Icarus Reference

Transcription

Icarus Reference

Aspen Icarus
Reference Guide
Icarus Evaluation Engine (IEE) V8.0
Version V8.0
December 2012
Generation No: 14 (G14)
Chapters with “G13” in the footer are new for this edition. Chapter generation numbers are also
indicated in the Table of Contents.
Copyright (c) 2001-2012 by Aspen Technology, Inc. All rights reserved.
Aspen In-Plant Cost Estimator, Aspen Process Economic Analyzer, Aspen Capital Cost Estimator,
AspenTech®, and the aspen leaf logo are trademarks or registered trademarks of Aspen Technology,
Inc., Burlington, MA.
All other brand and product names are trademarks or registered trademarks of their respective
companies.
This manual is intended as a guide to using AspenTech’s software. This documentation contains
AspenTech proprietary and confidential information and may not be disclosed, used, or copied without
the prior consent of AspenTech or as set forth in the applicable license agreement. Users are solely
responsible for the proper use of the software and the application of the results obtained.
Although AspenTech has tested the software and reviewed the documentation, the sole warranty for the
software may be found in the applicable license agreement between AspenTech and the user.
ASPENTECH MAKES NO WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED,
WITH RESPECT TO THIS DOCUMENTATION, ITS QUALITY, PERFORMANCE,
MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE.
Aspen Technology, Inc.
Burlington, MA 02141-2201
USA
Phone: 781-221-6400
Toll Free: (888) 996-7100
Website http://www.aspentech.com
Preface
Aspen Technology’s Icarus Office develops and provides knowledge-based
process evaluation technology, software, and services.
Icarus systems are based on a core design, estimating, scheduling, and expert
systems technology. They automatically develop preliminary design-based
economic results - early from minimal scope, and refined designs and
economics later in the project. Icarus systems are strategically located and
linked into the project knowledge stream of concurrent design 0 after process
simulation and before detailed design, CAD/CAE, detailed scheduling and
project control. This unique technology provides:
°
Key answers quickly
°
Dramatic reductions in evaluation time and resources
°
The best, most economical process and plant design for funding/
bidding decisions and project evaluation.
Aspen economic evaluation systems (including Aspen Capital Cost Estimator,
Aspen Process Economic Analyzer, and Aspen In-Plant Cost Estimator) are in
daily use. These systems have become industry-standard tools and are used
by discerning project evaluators in owner companies and engineering design
and construction firms in more than 1,000 locations in over 30 countries.
The Technology Behind
Icarus Systems
Icarus systems are based on mathematical modeling technology which has
been developed, refined and used since Icarus Corporation was founded in
1969. Aspen Technology purchased Icarus Corporation in 2000.
Stored in Icarus systems are design and cost models for:
°
Over 250 kinds of liquid, gas and solids handling and
processing equipment
°
More than 60 kinds of plant bulk items
°
Approximately 70 kinds of site preparation work
°
Nearly a dozen types of buildings.
Installation bulk models, used to develop installation quantities and field
manpower and costs to install equipment and plant bulks, round out the
“bank” of design and cost models. To support these design and cost models,
Icarus systems contain design procedures and costs data for hundreds of
types of materials of construction for general process equipment, vessel shells
and internals, tubing, castings, linings, packings, clad plates, piping, steel and
electrical bulks.
2
iii
Scope of Document
This document is designed as a reference tool for Icarus’ project evaluation
systems. The document is best referenced when you have a question about
system input.
How to Use This Document
This document uses generation numbers to track the history of updated
information within each chapter. New versions of this document are assigned a
new generation number, which increments by 1 (for example, G12).
The purpose of these numbers is to ensure you are looking at the latest
information. If you have a previous version of this document, you can compare
the numbers to confirm you have the most up-to-date information available.
Generation numbers are located on every page in the lower-inside corner as
well as in the Table of Contents. The generation number assigned to the latest
version of this document is located in the Copyright page.
A Note to Icarus System Users
Like Icarus systems, this document was designed using your ideas and
suggestions. Please contact the Aspen Technology Icarus Office if you have any
questions or comments regarding this document.
Related Documentation
In addition to this reference manual, AspenTech provides the following
documentation for Aspen Economic Evaluation V8.0.
iv
•
Aspen Economic Evaluation V8.0 Release Notes (What’s New, What’s Fixed,
and Known Issues)
•
Aspen Economic Evaluation V8.0 Installation Guide
•
Aspen Process Economic Analyzer V8.0 User Guide
•
Aspen In-Plant Cost Estimator V8.0 User Guide
•
Aspen Capital Cost Estimator V8.0 User Guide
•
Icarus Technology Application Programming Interface
•
Manpower Productivity Expert User Guide
2
Online Technical Support
Center
AspenTech customers with a valid license and software maintenance
agreement can register to access the Online Technical Support Center at:
http://support.aspentech.com
You use the Online Technical Support Center to:
•
Access current product documentation.
•
Search for technical tips, solutions, and frequently asked questions (FAQs).
•
Search for and download application examples.
•
Search for and download service packs and product updates.
•
Submit and track technical issues.
•
Search for and review known limitations.
•
Send suggestions.
Registered users can also subscribe to our Technical Support e-Bulletins. These
e-Bulletins proactively alert you to important technical support information
such as:
•
Technical advisories.
•
Product updates.
•
Service Pack announcements.
•
Product release announcements.
Phone and E-mail
Customer support is also available by phone, fax, and e-mail for customers
who have a current support contract for their product(s). Toll-free charges are
listed where available; otherwise local and international rates apply.
For the most up-to-date phone listings; please see the Online Technical
Support Center at:
http://support.aspentech.com/
Support Centers
2
Hours of Operation
North America
8:00 - 20:00 Eastern time
South America
9:00 - 17:00 Local time
Europe
8:30 - 18:00 Central europe time
Asia and Pacific Region
9:00 - 17:30 Local time
v
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2
Contents
(G11)
Preface . . . . . . . . . . . . . . . . . .
The Technology Behind
Icarus Systems . . . . . . . . . . .
Scope of Document . . . . . . . . .
How to Use This Document . . . .
A Note to Icarus System Users .
Related Documentation . . . . . .
Online Technical Support Center
Phone and E-mail. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . iii
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Introduction to Process Equipment (G6)
5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Process Equipment Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
List of Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Agitators (G6)
Agitators (AG) . . . . .
Agitated Tanks (AT) .
Blenders (BL) . . . . .
Kneaders (K) . . . . . .
Mixers (MX) . . . . . .
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Compressors (G6)
1
Air Compressors (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gas Compressors (GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fans, Blowers (FN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drivers (G11)
1
Electrical Motors (MOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Turbines (TUR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heat Transfer (G10)
Heat Exchangers (HE) . . . . . . .
Reboilers (RB) . . . . . . . . . . . . .
Furnaces, Process Heaters (FU) .
Icarus Supported TEMA Types . .
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Packing, Linings (G6)
Introduction to Packing. . . . . . . . . . . . .
Introduction to Lining . . . . . . . . . . . . . .
Packing, Linings (PAK, LIN) . . . . . . . . . .
Suggested Lining Difficulty Adjustments .
Contents (G11)
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Pumps (G10)
Centrifugal Pumps (CP) . . . . . . . . . . . . . . . .
Gear Pumps (GP) . . . . . . . . . . . . . . . . . . . . .
Piston, Other Positive Displacement Pumps (P)
Pump Efficiencies . . . . . . . . . . . . . . . . . . . . .
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Towers, Columns (G6)
1
Introduction to Towers and Columns . . . . . . . . . . . . . . . . . . . . . . 2
Double Diameter Towers (DDT) . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Single Diameter Towers (TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Vacuum Systems (G6)
1
Condensers (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ejectors (EJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Vacuum Pumps (VP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vessels (G10)
1
Horizontal Tanks (HT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Vertical Tanks (VT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crushers, Mills and Stock Treatment (G6)
Crushers (CR) . . . . . . . . . . . . . . . . . . .
Flakers (FL). . . . . . . . . . . . . . . . . . . . .
Mills (M) . . . . . . . . . . . . . . . . . . . . . . .
Stock Treatments (ST) . . . . . . . . . . . . .
Drying Systems (G6)
Crystallizers (CRY) . . . . . . . . .
Evaporators (E) . . . . . . . . . . .
Wiped Film Evaporators (WFE)
Air Dryers (AD) . . . . . . . . . . .
Dryers (D) . . . . . . . . . . . . . .
Drum Dryers (DD) . . . . . . . . .
Rotary Dryers (RD) . . . . . . . .
Tray Drying Systems (TDS). . .
Solids Conveying (G10)
Conveyors (CO) . . .
Cranes (CE) . . . . .
Elevators, Lifts (EL)
Feeders (FE) . . . . .
Hoists (HO) . . . . . .
Scales (S) . . . . . . .
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Separation Equipment (G7)
Centrifuges (CT) . . . . . . . .
Dust Collectors (DC). . . . . .
Filters (F) . . . . . . . . . . . . .
Separation Equipment (SE) .
Thickeners (T) . . . . . . . . . .
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Contents (G11)
Screens (VS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Utility Service Systems (G6)
Cooling Towers (CTW) . . . . . . . .
Steam Boilers (STB). . . . . . . . . .
Heating Units (HU). . . . . . . . . . .
Refrigeration Units (RU) . . . . . . .
Electrical Generators (EG). . . . . .
Water Treatment Systems (WTS)
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Flares and Stacks (G6)
1
Flares (FLR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stacks (STK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introduction to Plant Bulks (G6)
1
Introduction to Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Piping (G10)
Piping Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Equations for Pipe Diameter (Old) . . . . . . . . . .
Standard Equations for Pipe Diameter (New). . . . . . . . . .
Utility Piping Services . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Station Diagram . . . . . . . . . . . . . . . . . . . . . . . . .
Default Piping Materials . . . . . . . . . . . . . . . . . . . . . . . .
Pipe Materials - Ferrous Materials . . . . . . . . . . . . . . . . .
Pipe Materials - Non-Ferrous Materials . . . . . . . . . . . . . .
Plastic and Resin Materials . . . . . . . . . . . . . . . . . . . . . .
Lined Steel Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Icarus’ Pipe Fabrication, Erection and Testing Procedures .
Valve and Fitting Options for Installation Bulk Piping . . . .
Valve Trim Specifications . . . . . . . . . . . . . . . . . . . . . . .
Civil (G8)
Civil Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . .
Foundation Types. . . . . . . . . . . . . . . . . . . . . . . . .
Typical Structure Live Loads . . . . . . . . . . . . . . . . .
Soil Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifying Seismic Data . . . . . . . . . . . . . . . . . . . .
Specifying Wind Loads . . . . . . . . . . . . . . . . . . . . .
How Icarus Calculates Wind Load and Seismic Shear
Example of Equipment Foundation Design. . . . . . . .
Example of Pile Foundation for an Equipment . . . . .
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1
2
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14
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17
17
18
19
Steel (G6)
1
Steel Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Instrumentation (G10)
1
Instrumentation Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents (G11)
v
Sensor Loop Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote Control Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transmitter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical (G13)
Electrical Plant Bulks . . . . . . . . . . . . . . . . . . .
Schematic of Transmission Line . . . . . . . . . . . .
Substation Schematics . . . . . . . . . . . . . . . . . .
Electrical & Control Hook-Ups for Electric Motors
Power Distribution Network . . . . . . . . . . . . . . .
Wire Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . .
UK, EU, and JP Country Bases . . . . . . . . . . . . .
Electrical Class/Division . . . . . . . . . . . . . . . . .
International Electrical Code (IEC) . . . . . . . . . .
Insulation and Fireproofing (G8)
Insulation Plant Bulks . . . . . . . . . . . .
Insulation Materials . . . . . . . . . . . . .
Fireproofing Materials . . . . . . . . . . . .
Insulation Schedules - System Default
Customizing Insulation Specifications .
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Tables
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22
23
24
27
28
28
29
30
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2
4
4
5
15
Paint (G6)
1
Introduction to Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Paint Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How Icarus Systems Paint Equipment. . . . . . . . . . . . . . . . . . . . . . 3
Site Development (G6)
Introduction to Site Development
Demolition . . . . . . . . . . . . . . . .
Drainage. . . . . . . . . . . . . . . . . .
Earthwork . . . . . . . . . . . . . . . . .
Fencing. . . . . . . . . . . . . . . . . . .
Landscaping . . . . . . . . . . . . . . .
Roads - Slabs - Paving . . . . . . . .
Piling . . . . . . . . . . . . . . . . . . . .
Railroads . . . . . . . . . . . . . . . . .
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Buildings (G6)
Introduction to Buildings. . . . . . . . . . . .
Adding a Building . . . . . . . . . . . . . . . . .
Building Types and Defaults . . . . . . . . .
Default floor Heights/Levels . . . . . . . . .
Building Construction Range Adjustment
Calculating Building Costs and Labor . . .
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1
2
2
5
6
6
7
Quoted Equipment and Libraries (G6)
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Quoted Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
vi
Contents (G11)
User Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material Selections (G10)
ASME Design Code - Plate Materials . . . . . . . . . .
ASME Design Code - Clad Plate Materials . . . . . .
ASME Design Code - Tube Materials . . . . . . . . . .
ASME Non-Ferrous Tube Materials . . . . . . . . . . .
BS Design Code - Plate Materials . . . . . . . . . . . .
BS Ferrous Plate Materials - Carbon Steel
....
BS Design Code - Clad Plate Materials . . . . . . . .
BS Design Code - Tube Materials . . . . . . . . . . . .
JIS Design Code - Plate Materials. . . . . . . . . . . .
JIS Design Code - Tube Materials. . . . . . . . . . . .
DIN Design Code - Plate Materials . . . . . . . . . . .
DIN Design Code - Tube Materials . . . . . . . . . . .
EN 13445 Design Code - Plate Materials . . . . . . .
EN 13445 Design Code - Tube Materials . . . . . . .
GB 150 Design Code - Plate Materials. . . . . . . . .
GB 150 Ferrous Plate Materials - Low Alloy Steel .
GB150 Ferrous Plate Materials - High Alloy Steel .
GB150 Design Code - Tube Materials . . . . . . . . .
GB150 Ferrous Tube Materials - Low Alloy Steel .
Lining Materials . . . . . . . . . . . . . . . . . . . . . . . .
Casting Materials . . . . . . . . . . . . . . . . . . . . . . .
Packing Materials . . . . . . . . . . . . . . . . . . . . . .
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2
1
3
10
11
14
15
15
22
23
27
35
39
47
51
56
61
62
63
64
65
67
70
72
Units of Measure (G6)
1
Introduction to Units of Measure . . . . . . . . . . . . . . . . . . . . . . . . . 2
Units of Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Project Specifications and their Use of Units of Measure . . . . . . . . . 8
Field Manpower Titles and Wage Rates (G13)
US Country Base . . . . . . . . . . . . . . . . . . .
UK Country Base *** . . . . . . . . . . . . . . .
JP Country Base. . . . . . . . . . . . . . . . . . . .
EU Country Base . . . . . . . . . . . . . . . . . . .
ME Country Base . . . . . . . . . . . . . . . . . . .
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6
8
9
1
Engineering (G13)
Design and Construction Engineering Disciplines and Wage Rates . . 2
Engineering Expenses and Indirects (Aspen Capital Cost Estimator and
Aspen Process Economic Analyzer ) . . . . . . . . . . . . . . . . . . . . . . 12
Standard Engineering Drawing Types (Aspen Capital Cost Estimator and
Aspen Process Economic Analyzer) . . . . . . . . . . . . . . . . . . . . . . 17
Construction Equipment(G4)
1
Introduction to Construction Equipment Rental . . . . . . . . . . . . . . . 2
Construction Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents (G11)
vii
Base Indices (G13)
1
Base Indices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Code Accounts (G10)
Introduction to Code Accounts. .
Indirect Codes and Descriptions.
Direct Codes and Descriptions . .
Piping . . . . . . . . . . . . . . . . . . .
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1
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. 6
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. 10
Database Relations (G10)
Sequence Numbers of Attributes in Relations . . . . . . . . . . . .
Relationship of Database Relations. . . . . . . . . . . . . . . . . . . .
DETAILS Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESIGN Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMARKS Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROJDATA Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEWCOA Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQRENT Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRWSCH Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CSTCTRL Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPGRP Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CNTRCT Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDIRECTS Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K (CUSSPC)-TABLE Relation . . . . . . . . . . . . . . . . . . . . . . . .
R-TABLE Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QSUM Relations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STORED REPORTS Relation . . . . . . . . . . . . . . . . . . . . . . . . .
STORED QUERIES Relation . . . . . . . . . . . . . . . . . . . . . . . . .
CERATE Relation (F-Table) . . . . . . . . . . . . . . . . . . . . . . . . .
T-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
U-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Y-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Z-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aspen Capital Cost Estimator Indirect Codes and Descriptions .
Attribute Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
2
6
7
9
9
10
10
10
11
11
12
12
12
13
14
14
15
18
20
21
23
23
25
25
25
26
27
27
29
Icarus Technology (G10)
Introduction to Areas . . . . . . . . . . . . . . . . . . .
Project Schedule . . . . . . . . . . . . . . . . . . . . . .
Equipment Fabricate/Ship Items . . . . . . . . . . .
Barchart Report Format . . . . . . . . . . . . . . . . .
Process Control . . . . . . . . . . . . . . . . . . . . . . .
Notes for Defining the Standard Control Center .
Notes for Defining the PLC Control Center. . . . .
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Contents (G11)
Overview of System Input Specifications for Power Distribution .
Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Usage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reporting of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Project Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cost Reporting: Currency and System Base Indices . . . . . . . . .
Construction Overhead - Prime Contractor Basis . . . . . . . . . . .
Contracts: Description/Scope . . . . . . . . . . . . . . . . . . . . . . . .
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27
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Reserved (G7)
1
Glossary (G5)
1
Contents (G11)
ix
x
Contents (G11)
1 Introduction to Process
Equipment
(G6)
This chapter contains information on the following topics:
Introduction
Process Equipment Categories
List of Process Equipment
1 Introduction to Process Equipment (G6)
1-5
Introduction
Chapters 2 through 16 describe the process equipment available in
Icarus systems. The chapters are organized as the equipment appears in
the systems.
•
Liquid and gas equipment
•
Solids handling equipment
•
Off-site and packaged equipment
Process Equipment Categories
Icarus’ process equipment is divided into the following categories. Each
category is assigned an item symbol for identification purposes.
1-6
Item
Symbol
Description
Item
Symbol
Description
AC
Air Compressor
HE
Heat Exchanger
AD
Air Dryer
HO
Hoist
AG
Agitator
HT
Horizontal Tank
AT
Agitated Tanks
HU
Heating Unit
BL
Blender
K
Kneader
C
Condenser
LIN
Lining
CE
Crane
M
Mill
CO
Conveyor
MOT
Motor/Motor Reducer
CP
Centrifugal Pump
MX
Mixer
CR
Crusher
P
Pump
CRY
Crystallizer
PAK
Packing
CT
Centrifuge
R
Reactor
CTW
Cooling Tower
RB
Reboiler
D
Dryer
RD
Rotary Drum
DC
Dust Collector
RU
Refrigeration Unit
DD
Drum Dryer
S
Scale
DDT
Double Diameter Tower
SE
Separation Equipment
E
Evaporator
ST
Stock Treatment
EG
Electric Generator
STB
Steam Boiler
EJ
Ejector
STK
Stack
EL
Elevator
T
Thickener
F
Filter
TDS
Tray Drying System
FE
Feeder
TUR
Turbine
FL
Flaker
TW
Single Diameter Tower
FLR
Flare
VP
Vacuum Pump
FN
Fan
VS
Screen
FU
Furnace
VT
Vertical Tank
Item
Symbol
Description
Item
Symbol
GC
Gas Compressor
WFE
Wiped Film Evaporator
GP
Gear Pump
WTS
Water Treatment System
Description
List of Process Equipment
The following is a list of process equipment by chapter and category. The
process equipment descriptions in chapters 2 through 16 include some of the
entry fields for defining process equipment. The descriptions include the
minimum and maximum values and the defaults. Default values appear
between asterisks (*).
