutting fee, long weld neck 6-3

facing 4-3

labor hours

8-11

nozzle section, flange type 8-9

nozzles 11-72

standard cost/ labor 11-73

welding labor 11-76

FLANGE COST

appendix 2 11-36, 11-73

ASME B16.5/16.47 11-36

FLAT HEAD

calculations 11-29

FORMED HEADS 6-4

FORMING LABOR

cylinder 11-18

cylinder table 5-1

fabricated nozzles 8-11

skirt 11-66

skirt (straight) table 5-1

transition 11-20, 11-21

transition/conical skirt table 5-2

vacuum rings 11-23

FORMULAS

entering 8-1

miscellaneous items 8-2

FUNCTION KEYS

F3 2-1

GASKETS

cost table 6-5material 4-3

GIRTH SEAM LABOR

see also circumferential seam welding

cylinder 11-19

heads 11-28

transition 11-22

GIRTH SEAMS

added 3-4

GLOBAL UPDATE

revise database values 3-9

GRINDINGcalculations 11-95

cylinder 11-16

heads 11-27, 11-29inside 4-3

outside 4-3

rates 5-3

skirt 11-65

transition 11-20

HARDWARE

key 1-1

program activator 1-1

requirements 1-1

HEADS

bevel labor 5-2, 11-27, 11-28

blasting/cleaning 11-27, 11-29

calculations 11-27, 11-29

circumferential seam welding

11-27

cutting labor 11-30



grinding 11-27, 11-29

impact test 11-27, 11-29


labor cost 11-30

labor hours 11-30

layout labor 11-31

long seam labor 11-28, 11-34

machining labor 11-31


normalization 11-94

properties 11-27, 11-29

surface area, 2 to1 11-28

surface area, f&d 11-28

surface area, flat 11-34

surface area, hemispherical 11-29

welding labor 11-31

HELP MENU 10-1

about Coster 10-1



INDEX

< INDEX - vi >

Coster directories 10-1

database name 10-1

HEMISPHERICAL HEAD

calculations 11-27

HILLSIDEsee also nonradial

nozzles 11-77

pad plate size 11-81

HISTORY

printing iiHYDROTEST 7-5, 8-12

asme b16.5/ 16.47 body flange 11-35

calculations 11-96

factor a,b,c 7-5

labor 5-3

long weld neck 11-73

nozzles 11-72

IDENTICAL

attachments 8-12nozzles 8-10

IDENTIFIER 8-9, 8-12, 8-15, 8-16

IMPACT TEST

cylinder 11-16

heads 11-27, 11-29

saddles 11-46

skirt 11-64


transition 11-20

vacuum rings 11-23

IMPACT TESTING


calculations 11-93

cylinder

11-94

heads 11-94

nozzles 11-94

INSERT

miscellaneous items 8-1

INSTALL/OTHER 8-13

INSTALLATION 1-1

Coster files 1-1

hardware key 1-1


network 1-1

system requirements 1-1

INSULATION 3-11, 7-3

calculations 11-44

clip labor 7-3

clips 7-3

coverage 7-3

field/shop installed 11-44

labor costs 11-45

labor hours 11-45

material cost 11-45

shop installed 7-3

INTERPOLATION 2-1, 2-2

method 11-2

multiple 11-2

platform/ladder/top head platform 11-41

single 11-2ITEM

miscellaneous section 8-12

nozzle section 8-9

shell section 8-7

LABOR COSTS


heads 11-30



nozzle section 8-11

saddles 11-51

shell section 8-9

tray support 11-44

vacuum rings 11-26LABOR HOURS


attach blind flange 5-3

blast 8-9

blind 8-11

clean 8-9

cutting 8-13

cutting (nozzle) 8-11

cutting (pad) 8-11

drilling 8-13

fitup 8-12

flange 8-11

flange welding 8-11

form and tack cylinder

2-2

form cylinders 5-1

form fabricated nozzles 5-1

form straight skirts 5-1

forming 8-11

grind 8-9

heads 11-30

install couplings 5-2

install/other 8-13


layout 8-13

layout/cut/install pad 5-3

legs 11-90

long seam welding 8-11


miscellaneous section (cutting) 8-13

miscellaneous section (drilling) 8-13

miscellaneous section (fitup) 8-12

miscellaneous section (install/other) 8-13

miscellaneous section (layout) 8-13

miscellaneous section (welding) 8-13

nozzle section 8-11



INDEX

< INDEX - vii >

nozzle section (nozzle) 8-11

nozzle section (pad) 8-11

nozzle to shell or head 5-3

