appendix 1 equipment cost estimates

166 Pages·2012·21.52 MB·English

APPENDIX 1
EQUIPMENT COST ESTIMATES
The following section provides very rough cost estimates for a wide variety of process
equipment. It must be remembered in using these charts that there is no such thing as
an exact, definite, fixed price for any piece of equipment of a given size or capacity. As
with buying merchandise, clothing or a car there are many styles, quality differences,
optional features and designs to meet specific needs or services. Presumably charts could
be made for each of these variations, but the nuinber would be large and confusing, and
for many preliminary estimates the engineer would not know exactly what he wanted at
that stage of the design, so only average, representative equipment should be more useful.
Again, a range of prices could be shown, but usually a single line is more practical,
keeping in mind that the price could quite normally vary considerably depending upon
the exact design requirements and the company policy on quality, maintenance, and so
on.
With these generalities in mind, the following charts have been taken from a number
of sources. Most are from cost estimating articles or books, although some are from
recent vendor quotations. In case only a single source was available, that reference has
been noted. However, often many sources were available and a somewhat biased
consensus of opinion curve was selected. In this case the sources were not noted except
for inclusion in the reference list at the end of the appendix. In case different variables
were used as the sizing parameter, the most logical one in the author's opinion was
selected.
All costs were factored to an early 1987 basis, or a chemical engineering index number
of 320. When equations were available for the cost relationship they were listed beneath
the charts, and when straight line functions existed for the costs on log-log paper a sizing
exponent was given:
size 2)SiZe exponent
cost size 2 = cost size 1 (-.--
size 1
In a number of references various authors have estimated the fraction of the purchased
equipment cost that it takes to install the equipment. This generally included freight and
shipping costs, foundations, mounting, and simple electric and piping connections, such
as switch gear, starters, flange connections, and so on. Unfortunately these numbers
often varied widely, so the range and average are both listed when available:
255
256 APPENDIX 1
installed cost = purchase price x installation factor
A similar number that also includes all of the adjacent minor equipment and connec
tions is sometimes listed in the literature (principally by Guthrie 1975 and Ulrich 1984)
covering the cost of purchase and installation of the major equipment as well as all of
the supporting equipment around each major unit. This is called the module factor, and
when available is also listed under the charts as the range given by different authors and
the average value.
cost of the installed module = purchase price x module factor
As a final item under the equipment cost graphs, often a simple factor can be used to
estimate the cost of some other material, pressure, size, or other variable for the equip
ment, than is shown on the graph. For instance, the cost of a stainless steel agitated tank
is 1.7 times the cost of a mild steel tank (which is shown on the chart). These factors
have also been listed when available, and again, sometimes as a consensus of different
authors' estimates.
Adsorb.rs. Activated Carbon
Mild steel construction, including instruments and controls
8
0.
;;;
Ii
o
u
,
, ,
10
I 6 8 10 20 40 60 80 100 200
Weight of carbon. 1,000 lb.
Equations:
Cost = 15.200 + 1, 100WCO.481 for We >250. < 10,000 lb.
Cost ~ 76,200 + O.422Wc 1.2 for We > 10 .000, <200,000 lb.
We == weight of activated carbon, Ib,
EQUIPMENT COST ESTIMATES 257
Agiwtors
Dual [urbine blades; mild steel; 30-45 rpm, motor, gear reduction, shaft
Propeller; mild .teel, single blade
1000
800
600
400
200
100
80
60
a0 40
;;;
Ii
u0
20
10
8
6 8 10 20 40 60 80 100 200 400 600 BOO 1000
Size, HP
Size exponent: Installation factor: Factors for: ~ Average
Turbine: >30 HP 0.68 Range Average Turbine:
4-30 HP 0.56 Turbine 1.20-40 1.32 Single blade 0.75-0.85 0.82
<4 HP 0.23 Propeller 1.12-32 1.22 56-100 rpm 0.57-0.70 0.66
Propeller: 3-100 HP 0.51 125-230 rpm 0.37-0.51 0.47
1-3 HP 0.42 Module factor 2.0 316 stainless 1.23-1.87 1.47
Propeller:
Stainless steel 1.19
With seal Ifor closed tank) 1.32
258 APPENDIX 1
Agitated TankS'
Jacketed, ogitated, mild steel
lOOO~
_ _ __
800~
20 40 60 80 tOO 200 400 600 tOOO 2000 4000 6000 10000 20000
Size, gal
Size exponent 0.53 Installation factor: Material factors:
Module factor 2.5 Range Avg. Stain Ie .. steel
Open tank 1.41 -66 1.58 1.2·2.2,.",). = 1.7
low pressure 1.30 ·57 1.44 GI ... lined
Autoclave 1.50· 70 1.60 1.2 -2.0, ."') .• 1.6
• See Reactors
EQUIPMENT COST ESTIMATES 259
Air Conditioning
Compressor, motor, controls, condenser. refrigerant
1000
800 1-- '- 1- 1--
I- -
600
400
I~--1--
I:
1·-'-'-;"
200
1=-:- .. - .