Chapter 2: Agitators
Agitators (AG)
Item Type
Description
FIXED PROP
Fixed propeller gear motor type agitator
PORT PROP
Portable propeller agitator
DIRECT
Portable direct drive agitator
GEAR DRIVE
Portable gear drive agitator
MECH SEAL
Agitator, mechanical seal, variable diameter
ANCHOR
Fixed mount, gear drive, anchor, stuffing box
PULP STOCK
Pulp stock agitator
ANCHOR REV
Sanitary reversing anchor agitator
COUNT ROT
Sanitary counter-rotating agitator
HIGH SHEAR
Sanitary highshear homogenizing agitator
SAN FIXED
Sanitary fixed propeller/turbine mixer
SAN PORT
Sanitary port. propeller/turbine mixer
Agitated Tanks (AT)
Item Type
Description
MIXER
Agitated tank - enclosed
REACTOR
Agitated tank - enclosed, jacketed
OPEN TOP
Agitated tank - open top
FLOAT CELL
Floatation machine
COND CELL
Floatation conditioning cell
MACH PULP
On machine pulper
OFF MACH
Off machine pulper
1-7
Blenders (BL)
Item Type
Description
BLENDER
Rotary drum blender
ROTARY
Rotary double-cone blender
KETTLE
Sanitary kettle blender without agitator
ROTARYBOWL
Sanitary rotary bowl blender
MSHELSTAG
Sanitary multi-shell staggered blender
Kneaders (K)
Item Type
Description
STATIONARY
Stationary upright double-arm kneader
TILTING
Tilting double-arm kneader
VAC TILTING
Vacuum tilting double-arm kneader
Mixers (MX)
Item Type
Description
EXTRUDER
Cylinder type extruder with variable drive
MULLER EXT
Muller type extruder mixer
PAN
Pan mixer
PORT PROP
Portable propeller mixer
FIXED PROP
Fixed propeller gear motor type mixer
SIGMA
Double-arm sigma blade mixer
SPIRAL RIB
Spiral ribbon mixer
STATIC
Static mixer
TWO ROLL
Two-roll mixer
HIGH SPEED
Sanitary high-speed Norman-type mixer
RIBBON
Sanitary ribbon blender
PISTON HOM
Sanitary piston-type homogenizer
SHEAR HOM
Sanitary shear pump homogenizer
Chapter 3:
Compressors
Air Compressors (AC)
1-8
Item Type
Description
CENTRIF M
Centrifugal air compressor with motor
CENTRIF T
Centrifugal air compressor with turbine
RECIP GAS
Reciprocating air compressor with gas engine
RECIP MOTR
Reciprocating air compressor with motor
SINGLE 1 S
Single reciprocating air compressor - 1 stage
SINGLE 2 S
Single reciprocating air compressor - 2 stage
Gas Compressors (GC)
Item Type
Description
CENTRIF
Centrifugal compressor - horizontal
CENTRIF IG
Centrifugal - integrated gear
RECIP GAS
Reciprocating compressor - integral gas engine
RECIP MOTR
Reciprocating compressor
Fans, Blowers (FN)
Item Type
Description
PROPELLER
Propeller fan
VANEAXIAL
Vaneaxial fan
CENTRIF
Centrifugal fan
ROT BLOWER
General purpose blower
CENT TURBO
Heavy duty, low noise blower
Chapter 4: Drivers
Electrical Motors (MOT)
Item Type
Description
OPEN
Open drip-proof induction motor
SYNCHRON
Synchronous motor
ENCLOSED
Totally enclosed induction motor
EXP PROOF
Explosion-proof (Class I Division I, hazardous)
VARY SPEED
TEFC motor with variable speed drive
Turbines (TUR)
Item Type
Description
GAS
Gas turbine with combustion chamber
CONDENSING
Steam turbine driver, condensing type
NON COND
Steam turbine driver, non-condensing
Chapter 5: Heat Transfer
Heat Exchangers (HE)
Item Type
Description
FLOAT HEAD
Floating head shell and tube exchanger
FIXED T S
Fixed tube sheet shell and tube exchanger
AIR COOLER
Air cooling, free standing or rack-mounted
U TUBE
U-tube shell and tube exchanger
1-9
Item Type
Description
TEMA EXCH
Fixed tube, float. head, or u-tube exchanger
PRE ENGR
Pre-engineered (standard) U-tube exchanger
CROSS BORE
Cross-bore (all graphite) heat exchanger
SHELL TUBE
Graphite tube/CS shell heat exchanger
FIN TUBE
Finned double pipe heat exchanger
HEATER STM
Bare pipe immersion coil-heating/cooling
SUC HEATER
Tank suction
HEATER ELC
Electric immersion tank heater
JACKETED
Double pipe heat exchanger
SPIRAL PLT
Spiral plate heat exchanger
ONE SCREW
Thermascrew (Reitz) single screw conveyor
TWO SCREW
Twin screw agitated/jacketed heat exchanger
WASTE HEAT
Waste heat boiler
PLAT FRAM
Plate and frame heat exchanger
CORRUGATED
Sanitary double pipe exchanger
HOT WATER
Water heater (shell+tube - hot water set)
MULTI P F
Sanitary multizone plate+frame exchanger
STM HE MOD
Sanitary direct steam heat module
Reboilers (RB)
Item Type
Description
KETTLE
Kettle type reboiler with floating head
U TUBE
U-tube kettle type reboiler
THERMOSIPH
Thermosiphon type reboiler
Furnaces, Project Heaters (FU)
Item Type
Description
HEATER
A-frame type process furnace
BOX
Box type process furnace
PYROLYSIS
Pyrolysis unit
REFORMER
Box type reformer, without catalyst
VERTICAL
Vertical cylindrical process furnace
Chapter 6: Packing, Linings
1-10
Packing, Linings (PAK, LIN)
Item Type
Description
PACKING
Packing, variety of vessel packings
ACID BRICK
Acid brick lining
MONOLITHIC
Castable, refractory or gunned mix
OTHER
Lining - other than acid brick, monolithic
Chapter 7: Pumps
Centrifugal Pumps (CP)
Item Type
Description
API 610
API 610 pump (single or multi-stage)
ANSI
Standard ANSI single stage pump
ANSI PLAST
Plastic ANSI single stage pump
GEN SERV
General service pump
CENTRIF
Centrifugal single or multi-stage pump
AXIAL FLOW
Axial flow vertical pump
TURBINE
Vertical sump pump - turbine impeller
API 610 IL
API 610 in line pump
IN LINE
General service in line pump
PULP STOCK
Low consistency stock pump
MAG DRIVE
Standard ANSI magnetic drive pump
CANNED
Canned motor pump
- SAN PUMP
Sanitary centrifugal pump
- FLUME PUMP
Sanitary fluming pump with feeder hopper
Gear Pumps (GP)
Item Type
Description
GEAR
Standard external gear rotary pump
CANNED RTR
Canned rotary gear pump
MECH SEAL
Mechanical seal gear pump
Item Type
Description
SIMPLEX
Reciprocating simplex pump - steam driver
DUPLEX
Reciprocating duplex pump - steam driver
TRIPLEX
Triplex (plunger) pump - motor driver
DIAPHRAGM
Diaphragm pump - TFE type
SLURRY
Slurry pump
ROTARY
Rotary (sliding vanes) pump
1-11
Item Type
Description
RECIP MOTR
Reciprocating positive displacement plunger pump
HD STOCK
High density stock pump
ROTARYLOBE
Sanitary rotary lobe pump
AIR DIAPH
Sanitary air diaphragm pump
Chapter 8: Towers, Columns
Double Diameter Towers (DDT)
Item Type
Description
PACKED
Packed double-diameter tower
TRAYED
Trayed double-diameter tower
Single Diameter Towers (TW)
Item Type
Description
PACKED
Packed tower
TRAYED
Trayed tower
TRAY STACK
Tray stack for tray tower
DC HE TW
Direct contact heat exchanger tower
TS ADSORB
Dual vessel temperature swing adsorber
Chapter 9: Vacuum Systems
Condensers (C)
Item Type
Description
BAROMETRIC
Barometric condenser
Ejectors (EJ)
1-12
Item Type
Description
SINGLE STG
One stage ejector non-condensing
TWO STAGE
Two stage ejector with one condenser
2 STAGE
Two stage ejector non-condensing
4 STAGE B
Four stage ejector with two condensers
4 STAGE
Four stage ejector with one condenser
5 STAGE B
Five stage ejector with one condense
Vacuum Pumps (VP)
Item Type
Description
WATER SEALS
Water-sealed vacuum pump
MECHANICA
Mechanical oil-sealed vacuum pump
MECH BOOST
Mechanical booster vacuum pump
Chapter 10: Vessels
Horizontal Tanks (HT)
Item Type
Description
MULTI WALL
Multi-wall horizontal drum
HORIZ DRUM
Horizontal drum
JACKETED
Jacketed horizontal drum
SAN TANK
Sanitary horizontal drum
Vertical Tanks (VT)
Item Type
Description
CYLINDER
Vertical process vessel
MULTI WALL
Multi-wall vertical process vessel
JACKETED
Jacketed vertical process vessel
SPHERE
Sphere - pressure or vacuum storage
SPHEROID
Spheroid - pressure or vacuum storage
STORAGE
Flat bottom storage tank, optional roof
CRYOGENIC
Cryogenic storage tank
PLAST TANK
Plastic storage tank (FRP or Haveg)
WOOD TANK
Wooden storage tank
GAS HOLDER
Low pressure gas storage vessel
CONE BTM
Cone bottom storage bin
LIVE BTM
Live bottom storage bin
CHEST REC
Rectangular concrete tile chest
CHEST CYL
Cylindrical concrete tile chest
CHEST MTL
Metal tile chest
SAN TANK
Sanitary vertical cylindrical vessel
SAN HOPPER
Sanitary hopper assembly
Chapter 11: Crushers, Mills and Stock
Treatment
1-13
Crushers (CR)
Item Type
Description
CONES
Cone crusher - secondary crushing
GYRATORY
Gyratory - primary and secondary crushing
ECCENTRIC
Overhead eccentric jaw crusher
JAW
Swing jaw crusher
ROTARY
Rotary crusher
S ROLL LT
Single roll crusher - light duty
S ROLL MED
Single roll crusher - medium duty
S ROLL HVY
Single roll crusher - heavy duty
SAWTOOTH
Sawtooth roller crusher
REV HAMR
Reversible hammermill
HAMMER MED
Non-reversible hammermill, medium hard material
SWING HAMR
Non-reversible hammermill, hard material
BRADFORD
Bradford (rotary) breaker
S IMPACT
Single rotor impact breaker
PULVERIZER
Pulverizer - crushing soft material
ROLL RING
Ring granulator
Flakers (FL)
Item Type
Description
DRUM
Rotary drum flaker
Mills (M)
Item Type
Description
ATTRITION
Attrition mill
AUTOGENOUS
Autogenous mill
BALL MILL
Ball mill with initial ball charge
ROD MILL
Rod mill with initial rod charge
MIKRO PULV
Mikro-pulverizer
ROLLER
Roller mill
ROD CHARGR
Rod charger for rod mill
Stock Treatment (ST)
Item Type
Description
REFINER
Double disk refiner
DEFLAKE DK
Plate or tackle type deflaker
DEFLAKE CN
Conical type deflaker
Chapter 12: Drying Systems
1-14
Crystallizers (CRY)
Item Type
Description
BATCH VAC
Batch vacuum crystallizer
MECHANICAL
Mechanical scraped-surface crystallizer
OSLO
Oslo growth type crystallizer
Evaporators (E)
Item Type
Description
FALL FILM
Agitated falling film evaporator
FORCED CIR
Forced circulation evaporator
LONG TUBE
Long tube rising film evaporator
LONG VERT
Long tube vertical evaporator
STAND VERT
Standard vertical tube evaporator
STAND HOR
Standard horizontal tube evaporator
Item Type
Description
THIN FILM
Agitated thin film evaporator
WFE SYSTEM
Agitated thin film evaporator - package system
Air Dryers (AD)
Item Type
Description
AIR DRYER
Dual tower desiccant air dryer
Dryers (D)
Item Type
Description
ATMOS TRAY
Atmospheric tray batch dryer
VAC TRAY
Vacuum tray batch dryer
PAN
Agitated pan batch dryer
SPRAY
Continuous spray drying system
Drum Dryers (DD)
Item Type
Description
SINGLE ATM
Single atmospheric drum dryer
DOUBLE ATM
Double atmospheric drum dryer
SINGLE VAC
Single vacuum rotary drum dryer
S COOKCOOL
Rotary drum cooker-cooler
1-15
Rotary Dryers (RD)
Item Type
Description
DIRECT
Direct rotary dryer
INDIRECT
Indirect rotary dryer
JAC VACUUM
Jacketed rotary vacuum dryer
VACUUM
Conical rotary vacuum dryer
Tray Drying Systems (TDS)
Item Type
Description
ATM SYSTEM
Atmospheric tray dryer
VACUUM
Vacuum tray dryer
TURBO
Turbo tray drying system
VAC SYSTEM
Vacuum tray dryer with condenser
Chapter 13: Solids Conveying
Conveyors (CO)
Item Type
Description
OPEN BELT
Belt conveyor - open
CLOSED BLT
Belt conveyor - covered
APRON
Apron conveyor - pans on endless chain
PNEUMATIC
Pneumatic conveying system
ROLLER
Roller conveyor (non-motorized)
SCREW
Screw conveyor in a U-shaped trough
VIBRATING
Vibrating conveyor with inclined trough
CENT BKT L
Elevator-spaced bucket
CONT BKT L
Elevator-continuous bucket
Cranes (CE)
Item Type
Description
BRIDGE CRN
Traveling bridge crane
HOIST
Hoist with track beam
1-16
Item Type
Description
FREIGHT
Freight elevator
PASSENGER
Passenger elevator
Feeders (FE)
Item Type
Description
BELT
Volumetric belt feeder
BIN ACTVTR
Bin activator
ROTARY
Rotary feeder
VIBRATING
Vibrating feeder
WT LOSS
Loss-in-weight feeder
DUMPER
Sanitary dumper
SACK DUMP
Sanitary bulk bag unloader
SAN SCREW
Sanitary screw feeder
SAN BELT
Sanitary weigh belt feeder
Hoists (HO)
Item Type
Description
HOIST
5-speed electric hoist - motorized trolley
1 SPEED
1-speed electric hoist - no trolley
5 SPEED
5-speed electric hoist - no trolley
HAND GT
Hand hoist - manual pull chain trolley
HAND PT
Hand hoist - manual trolley
HAND NT
Hand hoist - no trolley
Scales (S)
Item Type
Description
BEAM SCALE
Beam scale
BELT
Conveyor belt scale
BENCH
Bench scale - dial and beam
FULL FRAME
Full floor scale - dial and beam
SEMI FRAME
Semi frame floor scale - dial and beam
TANK SCALE
Tank scale - weigh bridge and saddles
TRACK
Track scale for rail cars
TRUCK
Truck (lorry) scale
SAN FLOOR
Sanitary floor scale - flush mounted
Chapter 14: Separation Equipment
Centrifuges (CT)
Item Type
Description
ATM SUSPEN
Atmospheric suspended basket centrifuge
BATCH AUTO
Auto batch filtering centrifuge
BATCH BOTM
Batch bottom - suspended centrifuge
1-17
TOP UNLOAD
Batch top unload centrifuge
BOT UNLOAD
Batch bottom unload centrifuge
BATCH TOP
Batch top-suspended centrifuge
DISK
High-speed disk centrifuge
RECIP CONV
Reciprocating conveyor centrifuge
SCROLL CON
Scroll conveyor centrifuge
SOLID BOWL
Solid bowl centrifuge
SCREEN BWL
Screen bowl centrifuge
TUBULAR
High-speed tubular centrifuge
VIBRATORY
Vibrating screen centrifuge
INVERTING
Inverting filter centrifuge
Dust Collectors (DC)
Item Type
Description
CENTRF PRE
Centrifugal precipitator
CLOTH BAY
Baghouse with motor shakers
CYCLONE
Cyclone dust collector
MULT CYCLO
Multiple cyclone dust collector
ELC H VOLT
High voltage electrical precipitator
ELC L VOLT
Low voltage electrical precipitator
WASHERS
Washer dust collector
PULSE SHKR
Baghouse with injected pulsed air
Filters (F)
1-18
Item Type
Description
CARTRIDGE
Cartridge filter (5 micron cotton)
LEAF DRY
Pressure leaf-dry filter
LEAF WET
Pressure leaf-wet filter
PLATE FRAM
Plate and frame filter
ROTY DISK
Rotary disk filter
ROTY DRUM
Rotary drum filter
SEWAGE
Sewage filter
SPARKLER
Sparkler filter
TUBULAR
Tubular fabric filter (bank of 3)
SCROLL
Scroll discharge centrifugal filter
WHITEWATER
White water filter - centrifugal screen
METAL TRAP
Sanitary in-line metal trap
RECL REEL
Sanitary fluming reclaim reel
SAN AIR
Culinary (sterile) air filter
SAN PIPE
Sanitary pipe filter
SAN PRESS
Sanitary filter press
SAN STEAM
Culinary (sterile) steam filter
SAN STRAIN
Sanitary pipe strainer
SEDIMENT
REMOVAL
Sediment Removal
Separation Equipment (SE)
Item Type
Description
WATER CYCL
Water-only cyclone - mineral separation
OIL WATER
Oil-water separator - API type
PULP STOCK
Pulp stock centrifugal cleaner
Thickeners (T)
Item Type
Description
THICKENER
Thickener/clarifier
Screens (VS)
Item Type
Description
ONE DECK
Single deck rectangular vibrating screen
TWO DECK
Double deck rectangular vibrating screen
THREE DECK
Triple deck rectangular vibrating screen
HUMMER
Hummer type screen for fine separation
SIFTER 1
Single deck circular vibrating screen
SIFTER 2
Double deck circular vibrating screen
SIFTER 3
Triple deck circular vibrating screen
PRESSURE
Pressure screen
LD STOCK
Low consistency stock pump
BAR
Mechanical bar screen
Chapter 15: Utility Service Systems
Cooling Towers (CTW)
Item Type
Description
COOLING
Cooling tower, less pumps, field assembly
COOLING WP
Cooling tower, complete, field assembly
Item
Description
PACKAGED
Packaged cooling tower, factory assembly
1-19
Steam Boilers (STB)
Item Type
Description
BOILER
Packaged boiler unit
STM BOILER
Field erected boiler unit
Heating Units (HU)
Item Type
Description
CYLINDER
Process heater type dowtherm unit
Refrigeration Units (RU)
Item Type
Description
CENT COMPR
Centrifugal compression refrigeration unit
MECHANICAL
Mechanical compression refrigeration unit
Electrical Generators (EG)
Item Type
Description
PORTABLE
Portable electrical generator - diesel
TURBO GEN
Electrical generator - steam turbine drive
Item Type
Description
DEMINERAL
Two stage ion exchange water treatment
SOFTENING
Hot lime, zeolite water treatment system
AERATOR
Surface aerator
Chapter 16: Flares and Stacks
Flares (FLR)
1-20
Item Type
Description
DERRICK
Derrick-supported flare stack
GUYED
Guyed flare stack
SELF SUPP
Self-supported flare stack
HORIZONTAL
Horizontal ground flare
THRM OX LC
Recuperative thermal oxidizer
STORAGE
Vapor control flare for storage/loading
Stacks (STK)
Item Type
Description
STACK
Stack without flare tip
1-21
1-22
2 Agitators
(G6)
Agitators (AG)
Agitated Tanks (AT)
Description of Agitated Tanks
Impeller Types - General Range of Basic Data**
Impeller Type References
Impeller Materials
Blenders (BL)
Kneaders (K)
Mixers (MX)
2 Agitators (G6)
2-1
Agitators (AG)
Description
Type
Portable, clamp-on, direct drive with explosion-proof
motor. Typically used for rapid disperation or fast
reactions.
DIRECT
Material:
*CS*, SS304, SS316, MONEL, RUBCV
Driver Power:
0.25 - 3 HP [0.75 - 2.22 KW]
Portable, clamp-on, gear drive with explosion-proof
motor. Typically used to keep solids in suspension,
medium viscosity blending and dissolving.
GEAR DRIVE
Material:
Driver Power:
0.25 - 5 HP; [0.75 - 3 KW]
2-2
2 Agitators (G6)
Agitators (AG) - continued
Description
Type
Fixed mount, top-entering, gear drive, mechanical
seal, explosion-proof motor. Typically used for low
speed mixing on closed tanks. Shaft enters tank
through a mechanical seal.
MECH SEAL
Material:
Impeller diameter:
Max: 10 FEET [3.00 M]
Driver power:
Min: 2.00 HP [1.5 KW];
Max: 200 HP [140 KW]
Impeller Speed:
Min: 1,200 RPM [1,000 RPM];
Max: 1,800 RPM [1,500 RPM]
Driver type:
*STD*- Standard motor
VFD- Variable frequency drive
Impeller type:
*MP3B5*
Fixed mount, top-entering, gear drive, anchor, stuffing ANCHOR
box, explosion-proof motor. Typically used for low
speed mixing on closed tanks.
Material:
Driver power:
0.75 - 5 HP [0.75 - 3 KW]
Portable propeller mixer with motor to 7.5 HP
[5.5 KW].
PORT PROP
Material:
*CS*, SS
Driver power:
0.33 - 7.5 HP [0.75 - 5.5 KW]
Fixed propeller mixer with motor and gear drive to 100 FIXED PROP
HP [75 KW].
Includes motor, gear drive, shaft and impeller.
Material:
*CS*, SS
Driver power:
2 - 100 HP [1.5 - 75 KW]
2 Agitators (G6)
2-3
Description
Type
Top entry (for Open or Closed tanks) and Side entry
type. Includes motor driver, baseplate, bearings,
speed reducer, seals and a variety of shaft and
impeller configurations.
PULP STOCK
Material:
*CS*, SS403, SS316, SS321, SS347, 304L, 316L, NI,
INCNL, MONEL, HAST, TI
Driver type:
DRCT - Direct drive, no speed reduction
BELT- Belt driven speed reduction
VFD - Variable frequency drive
GEAR - Gear drive speed reduction
Liquid volume:
Enter Capacity or Impeller Diameter
Impeller diameter:
Enter Capacity or Impeller Diameter
Agitator orientation:
Default: *VTOP*
VTOP - Top entry agitator for open tanks
VTCL - Top entry agitator for closed tanks
SIDE - Side entry agitator
Driver speed:
Max: 3,600 RPM [3,000 RPM, metric units];
Default: *1,800* RPM: [*1,800* RPM, metric units]
Consistency - Air Dried%:
Max: 10.0; Default: *4.0*
Fluid density:
*62.4* PCF [*1000* KG/M3]
Seal type:
Default: *PACK*
PACK - Packing
MECH - Mechanical seal
Sanitary reversing anchor agitator
ANCHOR REV
With large paddle, reversing motor, and proximity
sensors. Stainless steel material for sanitation.
If you require a foundation for this item, it must be
added.
Liquid volume:
MIN: 50 GALLONS [0.19 M3],
MAX: 1,000 GALLONS [3.78 M3]
Agitator diameter:
MIN: 32 INCHES [813 MM],
MAX: 72 INCHES [1,825 MM]
Agitator height:
2-4
2 Agitators (G6)
Description
Type
Sanitary counter-rotating agitator
COUNT ROT
Two-piece agitator with center armed shaft and outer
frame parallel wall rotating opposite each other.
Stainless steel material for sanitation.
added.
Liquid volume:
MIN: 50 GALLONS [0.19 M3];
MAX: 1,000 GALLONS [3.78 M3].
Required to enter capacity.
Agitator diameter:
MIN: 32 INCHES [813
MM], MAX: 72 INCHES [1,825 MM]
Agitator height:
Sanitary highshear homogenizing agitator
HIGH SHEAR
Agitator’s perforated disk rotates to create shear for
homogenizing immiscible liquids. Used in the sanitary
industry.
added.
Liquid volume:
MAX: 1,500 GALLONS [5.67 M3].
Required: Enter either liquid volume or driver power.
Seal for shaft:
*NO*- Shaft seal not required
YES- Shaft seal is required
Driver power:
MIN: 0.33 HP [0.25 KW], 40 HP [30 KW].
Required: Enter either liquid volume or driver power.
Driver type:
*WXXDC*- Washdown, direct drive, CS
WVRDC - Washdown, VFD rated, direct drive, CS
WVCDC- Washdown, VFD controlled, direct dive,
CS
WXXDS - Washdown, direct drive, SS
WVRDS - Washdown, VFD rated, direct drive, SS
WVCDS - Washdown, VFD controlled, direct
drive, SS
TXXDC - TEFC, direct drive, CS
TVRDC - TEFC, VFD rated, direct drive, CS
TVCDC - TEFC, VFD controlled, direct drive, CS
- Continued on next page -
2 Agitators (G6)
2-5
Description
Type
HIGH SHEAR - continued
Impeller type:
*INTGH*- Integral head
RSDIH- Rotator stator w/ slotted disintegr. head
RSSQR- Rotator stator w/ high shear screen RSGENRotator stator w/ GP disintegrating head
Sanitary fixed propeller/turbine mixer.
SAN FIXED
Stainless steel material for total washdown capability
and no risk of open container contamination from
paint chips.
added.