nozzle welding 8-11

pad welding 8-11platform/ railing/ladder/top head platform 11-42

saddles 11-51

shell section 8-9

shell section bevel 8-8

shell section cutting 8-8

shell section forming 8-8

shell section forming, fitup, cutting 8-8

shell section girth seam 8-8

shell section long seam 8-7

skirt 11-67


tray support 11-44

vacuum rings 11-26

welding 8-13LABOR MENU

boltup blinds 5-3

coupling to vessel 5-2

davit 5-3

finishing 5-4

fitup 5-1

fitup labor - cylinder/cylinder 5-1

fitup labor - cylinder/transition 5-1

fitup labor - flat welded head sketch (c), (e), (f),

(g), (h) 5-1

fitup labor - head/cylinder includes formed heads

and flat welded heads sketch (b-1), (b-

2), (d) 5-1

fitup labor - nonradial nozzle factor

5-1

fitup labor - skirt 5-1

flange to nozzle 5-3

forming (cylinder/straight skirt) 5-1

forming (transition/skirt) 5-2

grinding rates 5-3

head bevel 5-2

layout - flat welded head 5-2

legs 5-4

legs labor 5-4

legs labor - base plate 5-4

legs labor - pad 5-4

machining - flat welded head 5-2

nozzle installation 5-2

nozzle/long weld neck 5-3

pad to nozzle/long weld neck 5-3

platform/ ladder 5-5

saddles 5-5

skirt base ring (layout) 5-5

tray support rings 5-5

vacuum rings 5-2

welding 5-6

LABOR RATE 7-8

welding 7-8

LABOR TABLES

base plate layout labor 5-5

blind flange labor 5-3cones forming labor 5-2

conical skirts forming labor 5-2

coupling installation labor 5-2

davit labor 5-3

davit weight 5-3

drilling 5-3

flange to nozzle fitup labor 5-3

flange to nozzle welding labor 5-3

grinding 5-3

head bevel labor 5-2

head layout labor (flat welded head) 5-2

head machining labor (flat welded head) 5-2

machining 5-3

misc fabrication 5-3nozzle to shell or head labor 5-3

pad to nozzle labor 5-3

platform/ladder cost and labor 5-5

saddles fitting labor 5-5

transition forming labor 5-2

tray installation labor 5-5

vacuum ring labor 5-2

LANGUAGE

regional settings 3-10, 8-1

LAYOUT

custom plate, cylinders 11-14

custom plate, nozzles 11-14

custom plate, skirt base rings 11-15

custom plate, skirts

11-14

LAYOUT LABOR 8-13

heads 11-31

LEGS 5-4

base plate 11-88, 11-91

calculations 11-87

fillet weld size 11-87

labor hours 11-90

major dimension 11-88

material cost 11-89

pad 11-88, 11-92

welding rod 11-90

LENGTH

circumferential seam weld 11-14, 11-15

longitudinal seam weld 11-14, 11-15, 11-16

LIBRARIESlabor 3-1

material 3-1

LICENSE AGREEMENT iLINING 3-10

calculations 11-44

clips 7-3



INDEX

< INDEX - viii >

cost 3-10

field/shop installed 11-44

labor 3-10

labor costs 11-45

labor hours 11-45material cost 11-45

LONG SEAM LABOR

cylinder 11-19

heads 11-28, 11-34

transition 11-22

LONG WELD NECK 6-2

attach to vessel 5-3

blind 11-73

cost 6-3

cutting fee 6-2, 6-3

flange costs 6-2

flange specs 6-2

hydrotest 11-73

length, standard 11-73LONGITUDINAL SEAM WELDING

skirt 11-65

transition 11-20

LONGITUDINAL WELD SEAMS RATIO 7-13

MACHINING LABOR

heads 11-31

MAIN MENU 3-1

MAJOR DIMENSION

legs 11-88

legs, base plate 11-88

legs, pad 11-88

MANUFACTURING LABOR

cost 7-8

MATERIAL

alternate layout (custom cut) 11-13



head material costs 6-4

matching names 3-5


names 3-5

nozzle section 8-9

plate layout 11-9

plate layout (default method) 11-3

scrap, custom transitions and conical skirts 11-15

shell section 8-7

waste 7-7

MATERIAL COST


cylinder 11-17

heads 11-27, 11-30


legs 11-89

miscellaneous section 8-12, 8-14

nozzle section 8-12



nozzles 11-70, 11-76