~
iii 100
B 80 .:_:-------'c ---
0
60 ,
-
40
,--
20
-I-
1- ./
1-
10
1 8 10 20 40 60 80 100 200 400 600 800 1000
Refrigeration, tons·
Size exponent 0.73
Installalion. Module factor
1.38-53 avg. 1.46
'One ton = 12,000 Btu
260 APPENDIX 1
Blenders
Mild steel construction
o
8,
iii
20 40 60 60100 200 400 600 BOO 1000 2000
Capacity, ftl
(Approximately HP X 0.125)
Size exponent.s: Installation factor 1.30
Ribbon, double arm, sigma,
twin shell 0.60 Modu Ie factor:
Double cone 0.42 H,DDon 2.0
Sigma 2.B
Material factor: Double arm, cone,
304 stain Ie" steel 1.6 twin shell 2.2
EQUIPMENT COST ESTIMATES 261
Blowers
30-in, water (-1 psi) to 30 psi; cast iron. with motor
1000
800
600
400
200
100
SO
60
0
8~ 40
in
is
u
20
10
8
6
1
100 200 400 600 800 1000 2000 4000 6000 10000 20000 40000 60000 100000
Blower capacity, cfm
Si2e exponent: Installation factor: Material Tactors:
30 psi 0,52 Range: 1.35-56 Fiberglass 2.5 to 4; avg. -2.6
10 psi 0,79 Average: 1.42 Stainless $1.t:!el 2.6
<3 psi variable
Module factor:
Rotary 2.2
Centrifugal 2,5
262 APPENDIX 1
..
Boilers
10000
8000
--ii- 6000
4000
:
2000
---
100 .. - 1000
80 800
~ 600
0" :: g
40 .. '00
;;;
~
20 I: 200 U
g
-- 1--·
<Ii 10 100
8 80
u0
60
.0
." ..
;"
-r 20
1 10
I 8 10 20 40 60 80 100 200 '00 600 1000
1000 10000 100000 1000000
Steam generated, Ib/hr (large I
Size exponents; Installalion factor; Prl!'$$Ure factor: Coal fired
Package boilers 1.21 -82 ''1.1.53 Large package Large package 1.61
5 - 1,000 HP 0.65 400 ps; 1.31 Field erected 1.36
6 -600· 10' Iblhr 0.77 Module factor: 500 p.; 1.74
Field .rected 0.82 Package 1.8 Field eree~ed
'One HP -33.5000 Btu Field erected 1.8 -2.0 aVQ_ 1.9 3l000000pp..;; 11..3558
EQUIPMENT COST ESTIMATES 263
Boilers, Waste Heat
1000
800
600
400
200
0
8.
;;; 100
S 80
<.>
60
40
20
20 40 60 80 100 200
Flue gas flow rate, 1,000 sclm
Size exponent 0.75 Factors:
High-temperature
I nstallation factor: operation 1.2
1.40-82 a.g. 1.67 Finned tubes 1.5
Alloy-clad tube. 3.0
Module factor 1.81 M@chanical ash
removal 1.8
Radiation section 2.0
264 APPENDIX 1
Building'
Office type with air conditioning. restrooms. plaster Or equivalent
walls, insulation, modest architectural features
1000
800
600
400
200
100
80
60
8
0. 40
;;;
B
u
20
10
6
100 200 400 600 800 1000 2000 4000 6000 10000 40000 60000 100000
Floor space, ftl lincl. all floors)
Size exponent O.S Factors:
Warehouse 0.25
Laboratory 1.5
Manufacturing bldg. 0.5