Driver power:
MIN: 0.5 HP [0.375 KW], 25 HP [18.5]
Driver type:
*WVRGP*- Washdown, VFD rated, gear drive
WVCGP - Washdown, VFD controlled, gear drive
WXXGP- Washdown, gear drive
Impeller type:
*PROP*- propeller type impeller (not available
above 3 HP [2.22 KW])
TURB- turbine type impeller
No. of impellers:
*1*, MIN: 1, MAX: 2
Angle riser:
*NO*- Angle riser not required
YES- Angle riser is required
Mounting type:
*UNSLF*- Unsealed flange mounting
SLF- Sealed flange mounting
FLWB- Flange with bridge
2-6
2 Agitators (G6)
Description
Type
Sanitary port. propeller/turbine mixer
SAN PORT
Stainless steel material for total washdown capability
and no risk of open container contamination from
paint chips. Quick-disconnect prop allows for easy
inspection.
Driver type selections allow you to choose between
gear or direct drives. Gear drives feature removable
shafts retained by a positive fit internal shaft coupling.
Direct drives have fixed, non-removable shafts with a
sealed entry at the mounting flange face for superior
sanitation.
added.
Driver power:
MIN: 0.33 HP [0.25 KW],
MAX: 0.75 HP [0.55 KW]
Driver type:
*WVRDN*- Washdown, VFD rated, direct
drive, NI plate
WVRGN- Washdown, VFD rated, gear drive, NI
plate
WVCDN- Washdown, VFD contr, direct drive,
NI plate
WVCGN- Washdown, VFD contr, gear drive, NI
plate
2 Agitators (G6)
2-7
Agitated Tanks (AT)
Small to large, pressure/vacuum, jacket, driver, motor-reducer, agitator and
supports.
For MIXER, REACTOR and OPEN TOP:
Liquid Volume: To secure desired vessel size, specify the diameter and height
directly. A value must be specified if diameter and height are not both
specified. Otherwise, calculated from diameter and height. If both vessel
dimensions and capacity are specified, the system-calculated capacity must
agree with the specified capacity to within +/- 10%.
Skirt or Leg Height: If the capacity is 1000 GAL. [37 M3] or less, the vessel
is designed with 4 FEET [1.25 M] pipe legs. For a capacity greater than 1000
GAL. [37 M3], the vessel is designed with a skirt. The skirt height is calculated
as 1.5 x (vessel diameter) with minimum and maximum heights of 4 and 32
FEET [1.25 and 9.5 M] respectively. Enter “0.0” if hung in open structure.
Manhole Diameter: If no value is specified, a value is calculated as a function
of vessel diameter and height with a maximum manhole diameter of 48
INCHES [1200 MM].
Corrosion Allowance: For CS alloys, the default is 0.125 INCHES [3 MM];
0.0 for all other materials.
Weld Efficiency%: 5- - 100 (For ASME and JIS codes only).
Product Density: *62.4* PCF [*1,000*KG/M3]
Viscosity: *1.0* CPOISE [*1.0* MPA-S]
Description
Type
Pressure/vacuum vessel, optional jacket
MIXER
Includes top entering impeller and geared motorreducer, tank designed for 15 PSIG
[100 KPA].
Application:
Defines vessel function and related pipe/instrum.
model.
CONT- Standard continuous process
BATCH- Batch process
Shell Material:
For clad plate, specify the backing plate material.
(Cladding is defined below.) Default: *A285C*.
Liquid Volume:
Enter either Capacity or Diameter and Height.
Vessel Diameter:
Vessel Tangent to Tangent Height:
2-8
2 Agitators (G6)
Agitated Tanks (AT) - continued
Description
Type
MIXER - continued
Design Gauge Pressure:
Default: *15* PSIG [*100* KPA]
If pressure and vacuum entered, design is for worst
case. Default: Pressure.
Vacuum Design Gauge Pressure:
case. Default: Pressure.
Design Temperature:
*250* DEG F [*120* DEG C]
Operating Temperature:
Default: Design temperature.
Jacket Design Gauge Pressure:
Pressure must be specified to obtain a jacket.
Default: No jacket.
Jacket Type:
Default: *FULL*
FULL - Full jacket
PIPE - Half-pipe jacket
Jacket Thickness:
Jacket pressure or thickness required to obtain jacket.
Default: No jacket.
Jacket Material:
Default: *CS*
CS - Carbon steel
A 515 - A 515
A 204C - C - .5Mo
A 387B - 1Cr - .5Mo
A 387D - 2.25Cr - 1Mo
SS304 - SS304
SS316 - SS316
SS321 - SS321
SS347 - SS347
SS410 - SS410
SS430 - SS430
304L - 304L
316L - 316L
NI - Nickel
INCNL - Inconel
MONEL - Monel
HAST - Hastelloy
2 Agitators (G6)
2-9
Description
Type
MIXER - continued
SEE CARBON STEEL
- Select from types of Carbon Steel
SEE HEAT-TREATED STEEL
- Select from types of Heat Treated Steel
SEE LOW ALLOY STEEL
- Select from types of Low Alloy Steel
SEE HIGH ALLOY STEEL
- Select from types of High Alloy Steel
SEE NON-FERROUS
- Select from types of Non-Ferrous Steel
Driver Type:
Default: *STD*
STD - Standard motor
Cladding Material:
Default: None.
Skirt or Leg Height:
Enter 0.0 if hung in OPEN structure, legs provided if
capacity < 10,000 GAL [37 M3].
Manhole Diameter:
If no value is specified, a value is calculated as a
function of vessel diameter and height with a
maximum manhole diameter of 48 INCHES [1200
MM].
Base Material Thickness:
Base material thickness including corrosion allowance.
Corrosion Allowance:
For CS alloys, the default is 0.125 INCHES [3 MM]; 0.0
for all other materials.
Weld Efficiency%:
5 - 100 (For ASME and JIS codes only).
Stress Relief:
CODE - Provide stress relief if code requires
YES - Provide stress relief
NO - No stress relief required
Cladding Thickness:
Default: 0.125 INCHES [3 MM] if cladding material is
specified; otherwise 0.0.
Fluid Depth:
Maximum fluid depth: vessel height less 12 INCHES
[300 MM]
2-10
2 Agitators (G6)
Description
Type
MIXER - continued
Fluid Density:
*62.4* PCF [*1,000* KG/M3]
Fluid Viscosity:
*1.0* CPOISE [*1.0* MPA-S]
Impeller Type:
See Impeller Types table later in this chapter.
Stiffening Ring Spacing:
Default stiffeners designed for vacuum only, enter 0.0
if not required.
Number of Body Flange Sets:
Number of sets (pairs) of body flanges of same
diameter as vessel.
Diameter Option:
Defines desired diameter as ID or OD.
Default: See Area Design Basis.
OD- Outside Diameter
ID- Inside Diameter
Open with loose-fitting cover, optional jacket. Includes OPEN TOP
impeller and geared motor reducer, supported by
structural steel spanning tank top, tank without head.
Shell Material:
Liquid Volume:
Enter either capacity or diameter and height.
Vessel Diameter:
Design Temperature:
Default: *68* DEG F [*20* DEG C]
Default: Design Temperature.
Default: no jacket.
Jacket Type:
Default: *FULL*
FULL- Full jacket
PIPE- Half-pipe jacket
2 Agitators (G6)
2-11
Description
Type
OPEN TOP - continued
Jacket Thickness:
Default: no jacket.
Jacket Material:
Default: *CS*
CS- Carbon steel
A 515- A 515
A 204C- C - .5Mo
A 387B- 1Cr - .5Mo
A 387D- 2.25Cr - 1Mo
SS304- SS304
SS316- SS316
SS321- SS321
SS347- SS347
SS410- SS410
SS430- SS430
304L- 304L
316L- 316L
NI- Nickel
INCNL- Inconel
MONEL- Monel
HAST- Hastelloy
SEE CARBON STEEL
SEE LOW ALLOY STEEL
SEE NON-FERROUS
Driver Type:
Default: *STD*
STD- Standard Motor
Cladding Material:
Default *none*.
Enter 0.0 if hung in OPEN structure, legs provides if
capacity < 10,000 GAL. [37 M3].
2-12
2 Agitators (G6)
Description
Type
OPEN TOP - continued
Manhole Diameter:
Max: 48 INCHES [1200 MM].
Default 0.125 INCHES [3.0 MM] for CS; 0.0 for other
material; double if jacketed.
Weld Efficiency:
ASME/JIS codes only, where allowed for thin wall
vessels; Default: Area Basis 50 - 100.
Stress Relief:
Default: See Area Basis
CODE- Provide stress relief if code requires
YES- Provide stress relief
NO- No stress relief required
Cladding Thickness:
specified; otherwise: 0.0.
Fluid Depth:
Maximum fluid depth: vessel height less 12 INCHES
[300 MM].
Fluid Density:
Default: *62.40* PCF.
Fluid Viscosity:
Default: *1.00* CPOISE.
Impeller Type:
See Impellor Types table.
if not required.
diameter as vessel.
Diameter Option:
Defines desired diameters as ID or OD;
OD- Outside diameter
ID- Inside diameter
2 Agitators (G6)
2-13
Description
Type
Pressure/vacuum vessel, jacketed.
REACTOR
Includes jacket motor gear drive and shaft seal,
agitator, shaft, thermometer well, blow-pipe,
insulation and safety valves. Rating of full vacuum and
design pressure.
Application symbol:
Defines vessel function and related pipe/instrum.
model.
<blank>- Standard continuous process
BATCH- Batch process
Shell Material:
Liquid Volume:
Vessel Diameter:
case.
Default: Pressure.
If pressure and vacuum entered,
design is for worst case. Default: Pressure.
Design Temperature:
Ferrous mat’l: 650 DEG F [340 DEG C];
Other mat’l: 250 DEG F [120 DEG C].
*90* PSIG [*620* KPA]
Jacket Type:
Default: *FULL*
FULL- Full jacket
2-14
2 Agitators (G6)
Description
Type
REACTOR - continued
Jacket Material: Default: *CS*
CS - Carbon steel
A 515 - A 515
A 204C - C - .5Mo
A 387B - 1Cr - .5Mo
A 387D - 2.25Cr - 1Mo
SS304 - SS304
SS316 - SS316
SS321 - SS321
SS347 - SS347
SS410 - SS410
SS430 - SS430
304L - 304L
316L - 316L
NI - Nickel
INCNL - Inconel
MONEL - Monel
HAST - Hastelloy
SEE CARBON STEEL
SEE LOW ALLOY STEEL
SEE NON-FERROUS
Driver Type:
Default: *STD*
STD - Standard motor
Cladding Material:
Default: None.
Enter 0.0 if hung in OPEN structure, legs provided if
capacity < 10,000 GAL [37 M3].
Manhole Diameter:
maximum manhole diameter of 48 INCHES
[1200 MM].
2 Agitators (G6)
2-15
Description
Type
REACTOR - continued
Weld Efficiency:
5 - 100 (For ASME and JIS codes only).
Stress Relief:
CODE- Provide stress relief if code
requires
Cladding Thickness:
Fluid Depth:
Maximum fluid depth: vessel height less
12 INCHES [300 MM]
Fluid Density:
*62.4* PCF [*1,000* KG/M3]
Fluid Viscosity:
*1.0* CPOISE [*1.0* MPA-S]
Impeller Type:
See Impeller Types table later in this chapter.
if not required.
diameter as vessel.
Diameter Option:
OD- Outside Diameter
ID- Inside Diameter
2-16
2 Agitators (G6)
Description
Type
Pulpers are used for pulping the waste generated by
MACH PULP
mill operation or in a paper recycling process. Hence OFF MACH
the two types: on-machine and off-machine pulpers.
Both include a pulping tank with support legs, nozzles
(feed, drain and level control). The pulper itself
consists of an extraction plate, extraction chamber
with flanged outlet, rotor blade, hub, shaft with gear
or V-belt drive, drive motor, motor coupling and an
adapter plate. Multiple rotors can be selected.
MACH PUMP
Application Symbol:
Default: *CONT*
BATCH - Batch pulper
CONT- Continuous pulper
Tank or Vat Material:
CS, SS304, *SS316*, SS321, SS347, 304L, 316L, NI,
Configuration:
Default: *RECT*
CYLIN- Cylindrical tank
RECT- Rectangular tank
Hydraulic Volume:
Enter pulping rate or hydraulic capacity.
Pulping Rate Air Dried:
Enter pulping rate or hydraulic capacity.
Tank Length or Diameter:
Enter length for rectangular tank or diameter for
cylindrical tank.
Vessel Width:
Rectangular tanks only.
Number of Rotors or Drives:
1-2; Default: *1*.
Consistency Air Dried:
Max: 18; Default: *4.00*
Impeller Type:
Default: *STD*
STD - Standard rotor shaft length
EXTD - Extended rotor shaft length
2 Agitators (G6)
2-17
Description
Type
MACH PULP - continued
Impeller Material:
CS, SS304, *SS316*, SS321, SS347, 304L,
316L, NI, INCNL, MONEL, HAST, TI
Driver Type:
Default: *GEAR*
BELT - Belt driven speed reduction
Design Temperature:
*68.0* DEG F [*20.0* DEG C]
Seal for Shaft:
Default: *PACK*
PACK - Packing
Driver Speed:
Max: 3,000 RPM [2,600 RPM];
Default: *1,500* RPM [*1,800 RPM]
Vessel Leg Height:
*10.0* FEET [*3.00* M]
Number of Manholes: Default: *1*.
Manhole Diameter:
maximum manhole diameter of 48 INCHES
[1200 MM].
Default: *18* INCHES [*450* MM]
Application Symbol: Default: *BATCH*
OFF MACH
BATCH - Batch pulper
CONT - Continuous pulper
Tank or Vat Material: CS, SS304, *SS316*, SS321,
SS347, 304L, S16L, NI, INCNL, MONEL, HAST, TI.
Configuration: Default: *CYLIN*
CYLIN - Cylindrical tank
RECT - Rectangular tank
Hydraulic Volume: Enter tank capacity or tank
dimensions.
Tank Length or Diameter: Enter tank capacity or
dimensions, diameter for cylindrical, length for
rectangular.
Vessel Height: Enter tank capacity or tank
dimensions.
2-18
2 Agitators (G6)
Description
Type
OFF MATCH - continued
Vessel Width:
Enter tank capacity or dimensions, width is for
rectangular tanks only.
Number of Rotors or Drives:
1-2, Default: *1*.
Max: 18; Default: *4.0*.
Impeller Type:
Default: *EXTD*.
STD - Standard rotor shaft length
EXTD - Extended rotor shaft length
Impeller Material:
CS, SS304, *SS316*, SS321, SS347, 304L, S16L, NI,
Driver Type: Default: *GEAR*
BELT - Belt driven speed reduction
Design Temperature:
Default: *68.0* DEG F [*20.0* DEG C].
Seal for Shaft:
Default: *PACK*.
PACK - Packing
For CS alloys, the default is 0.125 INCHES [3.0 MM];
0.0 for all other materials.
Driver Speed:
Max: 3,000 RPM [2,600 RPM];
Default: *1,500 RPM [*1,800* RPM].
Vessel Leg Height:
Default *10* FEET [*3.0* M].
Number of Manholes:
Default: *1*.
Manhole Diameter:
If no values is specified, a value is calculated as a
maximum diameter of 48 INCHES [1,200 MM].
Default: *18* INCHES [*450* MM].
2 Agitators (G6)
2-19
Description
Type
Conditioning cell for floatation machine.
COND CELL
Material:
Default: *CS*
Cell Volume:
10.0 - 1,500.0 CF [0.3 - 40 M3]
Floatation machine, minerals separation, multi-cell.
FLOAT CELL
Floatation machine for selectively separating
minerals by agitation, air dissemination and
chemical adhesion. Includes one row of cells
connected in series with one feed box, one
discharge box and one connection box for each
group of four cells.
Material:
Default: *CS*
Volume Per Cell:
10 - 1,500 CF [0.3
- 40 M3]
Number of Cells: Refers to number per row
connected in series.
Number of Cells Per Motor:
1 - 2; Default: *1*
2-20
2 Agitators (G6)
Description of Agitated Tanks
1
Reynolds Number (RN), dimensionless: RN = (D2N) (FD/FV)
2
Froude Number (FN), dimensionless: FN = g/N2D
3
Power Number (PN), dimensionless: PN = (Pgc/FD) (N3D5)
4
Power Function (PF), dimensionless:
For RN > 300 and for unbaffled tanks,
log PF = log PN - (a-log RN) (log FN) /b
For RN < or = 300 for tanks with or without baffles,
FP = PN
5
Relationships between PF, PN, FN, RN for each impeller listed in the
Impeller Types table are contained in the AT agitated tank model. Power is
derived from PN.
6
General Nomenclature
2 Agitators (G6)
Variable
Description
Value
a
impeller contant
See Impeller Types table
b
impeller contant
See Impeller Types table
D
impeller diameter
FN
Froude Number
g
local acceleration due to gravity
gc
gravitational constant
N
rotational speed of impeller
P
power to shaft of impeller
PN
Power number
RN
Reynolds number
FD
fluid density
FV
fluid viscosity
See Chapter 29: Units of
Measure
2-21
Impeller Types - General Range of Basic
Data**
Impeller
2-22
No.
Type
Symbol
1
T6FB
2
Reynolds Number
Type
D/d
Baffles
Low High
L/d
E/d
Turbine with six 3
flat blades.
B=0.25d;
Blade Height =
0.2d
2.7-3.9
0.75-1.3
6
1-10
4
No.
0.17
B/D
1
Ref
T6FB2
Same as No.1
3
2.7-3.9
0.75-1.3
1-106
4
0.10
1
3
T6FB3
Same as No.1
3
2.7-3.9
0.75-1.3
1-106
4
0.04
1
4*
T6FB4
Same as
No.1;a=1,
b=40
3
2.7-3.9
0.75-1.3
1-106
0
-
1
5
T6CB
Turbine with six 3
curved blades.
Blade sizes
same as No.1
2.7-3.9
0.75-1.3
1.8-106 4
0.10
1
6
T6AB
Turbine with six 3
arrowhead
blades. Blade
size same as
No.1
2.7-3.9
0.75-1.3
3-106
4
0.10
1
7
STDR
Shrouded
2.4
turbine with six
blades. 20
blade deflector
ring.
0.74
0.9
20,000- 0
90,000
-
2
8
STDR2
Similar to No.7, 3
but not
identical.
2.7-3.9
0.75-1.3
2.5-106 0
-
1
9
ST
Same as No.8, 3
but no deflector
ring.
2.7-3.9
0.75-1.3
10-106 4
0.10
1
10
AT8B45
Axial turbine
with eight
blades at a 45
degree angle.
See No.11.
3
2.7-3.9
0.75-1.3
1.8-106 4
0.10
1
11
AT4B60
Axial turbine
with four
blades at a 60
degree angle.
B=0.25d.
3
3
0.50
1560,000
-
3
2 Agitators (G6)
Impeller Types - General Range of Basic Data** - continued
Impeller
Reynolds Number
No.
Type
Symbol Type
D/d L/d
E/d
12
AT4B45
Axial turbine
with four
blades at a 45
degree angle.
See No. 11
5.2
5.2
0.87
13
P4B
Paddle with
four blades.
3
3
14
P2B3
Paddle with two 3
blades. See
No.13.
15
MP3B2
Marine
propeller with
three blades.
Pitch-2d;
a=1.7; b=18.
16
MP3B5
17*
Baffles
Low High
No. B/D
Ref
60040,000
0
-
3
0.50
200 70,000
0
-
3
2.7-3.9
0.70-1.3
2-106
4
0.10
1
3.3
2.7-3.9
0.75-1.3
2.5-106 0
-
1
Same as
No.15, but
pitch=1.05d;
a-2.3; b=18.
4.5
2.7-3.9
0.75-1.3
2.5-106 0
-
1
MP3B6
Same as
No.15, but
pitch=1.04d;
a=0; b=18.
4.5
2.7-3.9
0.75-1.3
2.5-106 0
-
1
18
MP3B7
Same as
No.15, but
pitch=d
3
2.7-3.9
0.75-1.3
2.3-106 4
0.10
1
19*
MP3B8
Same as
No.15, but
pitch=d;
a=2.1; b=18.
3
2.7-3.9
0.75-1.3
2.5-106 0
-
1
20
MP3B9
Same as
No.15, but
pitch=d
3.8
3.5
1.0
3000
500,000
-
4
21
HRA
Helical ribbon.
Ribbon
width=d/
8.5;helical
screw=D/30.
1.05 1.5
-
0.7-23
-
5
0
* Surface effects are important. Froude number is included for Reynolds
Numbers great than 300.
**System will permit extension beyond these ranges. Please check your
results.
2 Agitators (G6)
2-23
Impeller Materials
If Component
Impeller Material
CLAD
Match cladding
GLSCS
SS316 blades/shaft
Other
Match steel
Impeller Type References
Ref
Reference for Impeller Type
1
Rushton, J. H., E. Costich, and H. J. Everett, Presented at Annual Meeting of
the American Institute of Chemical Engineers, Detroit, 1947.
2
Olney, R. B., and G. J. Carlson, Chemical Engineering Progress, 43, 473, 1947.
3
Hixson, S. Q., and S. J. Baum, Industrial and Engineering Chemistry, 34, 194,
1942.
4
Stoops, C. E., and C. L. Lovell, Industrial and Engineering Chemistry, 35, 845,
1943.
5
Gray, J. B., Chemical Engineering Progress, 59, 55, 1963.
Legend for Impellers
B - Baffle width
D - Tank diameter
d - Impeller diameter
E - Impeller elevation
above tank bottom.
H - Tangent-to-tangent
height of tank.
L - Liquid level in tank.
Motor/Reducer
12
INCH
Min.
L
H
d
E
B
D
2-24
2 Agitators (G6)
Blenders (BL)
Rotary, batch, dry or semi-dry solids, motor and speed reducer.
Description
Type
Rotary drum.
BLENDER
For batch blending of dry or semi-dry solids. Includes
motor and drive.
Material:
*CS*, SS
Blender Volume:
1 - 450 CF [0.03 - 12 M3]
Product Density:
MAX: 200 PCF [3,200 KG/M3];
Default: *50* PCF [*800* KG/M3]
Driver Speed:
Default: *1,800* RPM
Rotary double-cone.
.ROTARY
For batch blending of dry solids. Includes motor and
drive.
Material:
*CS*, SS316
Blender Volume:
5 - 350 CF [0.02 - 9 M3]
Driver Speed:
30 x Hz RPM
Material:
GSLCS
Blender Volume:
2 - 165 CF [0.06 - 2.5 M3]
Driver Speed:
30 x Hz RPM
Sanitary kettle blender without agitator.
KETTLE
Used for “gentle” blending or folding of viscous
mixtures. Add agitator separately.
added.
Liquid Volume:
MIN: 50 GALLONS [0.19 M3], MAX: 600 GALLONS
[0.19 M3]
2 Agitators (G6)
2-25
Blenders (BL) - continued
Description
Type
KETTLE - continued
*68 DEG F
[20 DEG C]
Cover Type:
*LFTHG*- Lift-off or hinged cover
NONE- No cover required
Lift off cover to 80 GAL [0.3 M3], else hinged cover.