pads 11-80

platform/ railing/ladder/top head platform 11-42saddles 11-50

shell section 8-7

skirt 11-66

tables 6-1

transition 11-20, 11-21

tray support 11-43

vacuum rings 11-23, 11-26

MATERIAL MENU

ASME B16.5/16.47 flanges 6-2

couplings/fittings cost 6-1

davit material cost 6-5

finishing 6-5

flange specs table 6-3

formed heads 6-4gasket cost 6-5

long weld neck 6-2

material properties 6-4

misc items 6-4

misc items 1 6-4

pipe cost 6-4

platform/ladder 6-6

ring type joint r cost 6-6

ring type joint rx cost 6-6

stock plate sizes 6-5

structures /rings/tray supports cost 6-4

stud cost 6-6

MATERIAL TABLES

couplings costs

6-1

cylinder costs (purchased formed/tacked) 6-1

cylinder costs (purchased welded) 6-1

davit cost 5-3


gasket cost 6-5

head 2 to 1 material costs 6-4

head hemi material costs 6-4

material properties 6-4

misc items 1 6-4

misc items auto 6-5

paint 6-5

pipe cost schedule 6-4

plate material costs 6-4

platform /ladder cost and labor 6-6

primer 6-5



stock plate sizes 6-5

structures /rings/tray supports material costs 6-4

stud cost 6-6

MENU BAR



INDEX

< INDEX - ix >

main menu 3-1

MENUS

database tree 9-1

defaults menu 7-1

file menu 4-1help menu 10-1

labor menu 5-1

material menu 6-1

spreadsheet 8-1

METALLURGY 3-3

MISC ITEMS 6-4

auto 6-5

currency conversion 8-2

insert 8-1

units conversion 8-2

MISC SECTION 8-2, 8-7, 8-12

costs 8-2

MULTIPLIER

full joint examination 5-8NEUTRAL AXIS

vacuum rings 11-23

NONRADIAL

see also hillside

nozzles 11-77

NORMALIZATION


calculations 11-93

cylinder 11-16, 11-94

heads 11-27, 11-29, 11-94

nozzles 11-94

saddles 11-46

skirt 11-64

skirt base ring

11-52

transition 11-20

vacuum rings 11-23

NOZZLES 8-7

attach to vessel 5-3

bevel angle (groove welds) 7-12

blind cost/labor 11-72

calculations 11-68

custom cut plates (fabricated nozzles) 7-14

estimate 8-7, 8-9

flange cost/labor 11-72

hillside 11-77

hydrotest 11-72


installation labor 8-11

installation menu item 5-2

layout/ cutting/fitup 5-3

length 7-7, 8-10


material costs 11-70

nonradial 11-77

non-scheduled 11-74

normalization 11-94

pad calculations 11-80

pipe material cost 11-76

plate material cost 11-76

properties 11-70scheduled 11-74

tag 8-9

total cost 8-12

weld calculations 11-81

OPERATOR

weld efficiency 7-12

OVERVIEW

Coster 2-1

PACKED BED

calculations 11-41

weight 11-41

PAD 8-16

attach to long weld neck 5-3

attach to nozzle 5-3calculations 11-80

hillside plate size 11-81

installation time 8-11

layout/cutting/install 5-3

legs 11-92

material 8-9


material waste 7-6

plate size 11-80

properties 11-80

radial plate size 11-81

PAINT

application labor 5-4

calculations

11-96

coats 4-2

cost 5-4

coverage 5-4

inside 4-2

labor cost 7-8

labor menu 5-4

outside 4-2

remaining 5-4

stainless steel materials 4-2

standard container size 5-4

PARALLEL

port 1-1

PASSWORD

database 3-10

PIPEalias 7-1

alias list 3-6

alias names 7-2

cost 6-4

cylinder 11-16

material cost, nozzles 11-76



INDEX

< INDEX - x >

material waste 8-15

minimum cut length 7-7, 8-15

schedules 6-4

waste 7-7

PLATEalias 7-1

alias list 3-5

alias names 7-1

availability 3-4

custom cut 7-14, 11-13


cylinder 11-16

drop material remaining 8-17

drop material used 8-17

layout 11-3

layout, conical skirts 11-14

layout, fabricated cylinders 11-14

layout, fabricated nozzles 11-14

layout, skirt base rings 11-9, 11-15layout, skirts 11-14

layout, transitions 11-14

material cost, nozzles 11-76