Jacket option:
*NO*- Jacket not required
YES- Jacket is required
Mounting type:
*RIM*- Rim mounting
LEGS- Leg type mounting
Sanitary rotary bowl blender.
ROTARYBOWL
Consists of a stainless steel drum with motor
drive mounted on a frame. Used for wet or dry
mixtures.
If you require a foundation for this item, it must
be added.
Material:
SS304, *SS316*
Liquid Volume:
MAX: 160 GALLONS [0.6 M3]
Mounting type:
*FIXD*- Fixed type blender
PORT- Portable type blender on casters
2-26
2 Agitators (G6)
Blenders (BL) - continued
Description
Type
Sanitary, multi-shell, staggered blender
MSHELSTAG
Continuous, “zig-zag” type blender combines the
action of a rotating, eccentric drum with multiple
recycling. Used for either uniform solids-solids
blending (e.g., blending vitamins into cereals) or, if
SOL-LIQ is selected in the Application field, solidsliquids blending (e.g., coating food particles with
sweeteners). Solids are fed through an inlet chute. If
SOL-LIQ is selected, a dispersion head is included for
liquid injection.
Although not included on the inputs, this piece of
equipment either operates at 50% (recommended) or
at 100% of its capacity. When the capacity is specified,
the system selects a model that can provide the
capacity while operating at 50% of the model's rated
capacity. However, if a diameter is specified, the
system provides the rated capacity in the results.
be added.
Material: SS304, *SS316*
Flow rate:
MIN: 250.0 LB/H [115.0 KG/H],
MAX: 500,000.0 LB/H [227,000.0 KG/H]. Enter
diameter or capacity. Capacity limits are at default
density and residence time.
Blender diameter:
MIN: 8 INCHES [200 MM], 40 INCHES
[1,000 MM].
Blender type:
*SOL-SOL*- Solids-solids blending
SOL-LIQ- Solids-liquids blending
Driver type:
*WVRDC*- Washdown, VFD rated, direct
drive, CS
WVCDC- Washdown, VFD controlled, direct
drive, CS
Product residence time:
MIN: 1.00 MINUTES,
MAX: 3.00 MINUTES, Default: *1.50 MINUTES*
Product density:
MIN: 30.0 PCF [480.0 KG/M3],
MAX: 300.0 PCF [4,800.0 KG/M3}; Default: *40 PCF
[640 KG/M3].*
2 Agitators (G6)
2-27
Kneaders (K)
Jacket, motor, motor reducer, cover, nozzles and agitator.
Description
Type
Stationary, upright double-arm.
STATIONARY
Material:
*CS*, SS304, SS316, MONEL
Liquid Volume:
100 - 750 GALLONS [0.4 to 2.8 M3]
Tilting, double-arm.
TILTING
Material:
Liquid Volume:
10 - 500 GALLONS [0.5 to 1.8 M3]
Vacuum, tilting, double-arm.
VAC TILTNG
Material:
Liquid Volume:
10 - 500 GALLONS [0.5 to 1.8 M3]
2-28
2 Agitators (G6)
Mixers (MX)
Typically used for keeping solids in suspension, for dissolving solids and for
mixing and/or reacting two or more feed streams.
Description
Type
Cylinder type extruder with variable drive.
EXTRUDER
Material:
*CS*
Driver power:
5 - 40 HP [4 - 30 KW]
Driver speed:
Max: 60 x HZ; Default: *30 x HZ*
Extruder muller type with open motor.
MULLER EXT
Material:
*CS*
Driver Power:
3 - 75 HP [2.22 - 55 KW]
Driver Speed:
Pan includes motor and drive.
PAN
Material:
*CS*
Mixer Volume:
4 - 40 CF [0.2 - 1.1 M3]
Driver speed:
Portable propeller mixer with motor to 7.5 HP
[5.5 KW].
Includes motor driver.
PORT PROP
Material:
*CS*, SS
Driver power:
0.33 - 7.5 HP [0.75 - 5.5 KW]
Fixed propeller mixer with motor and gear drive to 100 FIXED PROP
HP [75 KW].
This item is a top entering mixer including a gear
drive, TEFC motor, shaft and impeller.
Material:
*CS*, SS
Driver power:
2 - 100 HP [1.5 - 75 KW]
2 Agitators (G6)
2-29
Mixers (MX) - continued
Description
Type
Sigma double-arm non-vacuum mixer with motor and SIGMA
drive.
Material:
*CS*
Driver power:
3 - 100 HP [2.22 - 6.0 KW]
Mixer Volume:
1 - 70 CF [0.05 - 1.9 M3]
Driver speed:
Spiral ribbon includes motor and drive.
SPIRAL RIB
Material:
*CS*
Driver power:
5 - 50 HP [4 - 37.5 KW]
Mixer Volume:
10 - 395 CF [0.3 - 11 M3]
Driver speed:
Static mixer used for instantaneous mixing of
two fluid streams.
STATIC
The unit includes the main pipe housing, the
mixer elements and the flanges at both ends.
Pipe material:
A 53, A 106, *304P*, 304LP, 316P, 316LP, 316PS
(SS316 sanitary pipe, MAX: 8 INCHES [200 MM]),
321P, NI, MONEL, INCNL, TI
Flow type:
*TRNS*, TURB, LAMN, PLUG (default for sanitary
material)
Pipe diameter:
0.5 - 12.0 IN DIAM [12 - 300 MM DIAM]
2-30
2 Agitators (G6)
Description
Type
STATIC - continued
Note: For non-sanitary material, use any pipe
diameter in the above range; for sanitary
material, use only the following:
INCHES
MM
0.50
15
0.75
20
1.00
25
1.50
40
2.00
50
2.50
65
3.00
80
4.00
100
Enter liquid flow rate or diameter and length.
Number of elements:
Default varies with flow type.
Element material:
CS, SS, NI, MONEL, TI, HAST, HASTC, PD; Default:
*SS304*
Design temperature Inlet:
*68.0* DEG F [*20.0* DEG C]
Fluid density:
*62.4* PCF [*300* KG/M3]
Fluid viscosity:
*1.0* CPOISE [*1.0* MPA-S]
Design gauge pressure Inlet:
15.0 PSIG [100 KPA]
2 Agitators (G6)
2-31
Description
Type
Two roll includes motor and drive.
TWO ROLL
Material:
*CS*
Driver power:
50 - 300 HP [37.5 - 224 KW]
Driver speed:
Sanitary high-speed Norman-type mixer
HIGH SPEED
For dissolving solids or semi-solids. Pulls product from
the top center of the square tank (shape ensures
complete hydration) down to the high-speed impeller,
which forces it out to the side of the tank and back up
to the surface.
added.
Material:
SS304, *SS316*
Liquid Volume:
MAX: 300 GALLONS [1.13 M3]
Impeller type:
FRZN- Frozen food mixing
*NFRZ*- Non-frozen food mixing
Driver type:
*WXXBC*- Washdown, belt drive, CS
WVRBC- Washdown, VFD rated, belt drive,
CS
WVCBC- Washdown, VFD controlled, belt
drive, CS
Sanitary ribbon blender
RIBBON
Provides means for mixing, homogenizing, and
drying a wide variety of products. Includes base
unit, direct drive motor, jacket, and stainless
steel legs. Cover has four safety interlock
sensors, as well as a manual control ball valve
for air supply. For sanitary reasons, material of
construction is stainless steel (carbon steel may
be specified for legs).
added.
2-32
2 Agitators (G6)
Description
Type
RIBBON - continued
Material:
SS304, *SS316*
Blender type:
*1SHAFT* - Single shaft blender
2SHAFT - Twin shaft blender (available only for
capacities of 500 - 750 GALLONS [1.9 - 2.85 M3]
Liquid volume:
MAX: 3,800 GALLONS [14.3 M3]
Driver power per shaft:
MIN: 1 HP [0.75 KW],
MAX: 150 HP [112 KW]
For twin shaft type, this is the driver power for each
shaft.
Driver type:
*WXXDC*- Washdown, direct drive, CS
WVCDC- Washdown, VFD controlled,
direct drive, CS
WXXIC- Washdown, indirect drive, CS
WVCIC- Washdown, VFD control, indirect
drive, CS
HXXCZ- Hydraulic drive with hydraulic
system (available for twin shaft
only)
No indirect drivers < 180 GALLONS [0.68 M3] or < 7.5
HP [5.5KW]
Cover type:
NONE- Cover not required
STD- Standard cover is required
LCHTS- Load chute for twin shaft blender only
Default: STD for twin shaft, NONE for single shaft
Jacket option:
NO- Jacket not required
*YES* - Jacket required
Not applicable for twin shaft blender type.
Leg material:
CS- Carbon steel
*SS*- Stainless steel
Not applicable for twin shaft blender type.
Seal for shaft:
*STD*- Standard shaft seal
MECO- Clean-In-Place steam proof seal
Applicable for twin shaft only
2 Agitators (G6)
2-33
Description
Type
RIBBON - continued
Operating temperature:
MIN: 68 DEG F [20 DEG C]
PISTON HOM
Sanitary piston-type homogenizer
Homogenizing valve employs cavitation, shear,
and impingement forces to reduce gobule/
particle size as the product passes through it.
Material is SS316 for sanitary reasons.
be added.
Liquid flow rate per hour:
MIN: 15 GPH [0.057 M3/H],
MAX: 9,900 GPH [37.4 M3/H] @ 2000 PSIG
[13800 KPA], 2000 GPH (7.5 M3/H) @ 10, 000
PSIG [68,900 KPA]
Driver power:
MIN: 3 HP [2.22 KW],
MAX: 250 HP [180 KW]
Plunger diameter:
MIN: 0.625 INCHES [16 MM],
MAX: 3.5 INCHES [90 KW]. Maximum is
influenced by capacity and gauge pressure (see
table below). Required: enter either plunger
diameter or gauge pressure.
Plunger Diameter
Capacity
@ 2000 PSIG
[13800 KPA]
Gauge
Pressure
@ 10000 PSIG
[68900 KPA]
Gauge
Pressure
GPH
M3/H INCHES MM
INCHES MM
15
.057
0.625
2000
7.5
6000
22.7
3.52
902
----
----
9000
37.4
3.1253
803
----
----
0.625
----
16
----
1.5
1
16
401
1 Maximum capacity at highest maximum operating pressure
2
Maximum diameter
3 Maximum capacity at lowest maximum operating pressure
Operating gauge pressure:
MIN: 2,000 PSIG [13,800 KPA], 10,000 PSIG
[68,900 KPA]
Required: enter either plunger diameter or
gauge pressure.
2-34
2 Agitators (G6)
Description
Item
Sanitary shear pump homogenizer.
SHEAR HOM
For continuous, in-line and controlled batch
course processing. Material of construction is
SS316 for sanitary reasons.
Liquid flow rate:
MIN: 10 GPM [0.64 L/S],
MAX: 575 GPM [36.0 L/S]
Cooler option:
*NONE*- No cooler is required
COOL- Cooler is required
Driver power:
MIN: 7.5 HP [4.0 KW],
MAX: 100 HP [75 KW]
Driver type:
TVRZC- TEFC, VFD rated, CS
*TVCZC*- TEFC, VFD controlled, CS
Number of stages:
*1*, MIN: 1, MAX: 3
The shear pump homogenizer is provided with 3
stages; however, if only 1 or 2 stages are required,
then the other stages are blocked.
2 Agitators (G6)
2-35
2-36
2 Agitators (G6)
3 Compressors
(G6)
Fans, Blowers (FN)
3 Compressors (G6)
3-1
For plant or instrument air.
For all air compressors, capacity is at inlet temperature and pressure.
Description
Type
Packaged unit including motor driver.
CENTRIF M
Includes inlet air filter, inlet throttle valve, bypass
throttle valve, bypass silencer, compressor*,
intercoolers**, aftercooler, automatic condensate
removal system with condensate bypass valve, lube oil
system, continuous baseplate, spacer coupling and
guard, induction motor, vibration shutdown system,
protection and regulation system, compressor
mechanical test run and check valve.
*The nominal 110 PSIG discharge machines have four
stages of compression. The nominal 325 PSIG
discharge machines have five stages of compression.
**The four stage machines have three intercoolers.
The five stage machines have four intercoolers.
Material:
*CS*, CI (Cast iron)
Actual gas flow rate:
1,000 - 25,000 CFM [1,700 - 42,400 M3/H]
Design gauge pressure Outlet:
15 - 325 PSIG [104 - 2,258 KPA]
3-2
3 Compressors (G6)
Air Compressors (AC) - continued
Description
Type
CENTRIF M - continued
-50 - 200 DEG F [-45 - 90 DEG C];
Default:
*68* DEG F [*20* DEG C]
Packaged unit including turbine driver.
CENTRIF T
Includes the same items as CENTRIF M except
the compressor driver is a steam turbine instead
of AC induction motor.
Material:
*CS*, CI (Cast iron)
1000 - 25000 CFM [1,700 - 42,400 M3/H]
15 - 325 PSIG [105 - 2,240 KPA]
-50 - 200 DEG F [-45 - 90 DEG C];
Integral gasoline engine driver, base plate, coupling,
RECIP GAS
reciprocating gas compressor for compression of large
volumes of air to high pressure, less coolers, filters,
condensate removal (not a packaged unit).
Material: *CS*
Max: 6,000 PSIG [41,300 KPA]
Driver power:
100 - 10000 HP [75 - 7100 KW]
3 Compressors (G6)
3-3
Air Compressors (AC) - continued
Description
Motor driven reciprocating gas compressor, with
speed reducer, pulsation dampers for
compression of large volumes of air to high
pressure, less coolers, filters, condensate
removal (not a packaged unit).
Type
RECIP MOTR
Material: *CS*
Design gauge Pressure Outlet:
Max: 6,000 PSIG [41,300 KPA]
Min: >0 PSIG
Driver Power:
Max: 15,000 HP [11,000 KW]
SINGLE 1 S
Single stage, non-lubricated, packaged
reciprocating compressor for oil-free air; includes
motor and drive, coupling, base plate, cooler.
Material:
*CS*
75 - 1,100 CFM [130 - 1,850 M3/H]
90 - 150 PSIG [620 - 1,000 KPA]
-50 - 200 DEG F [-45 - 90 DEG C];
Default:*0* PSIG [*0* KPA]
Two stage, non-lubricated, packaged
reciprocating air compressor for oil-free air;
includes motor and drive, coupling, base plate,
and cooler.
SINGLE 2 S
Material:
*CS*
80 - 700 CFM [140 - 1,150 M3/H]
150 - 500 PSIG [1,040 - 3,400 KPA]
-50 - 200 DEC F [-45 - 90 DEG C];
Default: *68* DEG F [*20* KPA]
3-4
3 Compressors (G6)
For process gas streams:
°
Centrifugal (motor, turbine, gasoline engine, no driver)
°
Reciprocating (motor, turbine, no driver) - with gear reducer, couplings,
guards, base plate, compressor unit, fittings, interconnecting piping,
vendo-supplied instruments, lube/seal system; less intercoolers and
interstage knock-out drums.
For all gas compressors, capacity is at inlet temperature and pressure.
Description
Type
Axial (inline) centrifugal gas compressor with driver
(motor, turbine or gasoline driven engine); excluding
intercoolers and knock-out drums.
CENTRIF
Casing material:
See “Casting Materials” in Chapter 28 for
a complete list of materials. Default: *CS*.
Actual gas flow rate Inlet:
60 - 200000 CFM [102 - 339000 M3/H]
-200 - 200 DEG F [-125 - 90 DEG C];
Default - *68* DEG F [*20* DEG C]
Max: 3050 PSIG [21130 KPA]
Molecular weight:
Default: *29*
Specific heat ratio:
Default: *1.4*
Compressibility factor Inlet:
Default: *1*
Compressibility factor Outlet:
Default: *1*
Maximum interstage temperature:
Specify the maximum temperature reached during
compression before inter-cooling.
Max: 400 DEG F [200 DEG C]; Default: *350* DEG F
[*175* DEG C]
Intercooler outlet Temperature:
Specify the interstage inlet temperature after cooling.
-50 - 150 DEG F [-45 - 65 DEG C]; Default: *90* DEG
F [*30* DEG C]
3 Compressors (G6)
3-5
Gas Compressors (GC) - continued
Description
Type
CENTRIF - continued
Driver type:
Default: *MOTOR*
NONE - No driver
GAS ENGINE - Gas engine driver
MOTOR - Motor driver
TURBINE - Turbine driver
Turbine gauge pressure:
Max: 1,600 PSIG [11,000 KPA];
Default:
*300* PSIG [*2050 KPA]
Gear reducer type:
Default: gear reducer included if driver type specified;
otherwise none.
YES - Gear reducer required
NO - No gear reducer
Lube oil system:
Default: *YES*
YES - Lube system required
NO - No lube oil system
CENTRIF IG
Integral gear centrifugal gas compressor with
driver (motor, turbine or gasoline engine), scrolls
(inter-stage piping), bull gear, coupling, guard;
may include lube oil system, intercoolers,
aftercooler: excludes filter and silencers.
Casing material:
See “Casting Materials” in Chapter 28 for a
complete list of materials. Default: *CS*.
500 - 70,000 CFM [850 - 118,900 M3/H]
-0.4 -100 PSIG [-2.7 - 689 KPA];
Default: *0.0* PSIG [*0.0* KPA]
32 - 200 DEG F [0 - 90 DEG C];
Max: 200 PSIG [1480 KPA]
Design temperature Outlet:
-200 - 200 DEG F [-125 - 90 DEG C]
Number of impellers:
2-4
3-6
3 Compressors (G6)
Description
Type
CENTRIF IG - continued
Gas type option:
Sets default gas properties and makes adjustments for
explosive gases.
Default: *AIR*.
AIR - Air
O2GAS - Oxygen
N2GAS - Nitrogen
ARGAS - Argon
FLGAS - Flammable gas
NONFL - Non-flammable gas
Molecular weight:
Default based on chosen gas type.
Default based on chosen gas type.
Default: *1.0*.
Compressibility factor Outlet:
Default: *1.0*.
Intercooler required:
Default: *YES*
YES - Cooler required
NO - None required
After cooler Required:
Default: *NO*.
YES - Cooler required
NO - None required
Specify the maximum temperature reached during
compression before inter-cooling.
Max: 400 DEG F [200 DEG C].
Intercooler outlet temperature:
The interstage inlet temperature after intercooling.
- 5- - 150 DEG F [-45 - 65 DEG C];
Default: *90* DEG F [*30* DEG C].
Driver type:
Default: *MOTOR*
NONE - No driver
MOTOR- Motor driver
TURBINE- Turbine driver
3 Compressors (G6)
3-7
Description
Item
CENTRIF IG - continued
Turbine gauge pressure:
Max: 1,600 PSIG [11,000 KPA];
Default: *300* PSIG [*2,050* KPA].
Lube oil system:
Default: *YES*
YES- Lube system required
NO- No lube oil system
Shop assembly option:
Partial assembly denotes multiple
skids field connected wither intercoolers.
Default:
*FULL*.
FULL- Full shop assembly
PART- Part shop assembly
NONE- No shop assembly
Motor or turbine-driven reciprocating process gas
compressor. Includes motor, gear reducer and
pulsation dampers. Does not include intercoolers or
aftercoolers.
RECIP MOTR
Max: 200,000 CFM [339,000 M3/H]
Inlet Temperature:
-200 - 200 DEG F [-125 - 90 DEG C];
Max: 6,000 PSIG [41,000 KPA]
Molecular weight:
Default: *30*
Default: *1.22*
Specify the maximum temperature
reached during compression before inter-cooling.
Max: 400 DEG F [200 DEG C];
Default: *270* DEG F
[135 DEG C].
3-8
3 Compressors (G6)
Description
Type
RECIP MOTR - continued
Intercooler outlet temperature:
The interstage inlet temperature after
intercooling. -50 - 150 DEG F
[-45 - 65 DEG C];
Default:
*95* DEG F [*35* DEG C].
Driver Type:
Default: *MOTOR*
NONE- No driver
MOTOR- Motor driver
Turbine Press. - Gauge:
Max: 1,600 PSIG [11,000 KPA];
Default: *300* PSIG [*2,050* KPA]
Gear Reducer Symbol:
Default: gear reducer included if driver type specified,
otherwise none.
YES- Gear reducer required
NO- No gear reducer
Lube Oil System:
Default: *YES*
YES- Lube system required
NO- No lube oil system
Reciprocating gasoline engine drive includes integral
gas engine driver, gear reducer, baseplate, coupling,
interstage pots and coolers.
RECIP GAS
Material:
*CS*
Max: 6,000 PSIG [4,100 KPA]
Driver power:
Min: 100 HP;
Max: 10,000 HP
Design temperature inlet:
Default: *68* DEC F [*20* DEG C]
3 Compressors (G6)
3-9
Fans, Blowers (FN)
The distinction between the terms fan, blower and compressor is confusing;
however, a distinction may be made based upon the mechanical construction
of the machine and the pressure rise from inlet to outlet produced by the
machine.
The Air Moving and Conditioning Association, Incorporated (AMCA) has made
12.25 INCHES of water pressure rise the cut-off between fans and blowers.
Assuming an inlet pressure of 0 PSIG, a 12.25 INCHES of water pressure rise
corresponds to a compression ratio of 1.3. Machinery used for compression
ratios greater than 1.03 are called blowers or compressors. A pressure of
12.25 INCHES of water corresponds to 0.44 PSIG. It is common practice,
however, to call any centrifugal gas-moving machine a fan if its construction is
of sheet metal and the rotating element is wheel rather than an impeller.
Single-stage fans are made with pressure rises of 50 INCHES of water, and
two-stage fans with pressure rises up to 100 INCHES of water. Centrifugal
blowers (or turbo-blowers) are primarily of cast iron construction and the
rotating element is an impeller. Centrifugal blowers normally produce pressure
rises in the range of 1 to 40 PSI. Centrifugal blowers may be single- (one
impeller) or multi-stage (two or more impellers). A gas-moving machine that
produces a pressure rise of more than 40 PSI is called a compressor. Another
difference between compressors and blowers is that the
design pressure of a blower is never more than 100 PSIG, while compressors
are frequently designed for more than 100 PSIG. It should be noted, however,
that in the range of 1 to 40 PSI pressure rise with a design pressure less than
100 PSIG, the terms are used interchangeably.
With driver, listed in ascending capacity.
Description
Type
Single or multi-stage centrifugal turbo blower.
Heavy duty, low noise blower. For moving up to
150,000 CFM of air or other gas through a
system with a pressure drop from 1 to 10 PSI.
Typical applications include: supplying air to
wastewater treatment plant aeration basins;
supplying air to blast furnaces, cupolas and
converters; pneumatic conveying and supplying
combustion air. This item is a centrifugal turbo
blower.
CENT TURBO
Material:
*CS*
100 - 40,000 CFM [170 - 67,950 M3/H]
0.5 - 30.0 PSIG [3.5 - 205 KPA]
Speed:
900 - 3,600 RPM
3-10
3 Compressors (G6)
Fans, Blowers (FN) - continued
3 Compressors (G6)
3-11
Description
Type
Centrifugal fan.
CENTRIF
Applications include: pulling a gas stream through a
baghouse, supplying combustion air to boilers and
furnaces, boosting the pressure of the combustion
gases from a boiler to push the gasses up the boiler
stack, pneumatic conveying, solids drying and
classifying and ventilation.
Centrifugal fans are used to move gas through a low
pressure drop system. The maximum pressure rise
across a centrifugal fan is about 2 PSI. The most
typical materials of construction are carbon steel sheet
or plate casing, aluminum or carbon steel wheel (or
impeller) and carbon steel shaft. Fans may be
fabricated from a variety of other materials such as
stainless steel and FRP. Centrifugal fans are classified
according to the design of the wheel. The different
wheels are: radial blade type, forward-curved,
backward-curved, backward-inclined and airfoil.
Centrifugal fans are manufactured in sizes that range
from less than 100 CFM to 1,000,000 CFM.
Material:
*CS*
700 - 900,000 CFM [1,200 - 1,529,000 M3/H]
Note: Max flowrate for Standard duty = 150,000 CFM
[254,850 M3/H]
Min flowrate for Heavy duty = 50,000 CFM [84,950
M3/H]
Fan outlet gauge pressure:
0 - 15 IN H2O [0 - 3,700 PA];
Default:
*6* IN H2O [*1,500* PA]
Application:
*STD - Max flowrate 150,000 CFM [254,850 M3/H]
HVY - Min flowrate 50,000 CFM [84,950 M3/H]
Note: If you leave the Application field blank:
• If the input flow rate is < 150,000 CFM, the system
estimates a standard duty fan.
• If the input flow rate is => 150,000 CFM, the
system estimates a heavy duty fan.
Driver type:
*MOTOR
VFD
TURBINE
NONE
Note: For MOTOR or VFD, electrical bulks for the
motor hookup are generated. For TURBINE, additional
lines and loops for the turbine are generated. For
NONE, Driver cost = 0 and no electrical bulks for
hookup are generated.
3-12
3 Compressors (G6)
Description
Type
Propeller fan.
PROPELLER
Material:
*CS*
1,000 - 15,000 CFM [1,700 - 25,400 M3/H]
Rotary blower.
This general purpose blower includes inlet and
discharge silencers. Applications include: pneumatic
conveying, combustion air, exhausting vapors,
instrument air and aeration of fluids.
ROT BLOWER
A rotary blower is a positive displacement machine.
That is, a constant volume of inlet air (or other gas) is
compressed regardless of any changes in the
discharge pressure required by the system. The rotary
blower moves air in the following manner. Two figure
eight shaped impellers are mounted on parallel shafts
inside a casing and rotate in opposite directions. As
each impeller passes the blower inlet a volume of gas
is trapped, carried through to the blower discharge
and expelled against the discharge pressure. The
casing of the rotary blower is cast iron and the
impellers are ductile iron. Rotary blowers are
manufactured in standard sizes.
Material:
*CS*
100 - 4,000 CFM [170 - 6,700 M3/H]
2 - 15 PSIG [15 - 100 KPA];
Speed: 900 - 3,600 RPM
3 Compressors (G6)
3-13
Description
Type
Vaneaxial fan.
VANEAXIAL
Material:
*CS*
2,300 - 45,000 CFM [3.950 - 76,450 M3/H]
3-14
3 Compressors (G6)
4 Drivers
(G11)
Power Level
Standard Motor Sizes
Synchronous Motor Speeds (RPM)
Turbines (TUR)
4 Drivers (G11)
4-1
Electrical motors serve as the primary means of driving the rotating
equipment, for example, pumps, compressors and fans.
Motors are built in a wide range of enclosure types, rotating speeds and
horsepowers. Selection of a particular motor warrants careful consideration of
the motor’s application. The considerations at the site (temperature, air-borne
particles, moisture, oil vapor, dust, abrasive or conducting particles, corrosive
fumes or explosive gases), and the specific use of a motor (e.g., pump,
compressor or crusher driver) determine the hazards involved and the
protective measures required for safe operation. These considerations led to
motor classification by enclosure types.
Description
Type
Standard open drip-proof motors with vent openings
for indoor service:
OPEN
Driver Power:
0.75 - 50,000 HP [0.75 - 37,000 KW]
Enclosure Type:
Default: *STD*
STD- Standard indoor service (open drip- proof with
vent openings)
WPI- Normal outdoor service (weatherprotected (rain, snow, air-borne particles)
WPII- Severe outdoor service (outside
weather-protected service)
4-2
4 Drivers (G11)
Electrical Motors (MOT) - continued
Description
Type
OPEN - continued
Driver Type:
Default: *STD*
STD- Standard motor
Speed:
Range: (15 x HZ) - (60 x HZ) RPM; Default: *
(30 x HZ)* RPM
Synchronous motors with high efficiency at low speed
for large HP [KW] requirements, reciprocating
SYNCHRON
compressors, pump compressors, pumps,
crushers and mixers.
Driver Power:
200 - 20,000 HP [150 - 15,000 KW]
Enclosure Type:
Default: Water cooled if greater than 8,000 HP
[6,000], else standard.
STD- Standard outdoor service
WPI- Normal outdoor service
WPII- Severe outdoor service
TEWAC- Water cooled
Speed:
Range: (3.7 x HZ) - (30 x HZ) RPM; Default: *
(30 x HZ)* RPM
Totally-enclosed fan-cooled motors (TEFC)
ENCLOSED
The TEFC motor is especially suitable for outdoor use
involving severe environmental conditions. It can also
withstand severe operating conditions (heat, lint and
dirt) when used indoors.
The TEFC is a totally enclosed machine constructed to
prohibit the exchange of air between the inside and
outside of the casing. It is cooled by means of a fan
integral with the machine but external to the electric
parts. TEFC motors are available from 1 - 500 HP. For
severe service conditions requiring up to 200 HP, TEFC
motors are less costly and provide better protection
than weather-protected motors. Except for some
specially designed enclosures, the TEFC motor
provides the best protection against moisture,
corrosive vapors, dust and dirt.
4 Drivers (G11)
4-3
Description
Type
ENCLOSED - continued
Driver Power:
0.75 - 10,000 HP [0.75 - 7,100 KW]
Driver Type:
Default: Water cooled (TEWAC) if greater than
300 HP [224 KW], else fan cooled (TEFC).
STD- Standard motor
Speed:
Range: (20 x HZ) - (60 x HZ) RPM; Default: *(30 x
HZ)* RPM.
Explosion-proof motors for Class I Division 1
hazardous use.
EXP PROOF
Explosion-proof motors are required when the location
of the motor is classified according to the NEC
(National Electrical Code) as a Class I, Division 1,
Hazardous Area. Class I represents an area containing
flammable gases or vapors and Division 1 specifies
that hazardous atmospheres can occur under normal
operation conditions. The source of a hazardous
atmosphere is generally leakage from process
equipment (e.g., pumps or compressors) handling
combustible volatile liquids or combustible gases.
An explosion-proof motor is basically a TEFC motor
with heavier construction and more careful machining.
An explosion-proof motor has an enclosure designed
to withstand the explosion of a gas or vapor occurring
within it and to prevent the ignition of the atmosphere
surrounding the machine by sparks, flashes or
explosions from within. Explosion proof motors are
available up to 3,000 HP at 3,600 RPM.
Driver Power:
0.75 - 4,000 HP [0.75 - 2,800 KW]
Driver Type:
Default: *STD*
STD- Standard motor
Speed:
Range: (20 x HZ) - (30 x HZ) RPM; Default: *(30 x
HZ)* RPM.
4-4
4 Drivers (G11)
Description
Type
TEFC motor integral with variable speed drive.
Includes handwheel control of sheaves with a built-in
indicator and TEFC motor as an integral part of the
unit.
VARY SPEED
This component is used when there is an optimum
speed at which to run a process machine (e.g., pumps,
fans, mixers, dryers and crushers).
A mechanical speed drive permits the adjustment of
output speed by mechanical means (manually
adjusted). The motor speed (input speed) is geared
down by a system of pulleys to supply lower shaft
speeds (output speed) to process equipment. Available
output speeds range from approximately 5 - 4,000
RPM. Pulley ratios of input to output speeds range
from 2:1 through 10:1. Mechanical variable speed
drives typically range from 0.5 to 50 HP. Speed
adjustment can be either manual, by turning a
handle, or automatic. Although the mechanical
variable speed motor provides high efficiency
over the entire speed range, it does not supply a
high degree of accuracy in speed regulation.
(Variable frequency driver available with OPEN,
ENCLOSED, EXP PROOF.)
Low Speed:
(.09 x HZ) - (9.6 x HZ) RPM
High Speed:
(1.4 x HZ) - (58 x HZ) RPM
Driver Power:
0.5 - 400 HP [0.75 - 300 KW]
4 Drivers (G11)
4-5
Power Level
Power is supplied to a motor at a voltage level as follows.
Voltage Level (3 Phase Service)
Motor Size
US Country Base UK Country Base
Less than 1 HP [0.75 KW]
110 V
240v
1 HP to under MDP (*200* HP)
[.75 KW to under MDP (*150* KW)]
Low Voltage
*230/480* V
Low Voltage
*415* V
MDP (*200* HP) to 4,000 HP
[MDP (*150* KW) to 3,000 KW]
4,160 V
3,300 V
Greater than 4,000 HP [3,000 KW]
13,800 V
11,000 V
Frequency
60 Hertz
50 Hertz
10000 - 37000 KW: Increments of
1000 KW
4-6
4 Drivers (G11)
Standard Motor Sizes
HP
0.125
0.25
0.333
0.5
0.75
1
1.5
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
KW
0.75
1.11
1.50
2.22
3.0
4.0
5.5
7.5
11.0
15.0
18.5
22.0
30.0
37.5
45.0
55.0
75.0
80
80
85
95
100
106
112
118
125
132
140
150
160
170
180
190
200
212
224
236
250
265
280
300
315
335
375
400
425
450
475
500
530
560
560
600
630
670
710
750
800
900
1000
1120
1250
1400
1600
1800
2000
2240
2500
2500
2800
3150
3550
4000
4500
5000
5600
6300
7100
8000
9000
10000
200 - 500 HP:increments of 50
4 Drivers (G11)
4-7
Synchronous Motor Speeds (RPM)
60 Hertz Service
1800
1200
900
720
600
514
450
400
360
327
300
277
257
240
225
4-8
50 Hertz Service
1500
1000
750
600
500
428
375
333
300
272
250
231
214
200
187
4 Drivers (G11)
Turbines (TUR)
Description
Type
Steam turbine driver includes condenser and
accessories.
CONDENSING
Material:
Default: *CS*
Power Output:
10 - 30,000 HP [8 - 22,300 KW]
Steam Gauge Pressure:
Max: 1,600 PSIG [11,000 KPA];
Speed:
Max: 3,600 RPM; Default: *3,600* RPM
Non-condensing type steam turbine driver includes
accessories.
NON COND
Material:
Default: *CS*
Power Output:
10 - 30,000 HP [8 - 22,300 KW]
Max: 1,600 PSIG [11,000 KPA];
Speed:
Max: 3,600 RPM;
4 Drivers (G11)
4-9
Description
Type
Gas turbine includes fuel gas combustion chamber and GAS
multi-stage turbine expander.
Material:
Default: *CS*
Power Output:
1,000 - 500,000 HP [750 - 375,000 KW]
Turbo expander includes only the expander (turbine)
part and any spare cartridges. It does not include
compressor (booster) part. So, all input/output
variables in the model refer to an expansion process,
and the resulting cost and weight data belong only to
the expander part.
TURBOEXP
Note: The material used by the system is A3003
(aluminum).
Range: 5 - 200,000 CFM [8.5 - 339,800 m3/hr]
Required field
Range: (>0) - 3000 PSIG [(>0) - 20,684 kPag]
Required field
Range: -450 to 600 DEG F [-267 to 315 DEG C]
Range: 0 - 1 ,000 PSIG [0 - 6,894 kPag]
Required field
Power output:
Range: (>0) - 2,000 HP [(>0) - 1,500 kW]
Molecular weight:
Range: 1 - 500
Default: *29*
Default molecular weight is that of air
Range: 1.04 - 2
Default: *1.4*
Default specific heat ratio is that of air
Range: 0.05 - 3
Default: *1*
Default compressibility factor assumes an ideal gas
Isentropic efficiency:
Range: 30 - 100 PERCENT
Default: *85* PERCENT
Number of spare cartridges:
Min: 0
Default: *0*
4-10
4 Drivers (G11)
5 Heat Transfer
(G10)
Reboilers (RB)
Furnaces, Process Heaters (FU)
TEMA Exchanger Construction Nomenclature
Icarus Supported TEMA Types
5 Heat Transfer (G10)
5-1
Heat exchangers are used to transfer heat from one fluid to another fluid. In
the terminology of chemical engineering, a fluid may be either a gas or a
liquid. Therefore, when we say we are transferring heat from one fluid to
another, we can mean either a gas-gas exchanger, a liquid-liquid exchanger or
a gas-liquid exchanger.
Heat exchangers may be called by other names depending upon their specific
purpose. If a process fluid is being cooled with water, the term “cooler” is often
used. If a gaseous process fluid is cooled with water until it becomes a liquid,
the term “condenser” is used. If a liquid process fluid is heated (usually with
steam) until it turns into a gas, the term “vaporizer” is used. If a process fluid
is heated (usually with steam) the term “economizer” is used. If two process
fluids exchange heat, the term heat exchanger is used.
The most common type of heat exchanger, and therefore, the kind described
here, is the shell and tube heat exchanger. The shell and tube heat exchanger
consists of a bundle of tubes. Each tube is usually 3/4 or INCH in outside
diameter and 20 to 40 FEET long. The tube bundle is held in a cylindrical shape
by plates at either end called “tube sheets.” The tube bundle is placed inside a
cylindrical shell. The design of the shell and tube heat exchanger is such that
one fluid flows inside the tubes, while the other fluid flows over the outside of
the tubes. Heat is transferred through the tube walls. The size of a heat
exchanger is defined as the total outside surface area of the tube bundle.
Wide variety of materials: floating head, fixed tube sheet, U-tube exchangers,
multiple shells/passes, TEMA Class B and other types.
5-2
Heat Exchangers (HE) - continued
Description
Type
Air cooler with variety of plenum chambers, louver
arrangements, fin types (or bare tubes), sizes,
materials, freestanding or rack- mounted, multiple
bays and multiple services within a single bay.
AIR COOLER
Bare tube area 1st service:
Primary or single service. Total bare tube surface area
for primary service. If the exchanger is a single
service, then this is the total bare tube surface area.
The surface area is for all bays.
Tube material 1st service:
Primary or single service; Default: *A 179*. See
Chapter 28 for tube materials.
Design gauge pressure 1st serv.:
Inlet temperature 1st service:
Tube outside diameter 1st serv.:
Default: *1.0* INCHES [*25.0* MM]
Tube wall thickness 1st service:
The wall thickness of tubing used for primary or single
services, in inches or BWG rating. For grooved tubes,
specify the thickness under the groove. Thickness may
be entered as a positive signed value in decimal
INCHES [MM] or as a negative signed integer value of
BWG (-1 to -24 BWG). If no value is specified, the
system calculates a value based on tube material,
temperature and pressure of service, with minimum of
0.1080 INCHES [2.74 MM] per API 661 code.
Corrosion allowance 1st service:
Default: 0.0, except CS: 0.125 INCHES [3 MM]
Tube length:
Range: 4 - 60 FEET [1.25 - 18.0 M]
Bay width:
Max: 30.0 [9.0 M]
Height: This is the leg height for air coolers at grade.
Default: *0.0* (rack mounted)
Number of walkways:
Default: *2*. Does not apply to Aspen In-Plant Cost
Estimator.
Plenum type symbol:
Default: *TRNS*
PANL- Panel shaped plenum
TRNS- Transition shaped
NONE- No plenum
5-3
Description
Type
AIR COOLER - continued
Louver type symbol:
Default: *FACE*
FACE- Face louvers only
SIDE- Side louvers only
BOTH- Face + side louvers
NONE- No louvers
Fin type symbol:
Default: L-footed if temperature below
400 DEG F [205 DEG C], esle embedded.
E - Embedded
L - L-foot tension wound
W - Wheel
X - Extracted
NONE - Bare tubes
Fin pitch:
Number of fin tubes per INCH [per 25 MM],
ignore if bar tube specified. Range: 6.0 - 20.0;
Default: *10.0*
Fin material symbol:
Ignore this field for bare tubes. Default: *AL*.
AL - Aluminum fins
CS - Carbon steel fins
CU - Copper fins
SS - Stainless steel fins
Tube fin height:
Ignore this field for bare tubes;
Range: 0.250 - 2.50 INCHES [10.0 - 65.0 MM];
Default: *0.625* INCHES [*15* MM]
Number of tube rows:
Max: 13
Tube pitch:
Default: *2.25* INCHES [55.0 MM]
Number of fans per bay:
Range: 1-3
Fixed tube sheet shell and tube exchangers.
FIXED T S
TEMA type BEM fixed tube sheet
The fixed tube sheet shell and tube heat exchanger is
applicable to trim cooler and other low temperature
applications, as well as services where the shell side
fluid is non-fouling, such as steam, dowtherm and
gasses. A fixed tube sheet heat exchanger has its tube
sheets fixed to both ends of the shell, with or without a
shell expansion joint.
5-4
Description
Type
FIXED T S - continued
Fixed tube sheet heat exchangers are more
economical to fabricate than floating head heat
exchangers, but unless an expansion joint is placed in
the shell the difference in temperature between the
shell and tubes must be small or the unequal thermal
expansion of the shell and tube bundle will cause
unacceptable mechanical stresses. The fixed tube
sheet design also does not allow the tube bundle to be
removed. Therefore, fixed tube sheet heat exchangers
are limited to clean services and services where the
dirt and scale on the outside surface of the tubes is
easily cleaned by chemical means.
Heat transfer area:
Enter either heat transfer area or number of
shells, tubes/shell and tube data.
Number of shells:
Tube material:
Default: A 214 to 900 DEG F [482 DEG C],
304S for higher temperatures. See Chapter 28 for
tube materials.
Tube design gauge pressure:
Tube design temperature:
Default: 400 DEG F [200 DEG C] for copper alloys;
other material: 640 DEG F [340 DEG C]
Tube operating temperature:
Default: design temperature
Tube outside diameter:
0.25 - 6.0 INCHES [6 - 150 MM];
Shell material:
Default: A285C to 900 DEG F [482 DEG C], SS304 for
higher temperatures. See Chapter 28 for materials.
Shell design gauge pressure:
Shell design temperature: Default: 400 DEG F [200
DEG C] for copper alloys; *650* DEG F [*340* DEG C]
for other materials.
5-5
Description
Type
Shell operating temperature:
Tube side pipe material:
See Chapter 18 for pipe materials.
Shell side pipe material:
Number of tubes per shell:
Enter either heat transfer area or number of shells,
tubes/shell and tube data.
Tube length extended:
8 - 60 FEET [2.5 - 18 M];
Default: *20* FEET [*6* M]
Tube gauge:
Enter tube gauge or thickness, not both,
including corrosion allowance; 1 - 24 BWG
Tube wall thickness:
including corrosion allowance; 0.02 - 0.34 INCHES
[0.6 - 8.6 MM]
Tube corrosion allowance:
Default: 0.0025 INCHES [0.06 MM] for CS, 0.0 for
other materials
Tube seal type:
Default: *SEALW*
EXPND- Expanded tube-to-tubesheet joints
SEALW- Seal welded tube joints
STRNW- Strength welded tube joints
Tube pitch:
1.25 x tube outside diameter
Tube pitch symbol:
Default: *TRIANGLE*
DIAMOND- Diamond tube pitch
SQUARE- Square tube pitch
TRIANGULAR- Triangular tube pitch
Shell diameter:
Max: 192.0 INCHES [4,875.0 MM]
Shell wall thickness:
Shell thickness including corrosion allowance.
Shell corrosion allowance:
Default: 0.125 INCHES [3 MM] for CS,
0.0 for other materials.
5-6
Description
Type
Expansion joint:
Default: *NO*
NO- No expansion joint in shell
YES- Expansion joint required in shell
Tube sheet material:
See Chapter 28 for tube materials.
Tube sheet corrosion allowance:
Default: lesser of 50 x tube corrosion
allowance or 0.25 INCHES [6 MM].
Channel material:
Default: tubesheet material. See Chapter
28 for materials.
Cladding thickness:
Default: 0.125 INCHES [3 MM] if cladding material
specified, otherwise 0.0.
Cladding material:
See Chapter 28 for material selection.
Cladding location:
Default: *SHELL*
SHELL- Cladding on shell side only
TUBE- Cladding on tube side only
BOTH- Cladding on both shell and tube sides
Number of tube passes:
Default: *1*
Number of shell passes:
Default: *1*
Stress relief:
Weld X-ray:
Max: 100; Default: *20*
TEMA type:
Default: BEM for 1 shell pass, BFM for 2 shell passes.
Vendor grade:
Default: *HIGH*
STAND - Standard vender
HIGH - Specialty vender - high grade/custom work
Regulation type:
Japanese country base only. Required government
regulation and testing; Default: *NONE*
NONE - No special regulations
PV - Pressure vessel regulations
HPG - High pressure gas regulations
5-7
Description
Type
Floating head shell of 48 INCHES [1200 MM]
FLOAT HEAD
maximum and exchanger.
Applicable to any heat exchange application, but not
normally used for clean and/or low temperature
services where the fixed tube sheet exchanger is
usually the more economic choice.
The floating head heat exchanger accommodates the
differential thermal expansion of tube bundle and
shell, and also allows the tube bundle to be completely
removed from the shell. The floating head heat
exchanger is consequentially specified for services
where the shell size of the tube bundle is subject to
fouling and services which involve large temperature
differentials between shell side and tube side fluids.
Heat transfer area:
Number of shells:
tube/shell and tube data.
Tube material:
Default: A 214 to 900 DEG F [482 DEG C],
304S for higher temperatures. See chapter 28 for tube
materials.
650 DEG F [340 DEG C] other material
0.25 - 6.0 INCHES [6 - 150 MM];
Shell material:
Default: A285C to 900 DEG F [482 DEG C], SS304 for
higher temperatures
Default: 150 PSIG [1,000 KPA]
5-8
Description
Type
FLOAT HEAD - continued
Shell design temperature:
Default: 400 DEG F [200 DEG C] for cooper alloys;
650 DEG F [340 DEG C] for other material
See Pipe Materials in Chapter 18.
See Pipe Materials in Chapter 18.