materials 7-2

maximum allowable length 7-7, 11-15

maximum allowable width 7-7, 11-15

minimum shell course length 7-6


quantity (bill of materials) 8-16

saddle layout 11-46

scrap material 8-17

size (bill of material) 8-16

size required 8-16

stock

11-16

stock required 8-17

unused material 8-17

user defined 3-4

user defined required 8-17

user defined size 11-14

plate 11-10

PLATFORM/LADDER/TOP HEAD PLATFORM

cage weight 11-41

calculations 11-41

interpolation 11-41

labor hours 11-42

ladder weight 11-41

material cost 11-42

square footage 11-41

table 5-5, 6-6

POST WELD HEAT TREATMENT

see PWHT 4-3, 11-97

PRIMER

calculations 11-96

coats 4-2

inside 4-2

labor cost 7-8

labor menu 5-4

outside 4-2

stainless steel materials 4-2

PRINTERparallel port 1-1

PRINTING

Coster estimate 8-1

database table 3-7

expanded form of estimate 7-9

print expanded form of estimate 8-1

spreadsheet error message 8-1

PROGRAM ACTIVATOR 1-1

PROGRAM OUTPUT 7-8

PROPERTIES

heads 11-27, 11-29

nozzles 11-70

pads 11-80

saddles 11-46skirt 11-64


transition 11-20

tray support 11-42

vacuum rings 11-23

PURCHASED CYLINDERS 11-16

PWHT

calculations 11-97

defaults 7-7

dialog 4-3

QUANTITY



nozzle section

8-10

saddles 11-46

shell section 8-7

RADIAL


RAISED FACE

flange facing 4-3

RANGE NAMES

see also defined names

RECORD

delete 3-7

insert 3-7

REGIONAL SETTINGS

database tables 3-10

spreadsheet 8-1

REPAIRCoster database 4-6

REPORT CURRENCY 7-4

RETRIEVE COSTER ESTIMATE 4-5

file name 4-5

files 4-5

REVISE ALIAS LISTS 7-1



INDEX

< INDEX - xi >

RING TYPE 4-3

flange facing 4-3

R 4-3

R cost table 6-6

RX 4-3RX cost table 6-6

SADDLES 5-5

calculations 11-46

fillet weld size 7-14, 11-46

impact test 11-46

inside rib width 11-46

labor costs 11-51

labor hours 11-51

material cost 11-50

normalization 11-46

plate layout 11-46

properties 11-46

quantity 11-46

saddle width 11-46surface area 11-52

welding 11-50

SAMPLE

cost estimation 2-1

SANDBLASTING LABOR

cost 7-8

SECTION DIMENSIONS


SECTION QTY


SHELL MATERIAL COST

shell section 8-9

SHELL SECTION 8-7

columns for components

8-7

SHELL TOTAL COST

shell section 8-9

SHOP INSTALLED


SINGLE BASE RING

external chairs 11-55

no gussets 11-59

with gussets 11-54

SKIRT

bevel conical skirt 11-67

bevel cylindrical skirt 11-67

bevelling 11-67


calculations 11-64

cutting labor 11-66


fitup labor 11-66

forming labor 11-66

grinding 11-65

impact test 11-64

labor hours 11-67

material cost 11-66

normalization 11-64

properties 11-64

surface area 11-68

welding 11-65SKIRT BASE RING 5-5


calculations 11-52

centered bolting chair 11-53, 11-58


double base ring 11-53, 11-57

estimating method 11-52

fillet weld size 11-53, 11-59

impact test 11-52

labor hours 11-59

normalization 11-52

one segment calculations 11-60

plate layout 11-9

properties 11-54single base ring with external chairs 11-53, 11-55

single base ring with gussets 11-53, 11-54

single base ring with no gussets 11-59

surface area 11-54

trial and error estimating method 11-60

two to six segments calculations 11-61

wastage 7-6

welding 11-59, 11-64

SKIRTS


SPLIT VIEW

database 3-8

SPREADSHEET

see also Coster

see also template

general operation 8-1

template file (CostSS.xls) 8-2

SQUARE ALL SIDES OF PLATE

default 7-8

SQUARE FOOTAGE


STARTING

Coster quick start 2-1

STOCK PLATE SIZES 6-5

STRUCTURAL TYPE

tray support 11-42

STRUCTURES/RINGS/TRAY SUPPORTS

table 6-4

STUDScost table 6-6

material 4-3

SURFACE AREA