Enter either heat transfer area or number
of shells, tubes/shell and tube data.
8 - 60 FEET [2.5 - 18 M];
Tube gauge:
including corrosion allowance; 1-24 BWG
including corrosion allowance; 0.02 - 0.34 INCHES
[0.6 - 8.6 MM]
Default: 0.0025 INCHES [0.06 MM]
for CS, 0.0 for other materials
Tube seal type:
Default: *SEALW*
SEALW- Seal welded tube joints
Tube pitch:
Default: 1.25 x tube outside diameter
Tube pitch symbol:
Default: *TRIANGULAR*
TRIANGLE- Triangular tube pitch
Shell diameter:
Max: 192.0 INCHES [4,875.0 MM]
5-9
Description
Type
FLOAT HEAD - continued
Expansion joint:
Default: *NO*
NO - No expansion joint in shell
YES - Expansion required in shell
See Tube Materials in Chapter 28.
Default: Lesser of 50 x tube corrosion allowance, or
0.25 INCHES [6 MM].
Channel material:
Default: tubesheet material. See Tube Materials in
Chapter 28.
Cladding thickness:
Cladding material:
See cladding material in Chapter 28.
Cladding location:
Default: *SHELL*
SHELL - Cladding on shell side only
TUBE - Cladding on tube side only
BOTH - Cladding on both shell and tube sides
Default: *2*
Default: *1*
Stress relief:
CODE - Provide stress relief if code required
Weld X-ray:
Max 100; Default: *20*
TEMA type:
Default: BES for 1 shell pass, BFS for 2 shell passes.
Vendor grade:
Default: *HIGH*
STAND - Standard vendor
HIGH - Specialty vendor - high grade/custom work
Regulation type:
For Japanese country base only. Required
government regulation and testing. Default: *NONE*
PV - Pressure vessel regulations
HPG - High pressure gas regulations
5-10
Description
Type
U-tube shell and tube exchangers. TEMA type BEU U- U TUBE
Tube.
U-tube shell and tube exchangers are normally used in
those services where the tubeside fluid is non-fouling
or where the deposits formed are easily removed with
chemical cleaning. Since the tube bundle is
removable, the fluid in the shell side can be fouling.
Since the U-tube design eliminates one tube sheet,
these exchangers are often used for high pressure
applications.
As the name indicates, all the tubes are U-shaped.
Consequentially, there is only one tube sheet. The
tube side fluid enters one leg of the U-tube and exits
from the other leg. The U-tubes are free to expand
inside the exchanger shell; thus, a large temperature
differences between shell side and tube side fluids can
be handled. The U-tube bundle is usually removable
for inspection and cleaning. The inside of the U-tubes
are hard to clean because of the U-bend. U-tube heat
exchangers are unsuitable for handling erosive fluids
because the U-bends rapidly wear out.
Heat transfer area:
Number of shells:
Tube material:
Default: *A 214* to 900 DEG F [482 DEG C], *304S*
for higher temperatures. See Chapter 28 for tube
data.
Default: *400* DEG F [*200* DEG C] for copper
alloys; other material: *650* DEG F [*340* DEG C]
Range: 0.25 - 6.0 INCHES [6 - 150 MM];
Shell material:
Default: *A285C* to 900 DEG F [482 DEG C],
SS304 for higher temperatures
5-11
Description
Type
U TUBE - continued
Default: *400* DEG F [*200* DEG C] for
copper alloys; *650* DEG F [*340* DEG C] other
materials
Range: 8 - 12 FEET [2.5 - 36 M];
Default: *40*Feet [*12* M]
Tube gauge:
Enter tube gauge or thickness, not both, including
corrosion allowance. Range: 1-24 BWG
corrosion allowance. Range:0.02 - 0.34 INCHES
[0.6 - 8.6 MM]
Default: *0.0025* INCHES [*0.06* MM] for CS, *0.0*
for other materials.
Tube seal type:
Default: *SEALW*
EXPD - Expanded tube-to tubesheet joints
SEALW - Seal welded tube joints
STRNW - Strength welded tube joints
Tube pitch:
Tube pitch symbol:
Shell diameter:
Max: 192 INCHES [4,875 MM]
Default: *0.125* INCHES [*3* MM] for
CS, *0.0* for other materials
5-12
Description
Type
U TUBE - continued
Expansion joint:
Default: *NO*
NO - No expansion joint in shell
YES - Expansion joint required in shell
*0.25* INCHES [*6* MM]
Channel material:
See Chapter 28 for materials.
Cladding thickness:
Default: *0.125* INCHES [3 MM] if cladding material
is specified; otherwise *0.0*
Cladding material:
See Chapter 28 for cladding materials.
Cladding location:
Default: *SHELL*
Default: *2*
Default: *1*
Stress relief:
Default: See Project Design Basis.
Weld X-ray:
TEMA type:
*BEU* for 1 shell pass, *BFU* for 2 shell passes.
Vendor grade:
Default: *HIGH*
STAND - Standard vendor
HIGH - Specialty vendor - high grade/custom work
Regulation type:
Japanese country base only. Required government
regulations and testing.
Default: *NONE*.
PV- Pressure vessel regulations
HPG- High pressure gas regulations
5-13
Description
Type
Fixed tube, float. head, u-tube exchanger
TEMA EXCH
This model merges the three TEMA heat exchangers,
which are retained for compatibility purposes (in
earlier system versions, changing the type of TEMA
heat exchanger required that one delete the entry and
specify another heat exchanger).
Heat transfer area: Enter either heat transfer area
or no. of shells, tubes/shell and tube data.
Number of shells: Enter either heat transfer area or
no. of shells, tubes/shell and tube data.
Front end head type: Use front head type, shell type
and rear head type to construct TEMA type symbol.
Front head type options:
A- Channel and removable cover
B- Bonnet integral cover
C- Tubesheet channel integral, remov. cover
N- Tubesheet channel integral, remov. cover
Shell TEMA symbol: Use front head type, shell type
and rear head type to construct TEMA type symbol.
Shell type options:
E- One pass shell
F- Two pass shell with longitudinal baffle
G- Split flow
H- Double split flow
J- Divided flow
X- Cross flow
Rear end head type:
Use front head type, shell type and rear head type to
construct TEMA type symbol. Rear head type options:
L - Fixed tubesheet, channel removable cover
M - Fixed tubesheet, bonnet integral cover
N - Fixed tubesheet, channel integral, remov.
P - Outside packed floating head
S - Floating head with backing device
T- Pull through floating head
U - U-tube bundle
W - Externally sealed floating tubesheet
Heat exchanger design option:
*<BLANK>*- Standard exchanger design
TBWNB- Tube bundle design only, w/o system bulks
Design/cost option for TBWNB only
5-14
Description
Type
TEMA EXCH - continued
Tube material: Default: CS to 900 DEGF [482 DEGC],
or else SS; see Proj Basis spec for welded/smls.
CS- Carbon steel
A 179- Seamless CS
A 214- Welded carbon steel
A 209- C - .5Mo
A213C- 1.25Cr - .5Mo - Si
A213F- 5Cr - .5Mo
304LW- 304L welded
316LW- 316L welded
321S- SS321 seamless
347S- SS347 seamless
C 20- Carpenter 20
TI50A- Titanium
NI200- Nickel
INCNL- Inconel
MONEL- Monel
*150 PSIG [1,000 KPA]*
Default: 400 DEGF [200 DEGC] for copper alloys;
other mat’l: 650 DEGF [340 DEGC
*1.0 INCHES [25 MM]*, MIN: 0.25 INCHES [6 MM],
MAX: 6.0 INCHES [150 MM]
Shell material:
Default: A285C to 900 DEGF [482 DEGC], SS304 for
higher temperatures.
CS- Carbon steel
A 515- A 515
A204C- C - .5Mo
A387B- 1Cr - .5Mo
A387D- 2.25Cr - 1Mo
SS304- SS304
SS316- SS316
SS321- SS321
SS347- SS347
SS410- SS410
SS430- SS430
304L- 304L
316L- 316L
NI- Nickel
5-15
Description
Type
INCNL- Inconel
*150 PSIG [1,000 KPA]*
Default: 400 DEGF [200 DEGC] for copper alloys; 650
DEGF [340 DEGC] other mat’l
A 53- A 53
A 106- A 106
A333C- 3.5Ni
A335C- A.25Cr - .5Mo - Si
304P- SS304
304LP- 304L
316P- SS316
316LP- 316L
321P- SS321
AL- Aluminum
NI- Nickel
MONEL- Monel
INCNL- Inconel
TI- Titanium
HAST- Hastelloy
See materials listed above for Tube side pipe material
Enter either heat transfer area or no. of shells, tubes/
shell and tube data.
For U-tube: MIN: 8 FEET [2.5M], MAX: 120 FEET
[36M], else
MIN: 4 FEET [1.25M], MAX: 60 FEET [18M]
Tube gage:
MIN: 1 BWG,
MAX: 24 BWG
corrosion allowance.
MIN: 0.02 INCHES [0.6 MM],
MAX 0.34 INCHES [8.6 MM]
5-16
Description
Type
Default: 0.0025 INCHES [0.06 MM] for CS, 0.0 for
other materials.
Tube seal type:
*SEALW*- Seal welded tube joints
Tube pitch:
Default: 1.25 x tube outside diameter.
Tube pitch symbol:
Shell diameter:
Shell thickness including corrosion all.
Default: 0.125 INCHES [3 MM] for CS, 0.0 for other
materials.
Expansion joint:
*NO*- No expansion joint in shell
YES- Expansion joint required in shell
CS- Carbon steel
A 515- A 515
A204C- C - .5Mo
A387B- 1Cr - .5Mo
A387D- 2.25Cr - 1Mo
SS304- SS304
SS316- SS316
SS321- SS321
SS347- SS347
SS410- SS410
SS430- SS430
304L- 304L
316L- 316L
NI- Nickel
INCNL- Inconel
Default: lesser of 50 x tube corr. all., or 0.25
INCHES [6 MM].
Channel material:
Default: tubesheet material
5-17
Description
Type
Cladding thickness:
specified; otherwise: 0.0
Cladding material:
SS304- SS304
SS316- SS321
SS347- SS347
SS410- SS410
SS430- SS430
304L- 304L
316L- 316L
NI200- Ni 200
NI201- Ni 201
MONEL- Monel
INCNL- Inconel
I800- Ni-Fe-Cr
I825- Ni-Fe-Cr-Mo-Cu
C 20- Carpenter 20
TI- Titanium
HASTB- Hastelloy B
HASTC- Hastelloy C
Cladding location:
*SHELL*- Cladding on shell side only
Number of tube passes: * 1*
Number of shell passes: * 1*
Stress relief:
Default: see Area Design Basis.
Weld X-ray:
* 20*, MAX: 100
Vendor grade:
STAND- Standard vendor
*HIGH*- Specialty vendor for high grade or
custom work
Regulation type:
only for Japanese country base, which requires
government regulation and testing.
*NONE*- No special regulations
PV- Pressure vessel regulations (Japan)
HPG- High pressure gas regulations (Japan)
- Continued next page -
5-18
Description
Type
The following three options can be found under "Heat exchanger design option".
•
•
•
Blank
Standard exchanger design
TBWNB Tube bundle design only, w/o system bulks
STABN Stabbed-in tube bundle design only, w/o system bulks
The third option (STABN) is available in the 2004 release. The "Standard exchanger
design" option would cost a regular heat exchanger (shell, tubes, baffles, etc.) and its
bulks, while TBWNB would cost a "tube bundle design only without any system bulks."
TBWNB would not generate any shell and heads, but it will include tubes, internals/
baffles, and tube sheet.
The STABN option is a variation of TBWNB with the following major differences from
TBWNB.
In STABN:
• The tube bundle is horizontally installed (stabbed) into the vertical vessel (tower),
in a way that the tube-side flow inlet/outlet headers stay outside the vessel beyond
the tubesheet.
• The front head is also included to act as a cap of the inlet/outlet headers for the
tube-side flow.
• STABN also costs a reboiler tub and support arrangement for the tube bundle. The
reboiler tub inside the vessel is designed to bear the liquid held-up in the tub
around the tube bundle to avoid the dry-out. The tub is designed to
contain and bear the hydrostatic load of the liquid held-up. The overall hydrostatic
load on the tub bottom is eventually supported by an I-beam design running in the
middle of the vessel along its diameter.
5-19
Description
Type
Pre-engineered (standard) U-tube exchanger for use PRE ENGR
as a sample cooler or other miscellaneous application.
Heat transfer area:
tubes and tube data. Range: 3.50 - 120.0 SF
[0.33 - 11.0 M2]
Tube material:
Default: *CA443*
A 179- Seamless CS
304LW- 304L welded
A 192- Seamless CS
316W- 316 welded
A 214- Welded carbon
316LW- 316L welded
steel
CA122- Cu seamless
304S- 304 seamless
CA706- Cu-Ni seamless
304LS- 304L seamless CA715- Cu-Ni seamless
316S- 316 seamless
CA443- Admiralty brass
316LS- 316L seamless CA444- Admiralty brass
304W- 304 welded
CA445- Admiralty brass
Range: 0.5 - 1.5 INCHES
[12.0 - 38.0 MM]; Default: *0.75* INCHES [*19* MM]
Shell material:
Default: *A285C*
A285C- Carbon steel
A 516- A-516
SS304- SS304
304L- 304L
SS316- SS316
316L- 316L
5-20
Description
Type
PRE ENGR - continued
Number of tubes:
Enter either heat transfer area or number of tubes and
tube data.
Enter either heat transfer area or number of tubes and
tube data. Range: 4.00 - 16.0 FEET [1.20 - 4.80 M]
Tube gage:
including corrosion allowance. Range: 16 - 20 BWG
corrosion allowance; Range: 0.035 - 0.065 INCHES
[0.900 - 1.65 MM]
for CS, *0.0* for other materials
Tube pitch:
Default: *.25 x tube outside diameter*
Tube pitch symbol:
Shell diameter:
Range: 4.00 - 10.00 INCHES
[102.0 - 254.0 MM]
Default: *0.125* INCHES [*3* MM] for CS, *0.0* for
other materials
5-21
Description
Type
Electric immersion tank heater.
HEATER ELC
Material:
Default: *CU*
CU- Copper
SS304- SS304
Power output:
Range: 6 -200 KW
Heating/cooling coil with spiral or serpentine coil of
HEATER STM
bare pipe, use as tank heater or column tray cooler to
keep the contents of a tank from solidifying or
becoming too viscous to pump.
This item is a steam coil. A steam coil is a long length
of pipe that covers the bottom of a tank usually in a
spiral or serpentine pattern. Steam is passed through
the coil to heat the contents of the tank. If cooling
water was passed through the coil instead of steam,
this item would be a cooling coil.
This is normally a field fabricated item.
Material:
Default: *CS*
CS- Carbon steel316LP- 316L
SS- Stainless steel321P- SS321
A333C- 3.5 NiCU- Copper
A335C- 1.25 Cr - .5 Mo - SiNI- Nickel
A335F- 5 Cr - .5 MoMONEL- Monel
304LP- 304LINCNL- Inconel
316P- SS316
Heat transfer area:
Range: 1 - 25,000 SF [0.1 - 2,300 M2]
Pipe diameter:
Range: 1 - 6 IN DIAM [25 - 150 MM DIAM]
Bare-tube double-pipe heat exchanger.
JACKETED
Applicable to any heat transfer application where only
a small amount of heat transfer surface area is
required.
This item is a hairpin heat exchanger. One or more
finned or bare U-shaped tubes are supported
concentrically inside a U-shaped
shell.
5-22
Heat Exchangers (HE) - continued.
Description
Type
JACKETED - continued
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Heat transfer area:
10 - 1,000 SF [1 - 90 M2]
Tube length:
Range: 8 - 25 FEET [2.5 - 7.5 M];
Default: *1*
1- 1 tube per shell
7- 7 tubes per shell
Design gauge pressure:
Max: 6,000 PSIG [40,000 KPA]
Design temperature:
Max: 1,200 DEG F [645 DEG C]
Longitudinal finned double-pipe heat exchanger.
Hairpin sections are connected in series or parallel.
FIN TUBE
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Heat transfer area:
Enter total heat transfer area (i.e., total extended
surface or finned tubes).
Range:
70 - 10,000 SF [7 - 920 M2]
Tube length:
Range: 8 - 25 FEET [2.5 - 7.5 M];
Number of fins:
Range: 12 - 48; Default: *24*
Max: 6,000 PSIG [40,000 KPA]
Default: *1*
1- 1 tube per shell
7- 7 tubes per shell
5-23
Description
All-graphite heat exchanger.
Type
CROSS BORE
Material:
Default: *GRAPH*
Heat transfer area:
Range: 8 - 150 SF [1.0 - 13.5 M2]
Rietz type thermascrew conveyor with motor
and drive.
ONE SCREW
Material:
Default: *CS*
CS- Carbon steel
SS304- SS304
Heat transfer area:
10 - 400 SF [1 - 37 M2]
Twin screw thermascrew conveyor with motor
and drive.
TWO SCREW
Material:
Default: *CS*
CS- Carbon steel
SS304- SS304
Heat transfer area:
10 - 400 SF [1 - 37 M2]
Graphite tube with carbon steel shell exchanger.
SHELL TUBE
Heat transfer area:
Range: 80 - 9,730 SF [7.5 - 870 M2]
Tube length:
Range: 6 - 20 FEET [2 - 6 M]
5-24
Description
Spiral plate heat exchanger.
Type
SPIRAL PLT
Material:
Default:*SS304*
SS304- SS304
SS316- SS316
TI- Titanium
HAST- Hastelloy
Heat transfer area:
Range: 40 - 1,330 SF [4 - 123 M2]
Range: 150 - 300 PSIG [1,000 - 2,000 KPA];
Default: 150 PSIG [1,000 KPA]
Tank suction heater without tank.
SUC HEATER
Material:
Default: *CS*
Heat transfer area:
Range: 135 - 4,000 SF [13 - 370 M2]
Waste heat boiler for generation of steam, hot WASTE HEAT
gas or liquid heating medium.
A waste heat boiler is used to generate steam
from heat that would otherwise be wasted. A
waste heat boiler is essentially the convection
section only of a normal water-tube gas or
liquid boiler. The heating medium is a hot gas
or liquid produced by exothermic chemical
reactions, regeneration of cracking catalyst,
etc. The flow rate is used only to calculate
piping diameters for the P&ID.
A steam production rate can be entered in this
field. If other flow types are needed, piping
diameters may need to be revised. The
equipment cost is determined solely by the
heat transfer area.
Material:
Default: *CS*
Flow Rate:
Steam production rate (lb/hr or kg/hr)
Heat transfer area:
Range: 1,300 - 10,000 SF [125 - 925 M2]
5-25
Description
Type
Plate and frame heat exchanger.
PLAT FRAM
Plate material:
Default: *SS304*
SS304- SS304
SS316- SS316
S04L- 304L
S16L- 316L
HAST- Hastelloy
Heat transfer area:
Range: 10 - 2,000 SF [1.0 - 185 M2]
Number of plates:
Max: 500
Max: 350 PSIG [2,410 KPA];
Design temperature:
Sanitary corrugated double pipe exchanger
CORRUGATED
Used to heat, cool, and pasteurize a variety of food
products, like concentrates and dairy by-products.
Tube material:
*SS316*- SS316
AL6XN- High Cr, Mo+Ni. Super-austentic
stainless steel.
Double pipe size:
Inch-Pound
Symbol
Outer
Tube
3x20
3 Inches
Inner
Tube
2 Inches
Metric
Outer
Tube
75 MM
Inner
Tube
50 MM
4x25
4 Inches 2.5 Inches 100 MM
60 MM
4x30
4 Inches
3 Inches
100MM
75 MM
5x30
5 Inches
3 Inches 125 MM
75 MM
6x40
6 Inches
4 Inches 150 MM 100 MM
(Close-up of piping)
Total tube area:
Required: any two must be entered: total area, tube
length/pass, number of passes.
Tube length per pass:
Any two must be entered: total area, tube length/
pass, number of passes.
5-26
Description
Type
CORRUGATED - continued
Any two must be entered: total area, tube length/
pass, number of passes.
Frame option:
*INCL*- Frame is included
HUNG- Frame is not included
Water heater (shell+tube - hot water set)
HOT WATER
Used mainly with a plate heat exchanger to
provide hot water for heating various process
liquids. Steam is supplied to the shell side. Since
this is a sanitary item, material of construction is
SS316.
Water flow rate:
MAX: 400 GPM [25 L/S]
Temperature rise:
MAX: 50 DEG F [27 DEG C]
SS skid water pipe required:
*NONE*- Not included
INCL- Included
Expansion tank:
INCL- Included
Condensate return pump:
INCL- Included
Sanitary multi-zone plate+frame exchanger
MULTI P F
Plates are of the vertical flow type. Alternate plates
can be inverted to obtain desired flow arrangement.
Frame consists of a head and end support connected
by a top carrying bar and a bottom guide bar to form a
rigid unit supporting the plates.
Plate material:
*SS*- SS304
TI- Titanium
5-27
Description
Type
MULTI P F - continued
Frame material:
Default: SS for plate areas equal to or less than 1.87
SF [0.174 M2], else SSCLD.
SS- Stainless steel. Only available for plate areas
equal to or less than 1.87 SF [0.174 M2]
SSCLD- SS clad carbon steel. Only available for plate
areas greater than 1.87 SF [0.1737 M2].
CS- Carbon steel. Available for all plate areas.
Area per plate:
MIN: 0.27 SF [0.025 M2], MAX: 6.0 SF [0.557 M2].
The maximum number of plates will depend upon the
area per plate. There are seven standard plate areas:
Plate Area
SF
M2
Max. No. of Plates
In All Zones
0.27
0.025
152
0.92
0.085
200
1.81
0.168
150
1.87
0.173
200
3.75
0.348
420
5.6
0.520
600
6.0
0.557
550
Plate area Zone 1:
Required: enter the total area or no. of plates for zone
1, other zones optional.
Number of plates Zone 1:
Required: enter the total area or no. of plates for zone
1, other zones optional.
Plate area Zone 2:
Enter either total area or no. of plates for Zone 2.
Plate area Zone 3:
5-28
Description
Type
Sanitary direct steam heat module
STM HE MOD
A custom-built skid that injects steam directly
into a product. The skid includes a steam filter
and separator, as well as instrumentation for
temperature and flow control. Local temperature
and pressure indication is provided. The module
also includes a regulator for the steam pressure,
automatic isolation values, and piping on the
skid.
Material of construction is SS316.
Liquid flow rate:
Input required. GPM [L/S].
Temperature rise:
Input required. DEG F [DEG C].
Specific heat:
Default: *0.85* BTU/LB/F [*3.56* KJ/KG/K]
5-29
Reboilers (RB)
Reboilers are a special kind of shell and tube heat exchanger specifically
designed to add heat to distillation columns.
Liquid from the bottom of the distillation column flows over the reboiler tubes
picking up heat from a hot fluid, such as steam, which is flowing inside the
reboiler tubes. The liquid from the column is vaporized and returned to the
column.
These are similar to the shell and tube heat exchanger, except that the shell is
considerably larger than the tube inside. The design provides space for vaporliquid disengagement so that only vapor is returned to the distillation column,
not a vapor-liquid mixture.
Description
Type
Kettle reboilers with floating head.
KETTLE
Kettle reboilers are used when the hydrostatic head
above the reboiler varies, when the operating pressure
is in the high vacuum range or when there is a low
percentage of volatiles (e.g., less than 5%) in the feed
to the reboiler.
A “Kettle” reboiler is a shell and tube heat exchanger
used to supply heat to a distillation column. Liquid
from the bottom of the column enters the shell of the
reboiler through nozzles in the underside of the shell.
In order for liquid entering the shell side of the reboiler
to get out it must overflow a weir at the end of the
tube bundle. The weir is slightly taller than the tube
bundle, thus, the reboiler tubes are always
submerged. Part of the tower bottoms entering the
reboiler vaporizes and returns to the tower via a vapor
line called the riser. A large vapor space is provided
above the tube bundle to allow for vapor liquid
disengagement. The portion of entering liquid which is
not vaporized overflows the weir and is removed from
the reboiler. The “Kettle” reboiler is a floating head
type exchanger.
Heat transfer area:
Number of shells:
Tube material:
for higher temperatures
5-30
Reboilers (RB) - continued
Description
Type
KETTLE - continued
*<BLANK>*- Standard exchanger design
TBWNB- Tube bundle design only, w/o system bulks
Default: *400* DEG F [*200 DEG C] for copper alloys;
other material: *650* DEG F [*340* DEG C]
Default: 0.25 - 6.0 INCHES [6 - 150 MM];
Shell material:
*SS304* for higher temperatures
alloys; *650* DEG F [*340* DEG C] other material
Range: 8 - 60 FEET [2.5 - 18 M];
Tube gage:
corrosion allowance. Range: 1 - 24 BWG
corrosion allowance. Range: 0.02 - 0.34 INCHES
[0.6 - 8.6 MM]
Default: *0.0025* INCHES [0.06 MM] for CS, *0.0*
for other materials
5-31
Description
Type
KETTLE - continued
Tube pitch:
Tube pitch symbol:
Shell diameter:
Max: 192 INCHES [4,875 MM];
Default: *1.5 x port diameter*
Shell wall thickness including corrosion allowance.
other materials.
Default: Lessor of 50 x tube corrosion allowance or
0.25 INCHES [6 MM].
Cladding thickness:
Cladding material: See Chapter 28 for cladding
materials.
Cladding location:
Default: *SHELL*
SHELL- Cladding on shell side only
Number of tube passes: Default: *2*
Duty:
Default: 0.004 x surface area (SF); 0.01262 x surface
area (M2).
Vaporization:
Specific gravity tower bottoms:
Default: *0.50*
Molecular weight bottoms:
Default: *100*
Heat of vaporization:
Default: *150* BTU/LB [*350* KJ/KG]
5-32
5-33
Description
Type
KETTLE - continued
Stress relief:
Default: See Area Design Basis
TEMA type: Default: *BKT*
Horizontal or vertical thermosiphon reboilers.
THERMOSIPH
If a shell diameter is not specified, a value is
calculated from the surface area, number of shells,
tubes per shell, tube diameter, tube pitch, etc.
The thermosiphon reboiler is the most common
reboiler used. However, the thermosiphon reboiler can
not be used when the hydrostatic head above the
reboiler varies, when the operating pressure is in the
high vacuum range or when there is a low percentage
of volatiles (for example, less than 5%) in the feed to
the reboiler.
The vertical thermosiphon reboiler, like the kettle
reboiler, is a shell and tube heat exchanger used to
supply heat to a distillation column. The thermosiphon
reboiler operates in the following manner. Liquid from
the bottom of the column or from a trapout tray flows
into the bottom of the reboiler through a pipe called
the downcomer.
The column bottoms are partially vaporized in the
reboiler and a two phase mixture is returned to the
column through a pipe called the riser. The difference
in density between the liquid in the downcomer and
the two phase mixture in the reboiler and riser causes
the tower bottoms to flow through the reboiler by
natural circulation. Usually about 25% of the tower
bottoms are vaporized in the thermosiphon reboiler.
Thermosiphon reboilers are classified as either vertical
or horizontal according to their erected position.
The tower bottom enter the bottom head of the
vertical thermosiphon, flow upward through the tubes
and leave the top head. The heating fluid, usually
steam, passes through the shell side. Vertical
thermosiphons are available only as fixed tube-sheet
exchangers.
The horizontal, fixed tube-sheet, thermosiphon
reboiler differs from the vertical thermosiphon in that
it is erected horizontally and the bottoms liquid from
the distillation column flows through the shell side of
the reboiler and the heat transfer fluid flows through
the tubes.
Thermosiphon type: Default: *V-FXD*
H-FLOT - Horizontal: float head
H-FXD - Horizontal: fixed tubesheet
H-UTUB - Horizontal: u-tube
V-FXD - Vertical: fixed tubesheet
5-34
Description
Type
Thermosiphon - continued
V-COLM a tube bundle that is designed to be installed
into a Column (Tower) to hold catalyst or function as
an exchanger within a Column. There are no bulks
associated with this item. If fluid is desired on the
shell side of the tubes, then the additional piping lines
must be added via Pipe-Item Details entries.
Heat transfer area: Enter either heat transfer area
or number of
Number of shells: Enter either heat transfer area or
number of
Tube material: See Chapter 28 for materials.
Default: *A 214* to 900 DEG F [*482* DEG C],
*304S* for higher temperatures
*<BLANK>* - Standard exchanger design
TBWNB - Tube bundle design only, w/o system bulks
Tube design temperature: Default: *400* DEG F
[*200* DEG C] for copper alloys; other material:
*650* DEG F [*350* DEG C].
Tube operating temperature: Default: design
temperature
Tube outside diameter: Range: 0.25 - 6.0 INCHES
[6 - 150 MM];
Shell material: See Chapter 28 for materials.
*SS304* for higher temperature
Shell design gauge pressure: Default: *150* PSIG
[*1,000* KPA]
Shell design temperature: Default: *400* DEG F
[*200* DEG C] for copper alloys; *650* DEG F
[*340* DEG C] other material.
Shell operating temperature: Default: design
temperature
Tube side pipe material: See Chapter 18 for pipe
materials.
Shell side pipe material: See Chapter 18 for pipe
materials.
5-35
Description
Type
Thermosiphon - continued
Tube Wall Thickness: Enter tube gauge or thickness,
not both, including corrosion allowance. Range: 0.02
to 0.34 INCHES
[0.6 - 8.6 MM].
Tube corrosion allowance: Default: 0.0025 INCHES
[0.06 MM] for CS, 0.0 for other materials.
Tube pitch: Default: *1.25 x tube outside diameter*
Tube pitch symbol: Default: *TRIANGULAR*
DIAMOND - Diamond tube pitch
SQUARE - Square tube pitch
TRIANGULAR - Triangular tube pitch
Shell diameter: Max: 192.0 INCHES [4,875.0 MM]
Shell wall thickness: Shell thickness including
Shell corrosion allowance: Default: 0.125 INCHES
[3 MM] for CS,
Tube sheet material: See Chapter 28 for tube
materials.
Tube sheet corrosion allowance: Default: Lesser of
50 x tube corrosion allowance, or 0.25 INCHES [6
MM].
Cladding thickness: Default: 0.125 INCHES [3 MM]
if cladding material is specified, otherwise 0.0
Cladding material: See Chapter 28 for materials.
Cladding location: Default: *SHELL*
Number of tube passes: Default: 1 pass per vertical
fixed tube sheet type, 2 passes for all others.
Duty: Default: 0.004 x surface area (SF); 0.01262 x
surface area (M2).
Vaporization: Max: 100; Default: *20*
Specific gravity tower bottoms: Default: *0.50*
Molecular weight bottoms: Default: *100*
Heat of vaporization: Default: *150*
Stress relief: Default: See Area Design Basis
TEMA type: Default: Based on the specified
thermosiphon design symbol.
5-36
Reboilers - continued
Description
Type
The “u-tube” reboiler is identical to the “kettle”
type reboiler except that there is a U-tube bundle in
it instead of a floating head type tube bundle. The
term kettle reboiler is derived from the fact that the
bottoms from the distillation column accumulate in
a pool (the height of the weir) in the reboiler and
boil like liquid in a kettle. Therefore, both the .utube. and .kettle. reboilers are kettle type reboilers
in the nomenclature of the chemical process
industry.
U TUBE
Heat transfer area:
Number of shells:
Tube material:
for higher temperatures. See Chapter 28 for tube
data.
alloys; other material: *650* DEG F [*340* DEG C]
Range: 0.25 - 6.0 INCHES [6 - 150 MM];
Shell material:
SS304 for higher temperatures
Shell design gauge pressure: Default: *150* PSIG
[*1,000* KPA]
Shell design temperature: Default: *400* DEG F
[*200* DEG C] for copper alloys; *650* DEG F
[*340* DEG C] other material.
Shell operating temperature: Default: design
temperature
Tube side pipe material: See Chapter 18 for pipe
materials.
Shell side pipe material: See Chapter 18 for pipe
materials.
Number of tubes per shell: Enter either heat
transfer area or number of shells, tubes/shell and tube
data.
5-37
U Tube continued
Description
Type
Tube length extended: Range: 8 - 120 FEET [2.5 - U TUBE
36 M]; Default: *40* FEET [*12 M]
Tube gage: Enter tube gauge or thickness, not both,
including corrosion allowance. Range: 1 - 24 BWG
Tube wall thickness: Enter tube gauge or thickness,
not both, including corrosion allowance. Range: 0.02 0.34 INCHES [0.6 - 8.6 MM].
Tube corrosion allowance: Default: *0.0025*
INCHES [*0.06* MM] for CS, *0.0* for other
materials.
Tube pitch: Default: *1.25 x tube outside diameter*
Tube pitch symbol: Default: *TRIANGULAR*
DIAMOND - Diamond tube pitch
SQUARE - Square tube pitch
TRIANGULAR - Triangular tube pitch
Shell diameter: Max: 192 INCHES [4,875 MM];
Default: *1.5 x port diameter*
Shell wall thickness: Shell thickness including
Shell corrosion allowance: Default: *0.125*
INCHES [*3* MM] for CS, *0.0* for other materials.
Tube sheet corrosion allowance: See Chapter 28
for materials.
0.25 INCHES [6 MM].
Cladding thickness: See Chapter 28 for materials.
Default: *0.125* INCHES [*3* MM] if cladding
material is specified; otherwise: *0.0*
Cladding location: Default: *SHELL*
Number of tube passes: *2*
Duty: Default: 0.004 x surface area (SF)
[0.01262 x surface are (M2)]
Vaporization: Max: 100; Default: *90*
Specific gravity tower bottoms: *0.5*
Molecular weight bottoms: *100*
Heat of vaporization: *150* BTU/LB [*350* KJ/KG]
Stress relief: Default: See Area Design Basis
TEMA type: Default: *BKU*
5-38
Furnaces, Process Heaters (FU)
Furnaces are commonly used to heat a process fluid to a high temperature
(600 - 1200 DEG F). Furnaces are also called fired heaters or direct fired
heaters because the source of heat is oil or gas fueled burners.
Furnaces are usually cylindrical (vertical heater) or rectangular (box heater) in
shape. The burners may be located in the sides or floor of the furnace. The
walls of the furnace are refractory (an insulating heat resistant material) lined.
The furnace will have one or more smoke stacks. The process fluid being
heated flows through horizontal tubes in a box furnace or vertical tubes in a
box furnace or vertical tubes in a vertical furnace. The amount of heat
absorbed by the process fluid defines the size of the furnace. Use absorbed
duty for calculations.
Description
Type
Gas or oil fired for preheating, cracking; bridge walls BOX
separate radiant and convection sections; horizontal
burners
Box furnaces are the choice when a large amount of
heat must be transferred to a process stream. Some
specific applications are:
• Pre-heating crude before it goes to the atmospheric
or vacuum
• topping units
• Heating for catalytic cracking
• Providing heat for hydrocarbon cracking for
ethylene
• Providing heat for viscosity breaking.
A box furnace is so named because the combustion
chamber is box shaped. The radiant and convection
sections of the box type furnace are separated by one
or more walls called bridge walls. The box furnace is
normally fired from end wall mounted burners; that is,
the burners are mounted parallel to the floor and
perpendicular to the tubes of the furnace. Box type
furnaces are usually designed for large heat duty,
typically above 170 MMBTU/HR. The burners may be
fired with oil or gas. The box furnace can be used to
provide heat input to several different process streams
simultaneously.
Material:
See Chapter 28 for materials. Default: *CS*
Duty:
Max: 500 MMBTU/H [145 MEGAW]
Standard gas flow rate:
Aspen Capital Cost Estimator and Aspen Process
Economic Analyzer only. For liquid process fluid, enter
liquid flow in GPM [L/S] in place of gas flow.
Process type:
GAS- Gas process fluid
LIQ- Liquid process fluid
5-39
Furnaces, Process Heaters (FU) - continued
Description
Type
BOX - continued
Max: 6,000 PSIG [41,000 KPA];
Design temperature:
Max: 1,500 DEG F [815 DEG C];
A-frame process heater with sloping walls, radiant
section along sides and roof of cabin, convection
section in duct above roof of radiant section and
vertical floor-mounted burners. For use as hot oil
heater, pre-heater or cracking. Includes integral
stacks.
HEATER
Material:
Default: *CS*
Duty:
liquid flow GPM [L/S] in place of gas flow.
Process type:
Max: 6,000 PSIG [41,000 KPA];
Design temperature:
Max: 1,500 DEG F [815 DEG C];
Pyrolysis.
PYROLYSIS
Material:
Duty:
Process type:
5-40
Furnaces, Process Heaters (FU) - continued
Description
Type
PYROLYSIS - continued
Max: 6,000 PSIG [41,000 KPA];
Design temperature:
Max: 1,500 DEG F [815 DEG C];
Box-type reformer without catalyst.
REFORMER
Material:
Duty:
Process type:
Max: 6,000 PSIG [41,000 KPA];
Design temperature:
Max: 1,500 DEG F [815 DEG C];
Gas or oil fired vertical cylindrical type for low heat
duty range moderate temperature with long contact
time.
VERTICAL
Material:
Duty:
For liquid process fluid, enter liquid flow in GPM [L/S]
in place of gas flow.
Process type:
Max: 6,000 PSIG [41,000 KPA];
Design temperature:
Max: 1,500 DEG F [815 DEG C];
5-41
TEMA Exchanger Construction
Nomenclature
5-42
Icarus Supported TEMA Types
Shell and Tube Heat Exchangers
U - TUBE
FLOAT HEAD
FIXED-T-S
Front End
Stationary Head
Types
A, B, C
A, B, C
A, B, N
Shell Types
E, F, G, H, J, X
E, F, G, H, J, X
E, F, G, H, J, X
Rear End Head
Types
U
P, S, T, W
L, M, N
THERMOSIPH
KETTLE
A, B, C
A, B, C, N
A, B, N
K,
E**, J*
K
U
L, M, N, P*, S*, T*, U*
T
Reboilers
Front End Stationary U-TUBE
Head Types
Front End
Stationary Head
Types
Shell Types
Rear End Head
Types
TEMA CLASS B: Equipment cost includes shell, tube bundle, nozzles and saddles.
* Horizontal only
**Vertical only
5-43
5-44
5-45
5-46
6 Packing, Linings
(G6)
Introduction to Packing
Introduction to Lining
Acid Brick
Castable Refractories and Gunning Mixes
Fluorocarbon Linings
Glass Linings
Refractory Brick
Resin Linings
Rubber Linings
Lead Linings
Zinc Linings
Suggested Lining Difficulty Adjustments
6 Packing, Linings (G6)
6-1
Introduction to Packing
There are two types of packing used in packed tower:
•
Packing that is chemically suitable to perform a mass transfer operation (e.g.,
activated alumina for desulfurization or desiccation.
•
Packing constructed of inert material to provide surface area for mass transfer.
Inert packing is most commonly used since it can be utilized repeatedly without
significant deterioration. The majority of inert packings used are of the ring or
saddle type.
Ring packings are commonly made of metal or plastic except for Raschig rings, which
are generally ceramic. Ring packings are used mostly in distillation because of their
excellent turndown properties and availability in press-formed metals of all types.
Usually ring-type packings are used in handling organic materials when there are no
major corrosion problems. Unfortunately rings do not promote most redistribution of
liquids, and the Raschig ring occasionally promote liquid maldistribution.
Saddle type packings are commonly made from ceramic or plastic, seldom from metal.
Saddles are used largely in absorption and regeneration operations because they
provide good liquid redistribution and are available in ceramic and plastic, which yield
good corrosion resistance at very low cost. Saddles are usually used for aqueous
systems when corrosion is a major factor.
Qualities that are desirable in the selection of tower packings are:
•
High percentage of void space.
•
Irregularity of shape to prevent pattern packing.
•
Low resistance to material flow (low pressure drop).
•
Large active surface exposed per unit volume (high surface area per
cubic foot/meter).
•
Complete utilization of surface for mass transfer.
•
Suitably shaped to produce turbulent contact between phases.
•
Large number of interstitial transfer points per unit volume.
•
Good internal liquid distribution characteristics.
•
Wide operating range with little efficiency variation.
•
Mechanically strong to withstand normal loads in service and
physical handling.
•
Minimum weight and low side thrust on the tower shell.
•
Available in a wide variety of materials.
•
Minimum investment per year of service life.
•
Clean design to minimize stagnant area and fouling.
•
Capable of easy removal from tower and cleaning.
The packing factor, F, is a standard parameter that provides a capacity rating
for packings, by correlation of pressure drop versus gas flow rate through the
packing. It represents a ratio of a specific packing surface to the bed voidage
space in the packed bed. Low packing factors are desirable.
Size 3:1.0CPR, 0.5PPR, 1.0PPR, 1.5PPR, 2.0PPR
6-2
0.5SPR, 1.0SPR, 1.5SPR, 2.0SPR
The Pall ring is especially useful for distillation operations at any pressure. The
Pall ring is also used in absorption and stripping operations, particularly in high
pressure absorbers with small diameter shells where the ability to handle high
liquid and gas rates allow for major cost savings.
Pall rings are Raschig rings that have their wall opened with the projections
bent inward, permitting complete access to the interior for both gas and liquid
flow. This design makes possible greater capacity, lower pressure drop, high
gas and liquid rates, greater efficiency, better maintenance of distribution,
lower liquid hold-up and less entrainment than the conventional Raschig ring.
Pall rings are available in carbon steel, stainless steel, aluminum alloys,
copper, monel, nickel and inconel. Plastic Pall rings are available in
polypropylene, glass reinforced polypropylene and halar. Diameter sizes range
from 0.5 to 2.0 INCHES.
Size 3:1.0CRR, 1.5CRR, 2.0CRR, 3.0CRR
1.0PRR, 1.5PRR, 2.0PRR, 3,0PRR
1.0SRR, 1.5SRR, 2.0SRR, 3.0SRR
1.0KRR, 1.5KRR, 2.0KRR, 2.0KRR
Raschig rings, perhaps the most commonly used packing, are useful in distillation,
absorption and stripping operations. They provide increasing efficiency as loading
increases to the point of incipient flooding, beyond which their operation becomes
unstable. They are not suggested for use when high efficiencies are required or when
liquid loading approaches flooding.
Raschig rings are small hallow cylinders. They are the least efficient inert
packing available because their construction does not promote much liquid
distribution, occasionally may promote liquid maldistribution, lends itself to
pattern packing, and does not provide much turbulent contact between
phases. They are available in carbon steel, stainless steels, stoneware,
porcelain, karbate and plastics. Diameter sizes range from 1.0 to 3.0 INCHES.
Size 3:0.5CIS, 1.0CIS, 1.5CIS, 2.0CIS
0.5PIS, 1.0PIS, 1.5PIS, 2.0PIS
There are widely used in the manufacturing of sulfuric acid, CO2 absorption in the pulp
and paper industry, cooling and drying of chlorine and removal of noxious fumes in may
industries.
The Intalox saddle is a packing that offers large total surface area per cubic
foot, minimum resistance to liquid and gas flow, high percentage of void
space, a low packing factor, excellent liquid distribution, maximum
randomness and high efficiency with a large capacity in mass transfer
operations. These qualities make Intalox saddles especially effective in
distribution and absorption operations. Saddles are available in ceramics and
plastics. Ceramics are chemical stoneware and chemical porcelain, of which
chemical porcelain is preferred since it is mechanically stronger, non-porous,
iron-free and inert to chemical attack. Plastic saddles are available in
polypropylene, linear polyethylene, rigid PVC, CPVC, glass reinforced
polypropylene, kynar and halar. Diameter sizes range from 0.25 to 3.0
INCHES.
Size 3:0.5CBS,.75CBS, 1.0CBS, 1.5CBS
0.5PBS,.75PBS, 1.0PBS, 1.5PBS
6-3
0.5FBS,.75FBS, 1.0FBS, 1.5FBS
0.5SBS,.75SBS, 1.0SBS, 1.5SBS
0.5KBS,.75KBS, 1.0KBS, 1.5KBS
These items are used with slightly less efficiency than Intalox saddles for
distillation, stripping and absorption operations.
A Berl saddle is a negatively warped surface resembling a saddle. Berl saddles
have one shortcoming. Their efficiency changes with changes in loading. As
loading approaches flooding, mass transfer becomes unstable and
unpredictable. However, they do promote good liquid distribution, have a high
percentage of void space and provide a large surface area for mass transfer.
They are available in stoneware, porcelain, ceramics, plastics, stainless steel,
carbon steel and in karbate. Diameter sizes range from 0.5 to 1.5 INCHES.
Size 3:ALMNA
Activated aluminas are used for desiccation of liquids and gasses, desulfurization,
catalytic applications and as scavengers for various contaminants such as fluorides.
Activated aluminas are manufactured in granular and ball forms as crystals
and gels. They are highly porous and inert.
Size 3:ACT-C
Activated carbon is effectively and economically utilized in decolorization, odor
removal, solvent recovery, refining gasses and liquids, catalysts and
adsorption. Its major uses are in solution purification, such as the clean-up of
cane, beet and corn sugar solutions, and for the removal of tastes and odors
from water supplies, vegetable and animal fats and oils, alcoholic beverages,
chemicals and pharmaceuticals. Also commonly used in the recovery of
gasoline from natural gas, recovery of benzol from manufactured gas and the
recovery of solvents vaporized in industrial processes such as the manufacture
of rayon, rubber products, film and plastics. Other common uses are removing
impurities from gases such as hydrogen, nitrogen, helium, ammonia, and CO2
and removing organic sulfur compounds, H2S, and other impurities (Fe, Cu)
from manufactured and synthesis gases.