2 to1 heads 11-28

cylinder 11-19

f&d heads 11-28



INDEX

< INDEX - xii >

flat heads 11-34

hermispherical heads 11-29

saddles 11-52

shell section 8-7

skirt 11-68skirt base ring 11-54

transition 11-23

TABLES

see also database

6000# couplings costs A-1

base plate layout labor 5-5, A-1

blind flange labor 5-3, A-1

circ seam weld deposition rate 5-6, 5-8

cones forming labor 5-2

cones/skirts forming labor 11-20, 11-64, A-1

conical skirt forming labor 5-2

coupling costs 7-2

coupling installation labor 5-2, A-1

couplings costs 3-7, 6-1create misc items 8-2

currency 8-6

cylinder costs (formed/tacked) A-1

cylinder costs (purchased formed/tacked) 6-1

cylinder costs (purchased welded) 6-1

cylinder costs (welded) A-1

cylinder forming 11-16

cylinder forming labor 2-2, 5-1, 11-64, A-1

cylinders costs (formed/tacked) 11-16

cylinders costs (welded) 11-16

davit cost 5-3, A-1

davit labor 5-3, A-2


davit weight

5-3

,A-2

default 3-2

drilling 5-3

drilling labor A-2


fitup labor - cylinder/cylinder 5-1

fitup labor - cylinder/transition 5-1

fitup labor - flat welded head sketch (c), (e), (f),

(g), (h) 5-1

fitup labor - head/cylinder includes formed heads

and flat welded heads sketch (b-1), (b-

2), (d) 5-1

fitup labor - nonradial nozzle factor 5-1

fitup labor - skirt 5-1

fitup labor (cylinder/cylinder) A-2

fitup labor (cylinder/transition) A-2

fitup labor (head/cylinder) A-2

fitup labor (nonradial nozzles) A-2

fitup labor (skirt) A-2

flange costs A-2

flange cutting fee - long weld neck 6-3

flange cutting fee (lwn) A-2

flange specs 6-3

flange specs (lwn) A-2

flange to nozzle fitup labor 5-3, A-2

flange to nozzle welding labor 5-3

flat head fitup labor 11-31flat head layout labor 11-31

flat head machining labor 11-31

gasket cost 6-5, A-2

global update 3-9

grinding 11-17

grinding labor 5-3

grinding rates A-3

grinding table 11-27, 11-29

head 2 to 1 material costs 6-4

head bevel labor 5-2, 11-27, A-3

head costs 3-6, A-3

head f&d material costs 6-4

head flat fitup labor A-3

head flat layout labor A-3head flat machining labor A-3

head hemi material costs 6-4

head layout labor (flat welded head) 5-2

head machining labor (flat welded head) 5-2

head, 2

1 material costs 7-2

head, f&d material costs 7-2

head, hemispherical material costs 7-2

insert field 2-2

insert record 2-2

labor 3-1

legs labor 5-4, 11-90, A-3

legs labor - base plate 5-4, 11-91, A-3

legs labor - pad 5-4, 11-92, A-3listing A-1

long seam weld deposition rate 5-6, 5-8

machining 5-3

machining labor A-3

material 3-1

material properties 6-3, 6-4, 8-6, 11-16, A-3

misc fabrication 5-3, 11-16, 11-46, 11-51, 11-53,11-59, 11-87, 11-92, 11-93

misc items 1 6-4, 8-2, A-3

misc items auto 6-5, A-3

miscellaneous fabrication labor A-3

nozzle fillet weld deposition rate 5-6, 5-8

nozzle groove weld deposition rate 5-6, 5-8

nozzle to shell or head labor 5-3, A-4pad to nozzle labor 5-3, A-4

paint 5-4, 6-5

painting A-4

pipe cost schedule 6-4, A-4

plate material costs 2-1, 3-5, 3-6, 6-4, 7-2, 11-20,11-88, A-4



INDEX

< INDEX - xiii >

platform /ladder cost and labor 5-5, 6-6, 11-42, A-4

primer 5-4, 6-5, A-4


revising 8-6

revising currency 3-9revising units 3-9

ring joint r cost A-4

ring joint rx cost A-4



saddles fitting labor 5-5, 11-46, 11-51, A-4

skirt (straight) forming labor 5-1

sorting records 2-2

stock plate sizes (english/metric) 6-5, 8-16, A-4

structures/rings/tray supports material costs 3-6,6-4, 7-2, 11-23, 11-42, 11-88, A-4

stud cost 6-6, A-4

transition forming labor 5-2

tray installation labor 5-5, 11-42, A-4units 8-6

vacuum ring labor 5-2, 11-23, A-4

weld deposition rate - circumferential seam 11-16,A-5

weld deposition rate - longitudinal seam 11-16, A-

5

weld deposition rate - nozzle fillet weld 11-83, A-5

weld deposition rate - nozzle groove weld 5-8, 11-

83, A-5

weld deposition rate, circumferential seam 5-6, 5-

8

weld deposition rate, longitudinal seam 5-6, 5-8

weld deposition rate, nozzle fillet weld 5-6, 5-8

weld deposition rate, nozzle groove weld

5-6

weld reinforcement 5-7, 7-13, A-5

welding time - circumferential seam A-5

welding time - longitudinal seam A-5

welding time - nozzle fillet weld A-6

welding time - nozzle groove weld A-6

welding time, circumferential seam 5-6, 5-7

welding time, longitudinal seam 5-6

welding time, longitudinal seams 5-7

welding time, nozzle fillet weld 5-6, 5-7

welding time, nozzle groove weld 5-6, 5-7

TEMPLATE

see also Coster

see also spreadsheet

Coster spreadsheet file (CostSS.xls) 8-2

TOTAL COSTmiscellaneous section 8-14

nozzle section 8-12

vessel 8-15

TOTAL VESSEL COST 8-15

TOTAL VESSEL LABOR COST 8-15

TOTAL VESSEL LABOR HOURS 8-15

TOTAL VESSEL MATERIAL COST 8-15

TRADEMARKS iiTRANSITION


calculations 11-20custom cut plates 7-14

cutting labor 11-21


fitup labor 11-21

forming labor 11-20, 11-21


grinding 11-20

impact test 11-20

long seam labor 11-22


normalization 11-20

properties 11-20

surface area 11-23

TRAY SUPPORTS 7-10calculations 11-42

installation labor 5-5

labor costs 11-44

labor hours 11-44

material cost 11-43

properties 11-42

structural type 11-42

weight 11-44

weld deposition rate 7-14

U GROOVE

weld radius 7-12

UNINSTALLING 1-2

UNITS

database tables

8-6

defaults menu 7-4

estimate 8-3, 11-1

revising on tables 3-9

USE SQUARED PLATES

calculations 11-10

USER SELECTABLE ITEMS

cleaning method 4-3

cylinder 4-2

dialog 4-1

flange facing 4-3

gasket material 4-3

grinding inside 4-3

grinding outside 4-3

number of paint/primer coats 4-2

paint inside/outside 4-2

paint/prime stainless steel materials 4-2

primer inside/outside 4-2

ring type 4-3

stud material 4-3

USING COSTER 3-1

VACUUM RINGS 5-2



INDEX

< INDEX - xiv >

butt welding 11-23

calculations 11-23

Compress 5.x files 11-23, 11-24

Compress 6.x files 11-23, 11-25

fillet weld size 7-14forming labor 11-23

impact test 11-23

intermittent welding 7-14

labor hours/costs 11-26


neutral axis 11-23

normalization 11-23

properties 11-23

roll and fitup 5-2

weld deposition rate 7-14

weld gap 11-23

welding 1 or 2 sides 7-15

VERIFICATION

asme b16.5/16.47 body flange 11-35blasting/cleaning 11-95

calculations 11-1

cylinder 11-16

davits 11-94

grinding 11-95

heads 11-27, 11-29

hydrotest 11-96


legs 11-87

nozzle weld 11-81

nozzles 11-68

packed bed 11-41

pads 11-80

paint

11-96


post weld heat treatment 11-97

primer 11-96

saddles 11-46

skirt 11-64


transition 11-20

tray support 11-42

vacuum rings 11-23

welding 11-97

x-ray 11-97

VESSEL DETAIL COST 7-7

VESSEL FILE

compatible with Coster 1-1

VESSEL MODELER 3-1

WASTE

flame cutting 7-6

legs, base plate (flame cutting) 11-92

legs, pad (flame cutting) 11-93

pipe 7-7, 8-15

WEIGHT

bill of materials (source material) 8-16

cage 11-41

cylinder (source material) 11-16

ladder 11-41

miscellaneous section 8-12nozzle section (blind) 8-10

nozzle section (flange) 8-10



packed bed 11-41

shell section 8-7

source material, cylinder 11-16

source material, transition 11-20

total finished vessel 8-14

transition (source material) 11-20

tray support 11-44

WELD BEVEL ANGLE 7-11

WELD DEPOSITION RATE

circumferential seam 5-8fillet/groove weld 5-8

longitudinal seam 5-8

tray supports 7-14

vacuum ring 7-14

WELD DETAIL 7-10

WELD EFFICIENCY

operator 7-12

WELD GAP 7-10

vacuum rings 11-23

WELD RADIUS

U groove 7-12

WELD RECOVERY 7-12

WELD REINFORCEMENT

table

7-13

WELD STRAIGHT SECTION 7-11

WELDING 5-6, 7-10, 8-13

bevel angle (nozzle groove welds) 7-12

calculations 11-97

circumferential seam 11-27

circumferential weld length 11-14, 11-15

conversion default values 5-6

convert welding time to deposition rate 5-7

cylinder 11-16

deposition rate 5-6

flange 8-11, 11-76

heads 11-31

intermittent 7-14

labor 2-2

labor cost 7-8

legs 11-90

long seam 8-11

longitudinal seam weld length 11-14, 11-15, 11-16

nozzle 8-11

nozzle calculations 11-81

operator weld efficiency 7-12



INDEX

< INDEX - xv >

pad 8-11

saddles 7-15, 11-50

single/double 7-10

skirt 11-65

skirt base ring 11-59, 11-64tables used in calculations 5-6

time to weld 5-6

transition 11-20

type of welding 7-10

u groove weld radius 7-12

vacuum ring (1 side/2 sides) 7-15

vacuum ring fillet weld size 7-14

vacuum ring intermittent welding 7-14

weld bevel angle 7-11

weld gap 7-10

weld gap, vacuum rings 11-23

weld recovery 7-12

weld reinforcement 7-13

weld straight section 7-11

WELDING LABORflange to nozzle 5-3

WIRE BRUSH LABOR

cost 7-8

X-RAY


calculations 11-97

cost 8-14

dialog 4-4

total cost 4-5



INDEX

Documents

Pressure Vessel Coster