Activated carbons can be divided into two main classes:
•
Those used for adsorption of gases and vapors, for which a granular material,
providing great surface area and pore volume is generally employed.
•
Those used in purification of liquid, for which a powdered material is desired.
Many carbonaceous materials treated with oxidizing gases (e.g., coal, lignite,
sawdust) may be used for the manufacture of activated carbon depending on
its desired application. Activation is a physical change where the surface of the
carbon is greatly increased by the removal of hydrocarbons.
Size 3: M107YA, M107YB, M107YC, M76YA, M76YB, M76YC,
M76XA, M76XB, M76XC, M62YA, M62YB, M62YC,
M35YA, M35YB, M35YC, M35XA, M35XB, M35XC
Structured packing consists of layers of corrugated (crimped) steel sheets
stacked parallel to each other in sections that are typically 8 to 12 inches high.
The sheets are typically grooved and perforated and are arranged at a fixed
angle with respect to the vertical axis. For a given packing type, changing this
angle of orientation will alter the packing factor while maintaining the surface
area per unit volume and weight per unit volume. When installed in a column,
6-4
these sections, or "elements", are placed at a predetermined angle to each
other (horizontal rotation). This angle is typically 90°.
At low liquid rates, structured packing is typically more efficient than random
packing due to greater surface area per unit volume. Although the actual
packing cost is significantly greater for structured packing, the increased
efficiency allows for a smaller, less expensive column. Structured packing is
also more desirable because it is less prone to distribution problems and it
gives a lower pressure drop per theoretical stage. As the liquid rate increases
(beyond 20 gpm/ft2), the advantage of structured packing diminishes
significantly.
Introduction to Lining
A lining is material that lines the inside surface of a tank, tower, furnace, or
other piece of process equipment and protects that piece of equipment from
destruction by high temperature, corrosion or abrasion. Some of the common
lining types follow.
Acid Brick
These linings are used in Acid Service (pH less than 4.5) to protect a
membrane coating from deterioration due to abrasion or high temperature (T
greater than 150 DEG F). Red Shale Brick (RSB) is the cheapest and can be
used in low temperature service. When a more refractory material is desired,
acid resistant fireclay (30% alumina) is used.
Acid brick can be installed with two different mortars. Silica mortar is more
economical but can not be used in all applications. Furfural based mortar is
more expensive but is resistant to a wider range of materials.
Castable Refractories and Gunning Mixes
These materials can be installed in varying thicknesses. For thicknesses
greater than 4 INCHES, it is necessary to use anchors to hold the refractory to
the metal surface. Gunning mixes have higher material costs and lower labor
cost than castables; thus, installed costs of the two are approximately equal.
Fifty percent alumina gunning mix is useful in services involving severe
abrasion, reducing atmospheres and moderate temperatures. Typical
applications are cyclones, fluid catalytic cracking, naphtha reforming and
coking.
Ninety percent alumina castable and 90% alumina gunning mix are useful for
applications with temperatures higher than 50% alumina gunning mixes.
Fluorocarbon Linings
Fluorocarbon linings are resistant to a wide variety of corrosive chemicals at
temperatures up to 180 DEG F. The most common fluorocarbon linings are TeflonTM and
KynarTM.
6-5
Glass Linings
Glass linings are shop installed and are all satisfactory for a wide range of
corrosive services at temperatures up to 450 DEG F.
Refractory Brick
These linings are used in high temperature service. Selection of the type brick
to be used is a function of the process temperature, expected degree of
chemical attack and expected degree of abrasion.
Insulating firebrick has lower thermal conductivity and heat capacity than
refractory firebrick. It is generally used as a backing for refractory firebrick.
Since it is relatively non-resistant to chemical attack and abrasion, it is used as
the inner lining only when no erosion or abrasion is expected. Insulating
firebrick is ASTM Group 26 material (good to 2,600 DEG F).
Sixty percent alumina firebrick is a high alumina refractory useful for operating
conditions involving thermal cycling and chemical attack. Sulfuric acid
processing and spent acid regeneration are two applications for this material.
Ninety percent alumina firebrick is a high alumina refractory useful in
operating conditions involving thermal shock, slagging, corrosion and high
temperatures. Typical applications for this material are hydrotreating and
sulfur burners.
Resin Linings
Resin linings are used in a variety of corrosive services at operating
temperatures up to 250 DEG F. These linings offer good solvent resistance.
Some common resis linings are asphaltic resin, epoxy resin and phenolic resin.
Resin linings may be applied by spray gun, brush or roller.
Rubber Linings
These linings are satisfactory in a wide range of corrosive services at
temperatures less than 150 DEG F. Rubber linings are almost always applied in
the vendors shop. The most common rubber linings are butyl rubber, natural
rubber and neoprene.
Lead Linings
Lead sheet was used extensively in the manufacture of sulfuric acid. Today,
new process technology has nearly eliminated the use of lead as a lining
material.
Zinc Linings
Zinc is frequently applied to water tanks for cathodic protection. The zinc can be flame
sprayed (also called metallizing) or painted onto the carbon steel base material. Flame
spraying is the process whereby metallic zinc is vaporized in a flame and sprayed onto
the steel base material. The hot zinc does not merely coat the carbon steel, it forms an
alloy with the steel several mils deep.
6-6
Zinc can also be supported in an epoxy base paint and brushed, rolled or sprayed onto
the steel.
See Material Selections chapter for a complete list.
Description
Type
Variety of vessel packing materials including rings,
saddles and other formed shapes, crushed materials,
adsorbents, resins, etc.
PACKING
Packing type:
See Chapter 28 for packing materials.
6-7
Description
Type
Brick and mortar for acid service applied to protect a
membrane coating from deterioration under
ACID BRICK
abrasive or high pressure service.
Lining material:
Default: *25RSB*
25RSB- 2.5 INCHES [62 MM] red shale
45RSB- 4.5 FINCHES [112 MM] red shale
80RSB- 8.0 INCHES [200 MM] red shale
25AFC- 2.5 INCHES [62 MM] Al f-clay
45AFC- 4.5 INCHES [112 MM] Al fclay
90AFC- 9.0 INCHES [225 MM] Al fclay
Mortar type:
Default: *FUR*
FUR- Furfural base motar
SIL- Silicone base motar
Lining adjustment:
See “Suggested Lining Difficulty Adjustment.”
Range:
1 - 10; Default: *4*
Castable refractory or gunned mixes.
MONOLITHIC
Lining material:
Default: *GUNIT*
GUNIT- Gunite on wire mesh
GUNA5- Gunn. 50% Al anchored
GUNA9- Gunn. 90% Al anchored
CASA9- Cast. 90% Al anchored
GUN50- Gunn. 50% Al no anchor
GUN90- Gunn. 90% Al no anchor
CAS90- Cast. 90% Al no anchor
Lining thickness:
Max: 9 INCHES [225 MM];
Default: 4 INCHES [100 MM]
6-8
Packing, Linings (PAK, LIN) - continued
Description
Item
MONOLITHIC - continued
Lining adjustment:
See “Suggested Lining Difficulty
Adjustment.” Range: 1 - 10; Default: *4*
Brick: 60%, 90% alumina firebrick, insulating
firebrick; abrasion resistant, replaceable linings:
ceramic, rubber, steel, alloy; coatings: organic, glass
and metallic.
OTHER
Lining material:
See Chapter 28 for lining materials.
Default:
*EPLCS*
Lining adjustment:
See “Suggested Lining Difficulty
Adjustment.” Range: 1 - 10; Default: *4*
Suggested Lining Difficulty
Adjustments
Work Item
Difficulty Adjustment
Lining a straight tank
1
Typical lining
4
Lining a large horizontal vessel
(<5000 GALLON [19 M3] capacity)
6
Lining a small horizontal vessel
(<5000 GALLON [19 M3] capacity)
8
Small, obstructed area
10
6-9
6-10
7 Pumps
(G10)
Gear Pumps (GP)
Pump Efficiencies
7 Pumps (G10)
7-1
Includes pump, baseplate, driver; general types:
API-610 type:
High (60xHZ), low (30xHZ) speed.
ANSI type:
ANSI B123.1 or American Voluntary Standard, single stage
centrifugal, process and general service; horizontal, end
suction, centerline discharge; high (60xHZ), medium (30xHZ),
low (20xHZ) speed.
CENTRIF type:
Single and multiple stage centrifugal pumps, horizontal, split
casing (not barrel or cartridge type), for process or general
service when flow, head and pressure conditions exceed
general service; electric, turbine, gasoline engine drives.
General Service:
Cast iron pumps for general service; high (60xHZ), medium
(30xHZ) speed.
IN LINE type:
Mounted for service on the line; high (60xHZ), medium
(30xHZ), low speed (20xHZ).
Description
Type
Available in a wide variety of alloys and exotic
ANSI
materials including carbon steel casings with stainless
steel impellers (SF = stainless fitted) for flows to 2000
GPM [125 L/S], and additionally in FRP for flows to 500
GPM [31 L/S].
Casing material:
Liquid flow rate:
MAX: 2,000 GPM [125 L/S]
7-2
7 Pumps (G10)
Centrifugal Pumps (CP) - continued
Description
Type
ANSI - continued
Fluid head:
MAX: 75 FEET [25 M] at 20 x HZ; 200 FEET
[60 M] at 30 x HZ; 575 FEET [175 M] at
60 x HZ.
Speed:
Range: 1,200 - 3,600 RPM;
Speed varies with pump head
Fluid specific gravity:
Range: 0.2 - 5.0; Default *1.0*
Driver type:
NONE- No driver
*MOTOR*- Standard motor driver
VFD- Variable frequency motor driver
TURBINE, - Turbine driver
GAS ENGINE- Gas engine driver
Seal type:
PACK- Packing
*SNGL*- Single mechanical seal
TNDM- Tandem mechanical seal
DBLE- Double mechanical seal
Design temperature:
MAX: 500 DEG F [260 DEG C];
Fluid viscosity:
Default: *1.0* CPOISE [*1.0* MPA-S]
Pump efficiency:
Range: 10 - 100
Steam gauge pressure:
Steam pressure for turbine drivers only.
Default: *400* PSIG [*2,800* KPA].
Primary seal pipe plan:
*11*- API primary seal piping plan number 11
12- API primary seal piping plan number 12
7 Pumps (G10)
7-3
Description
Type
ANSI - continued
Secondary seal pipe plan:
Default: *NONE*
51- API secondary seal piping plan number
Cooling water pipe plan:
Default: *NONE*
A- API cooling water piping plan A
B- API cooling water piping plan B
C- API cooling water piping plan C
D- API cooling water piping plan D
E- API cooling water piping plan E
F- API cooling water piping plan F
G- API cooling water piping plan G
H- API cooling water piping plan H
J- API cooling water piping plan J
K- API cooling water piping plan K
L- API cooling water piping plan L
Pipe plan pipe type:
Default: *WELD*
TUBE- Tubing
THRD- Threaded pipe/fittings
*WELD*- Welded pipe/fittings
WFLG- Welded/flanged pipe fittings
Pipe plan material type:
Default: Based on casing material.
A 106- A 106
304P- SS304
316P- SS316
51
52
53
54
61
62
Plastic ANSI single stage pump.
ANSI PLAST
Liquid flow rate:
Capacity limit: 250 GPM [15 L/S] at 30 x HZ; 500 GPM
[31 L/S] at 60 x HZ.
Fluid head:
MAX: 90 FEET [27 M] at 30 x HZ, 575 FEET [175 M] at
60 x HZ]; Default: *75* FEET [*25* M]
Speed:
Range: 1,800 - 3,600 RPM; Speed varies with pump
head
Range: 0.2 - 50; Default: 1.0
7-4
7 Pumps (G10)
Description
Type
ANSI PLAST - continued
Driver type:
Default: *MOTOR*
NONE- No driver
MOTOR- Standard motor driver
Seal type:
Default: *SNGL*
PACK- Packing
SNGL- Single mechanical seal
Design temperature:
Default *120* DEG F [*50* DEG C]
Fluid viscosity:
Pump efficiency:
Range: 1 - 100
Steam pressure for turbine drivers only. Default:
*400* PSIG [2,800 KPA].
API 610 type available in a variety of casing materials. API 610
Casing material:
Fluid head:
MAX: 200 FEET [60 M] at 30 x HZ; 700 FEET [210 M]
at 60 x HZ RPM. Default: *225* FEET [*25* M] RPM
Speed:
Range: 1,800 - 3,600 RPM;
Range: 0.2 - 5.0; Default: *1.0*
Driver power:
MIN: >0
If you specify a driver power greater than 300 HP with
a MOTOR driver type, Icarus generates a Totally
Enclosed Water Cooled (TEWAC) motor. In Aspen
Process Economic Analyzer and Aspen Capital Cost
Estimator, Icarus also generates additional piping lines
for cooling water and an additional temperature
control loop.
7 Pumps (G10)
7-5
Description
Type
API 610 - continued
Driver type:
Default: MOTOR
NONE- No driver
Seal type:
Default: *SNGL*
PACK- Packing
Design temperature:
Fluid viscosity:
Pump efficiency:
Range: 10 - 100
Steam pressure for tubine drivers only. Default:
*400* PSIG [*2,800* KPA].
*11*- API primary seal piping plan number 11
Secondary seal pipe plan: Default: *NONE*
51- API secondary seal piping plan number 51
7-6
7 Pumps (G10)
Description
Type
API 610 - continued
Default: *NONE*
Default: *WELD*
TUBE- Tubing
THRD- Threaded pipe/fittings
*WELD*- Welded pipe/fittings
WFLG- Welded/flanged pipe fittings
Pipe plan material Type:
A 106- A 106
304P- SS304
316P- SS316
API 610 in-line pump
API 610 IL
Casing material:
Liquid flow rate:
MAX: 450 GPM [38 M] at 30 x HZ,
900 GPM [56 L/S] at 60 x HZ.
Fluid head:
MAX: 125 FEET [38 M] at 30 x HZ, 500 FEET [152 M]
at 60 x HZ; Default: *225* FEET [*25* M]
Speed:
Range: 1,800 - 3,600 RPM; Default: *1,800* RPM.
Range: 0.2 - 5.0; Default: *1.0*
Driver type:
NONE- No driver
7 Pumps (G10)
7-7
Description
Type
API 610 IL - continued
Seal type:
PACK- Packing
Design temperature:
Fluid viscosity:
Default: *1.0* CPOISE [*1.0* MPA-S].
Pump efficiency:
Range: 10 - 100
Default: *11*
2- No primary seal piping plan
Default: *NONE*
51- API second seal piping plan number 51
Default: *NONE*
7-8
7 Pumps (G10)
Description
Type
High speed vertical in-line API 610 centrifugal pump
HIGH SPEED
with a single impeller stage, integral speed-increasing
gearbox, with a vertical motor mount, for use in high
head/low flow applications.
Casing material:
Default: *CS*
See Chapter 28 of the Icarus Reference Guide for
materials.
Fluid head:
MAX: 2,000 FEET [600 M]
MIN: 500 FEET [150 M]
Speed:
Range: 1,800 - 3,600 RPM; Default: *3,600*
Note: Applies to motor speed, not impeller speed.
Range: 0.2 - 5.0; Default: *1.0*
Driver power:
MIN: >0
Note: If you specify a driver power greater than 300
HP with a MOTOR driver type, Aspen Economic
Evaluation generates a Totally Enclosed Water Cooled
(TEWAC) motor. In Aspen Process Economic Analyzer
and Aspen Capital Cost Estimator, Aspen Economic
Evaluation also generates additional piping lines for
cooling water and an additional temperature control
loop.
Driver type:
Default: MOTOR
NONE - No driver
*MOTOR* - Standard motor driver
VFD - Variable frequency motor driver
Seal type:
Default: *SNGL*
PACK - Packing
*SNGL* - Single mechanical seal
TNDM - Tandem mechanical seal
DBLE - Double mechanical seal
Design temperature:
MAX: 850 DEG F [450 DEG C]
Fluid viscosity:
Pump efficiency:
Range: 10 - 100
7 Pumps (G10)
7-9
Description
Type
*400* PSIG [*2,800* KPA].
*11* - API primary seal piping plan number 11
12 - API primary seal piping plan number 12
Default: *NONE*
51 - API secondary seal piping plan number 51
Default: *NONE*
A - API cooling water piping plan A
B - API cooling water piping plan B
C - API cooling water piping plan C
D - API cooling water piping plan D
E - API cooling water piping plan E
F - API cooling water piping plan F
G - API cooling water piping plan G
H - API cooling water piping plan H
J - API cooling water piping plan J
K - API cooling water piping plan K
L - API cooling water piping plan L
Default: *WELD*
TUBE - Tubing
THRD - Threaded pipe/fittings
*WELD* - Welded pipe/fittings
WFLG - Welded/flanged pipe fittings
Pipe plan material type:
A 106 - A 106
304P - SS304
316P - SS316
7-10
7 Pumps (G10)
Description
Type
Vertical axial flow pump for flows greater than
1600 GPM [100 L/S].
Includes pumping unit and motor driver.
AXIAL FLOW
Material:
Liquid flow rate:
Max GPM <1,300,000/head [FT],
Max L/S <25,000/head [M].
Fluid head:
MAX: 75 FEET [25 M]; Default: *75* FEET [*25* M]
Temperature:
Range: 0.2 - 5.0; Default: *1.0*
Horizontal pump with canned motor.
CANNED
Casing material:
Liquid flow rate:
MAX: 400 GPM [25 L/S]
Fluid head:
MAX: 200 FEET [60 M]; Default: *75* FEET [*25* M]
Range: 0.2 - 5.0; Default: *1.0*
Design temperature:
Fluid viscosity:
Pump efficiency:
Range: 10 - 100
Single and multistage centrifugal pumps available in a CENTRIF
variety of casing materials.
For process or general service when flow/head
conditions exceed general service; horizontally split
casing not a cartridge or barrel pump.
Casing material:
Default: *CS*
Fluid head:
Speed:
Varies with pump head
7 Pumps (G10)
7-11
Description
Type
CENTRIF - continued
Range: 0.2 - 5.0; Default: 1.0
Driver type:
Default: MOTOR
NONE- No driver
Seal type:
PACK- Packing
Design temperature:
Fluid viscosity:
Pump efficiency:
Range: 10 - 100
*400* PSIG [*2,800* KPA].
General service, cast iron for flows to 2000 GPM GEN SERV
[125 L/S].
Casing material:
Default: *CI*
Liquid flow rate:
MAX: 2,000 GPM [125 L/S]
Fluid head:
MAX: 200 FEET [60 M] at 30 x HZ, 275 FEET [80 M] at
60 x HZ; Default: *75* FEET [*25* M]
Speed:
Range: 1,800 - 3,600 RPM
0.2 - 5.0; Default: *5.0*
Driver type:
NONE- No driver
7-12
7 Pumps (G10)
Description
Type
GEN SERV - continued
Seal type:
PACK- Packing
Design temperature:
Fluid viscosity:
Pump efficiency:
Range: 10 - 100
*400* PSIG [*2,800* KPA].
General service in-line pump.
Includes pump and motor driver.
IN LINE
Casing material:
Liquid flow rate:
MAX: GPM x head [FEET] < 43,000, L/S x head
[M] < 825.
Fluid head:
Speed:
Range: 1,200 - 3,600 RPM; Default: *1,800* RPM.
Range: 0.2 - 5.0; Default: *1.0*
Driver type:
NONE- No driver
Seal type:
PACK- Packing
Design temperature:
Fluid viscosity:
Pump efficiency:
Range: 10 - 100
7 Pumps (G10)
7-13
Description
Type
Vertical motor with turbine impeller for wet pits, TURBINE
tanks and sumps.
Includes pumping unit and motor driver.
Material:
Liquid flow rate:
MAX: Flow (GPM) x Head (FT) < 990,000 [Flow (L/S) x
Head (M) < 8250]
Fluid head:
Default: *75* FEET [*25* M]; MAX: Flow (GPM) x
Head (FT) < 990,000 [Flow (L/S) x Head (M) < 8250]
Temperature:
Default: *120* DEG F [*50* DEG C]; MAX: 500 DEG F
[260 DEG C]
Fluid Specific Gravity:
Range: 0.2 - 5.0; Default: *1.0*
Low consistency stock pump.
PULP STOCK
Casing material:
*CI*- Cast iron
SS316- SS316
Liquid flow rate:
Range: 100 - 28,000 GPM [6.4 - 1,765 L/S]
Fluid Head:
Range: 15 - 350 FEET [4.6 - 106 M]
Speed:
Fluid specific gravity.:
Range: 0.2 - 5.0; Default: 1.0
Driver type:
NONE- No driver
VFD- Variable frequency driver
Design temperature:
Consistency Air Dried: Percent by weight of air dried
(AD)
solids in fluid. Range: 0.0 - 6.0; Default: *1.0*
Pump efficiency:
Range: 10 - 100
*400*PSGI [*2,800 KPA].
7-14
7 Pumps (G10)
Description
Type
Standard ANSI magnetic drive pump.
MAG DRIVE
Casing material:
C 20- Carpenter 20
HASTC- Hasteloy C
Liquid flow rate:
MAX: 300 GPM [18.9 L/S] at 30 x HZ, 600 GPM
[37.8 L/S] at 60 x HZ
Fluid head:
MAX: 200 FEET [60 M] at 30 x HZ, 400 FEET [120 M]
at 60 x HZ; Default: *75* FEET [*25* M]
Speed:
Range: 1,800 - 3,600 RPM; Speed varies with pump
head
Range: 0.2 - 5.0; Default: *1*
Driver type:
VFD- Variable frequency driver
NONE- No driver
MAX: 275 PSIG [1,895 KPA]
Design temperature:
Fluid viscosity:
Default: *1* CPOISE [*1* MPA-S]
Pump efficiency:
Range: 10 - 100
SAN PUMP
Sanitary centrifugal pump
For use as a product mover in a wide range of
sanitary and industrial applications. Material of
construction is SS316.
Pump size selection:
Symbol
Inlet
InchPound
Outlet
Inch-
Metric
Pound
Metric
25x20
2.5 INCHES
65 MM
2 INCHES
50 MM
30x20
3 INCHES
75 MM
2 INCHES
50 MM
30X25
3 INCHES
75 MM
2.5 INCHES 65 MM
40X30
4 INCHES
40X40
4 INCHES
100 MM 3 INCHES
100 MM
4 INCHES
75 MM
100 MM
7 Pumps (G10)
7-15
Description
Type
SAN PUMP - continued
SAN PUMP
Required: select pump size or enter capacity and head.
Fluid head: MAX: 365 FEET [109 M] (at maximum
speed)
Speed
*30xHZ*
60XHZ
Maximum Head
Inch- Pound
Metric
92 FEET
28 M
365 FEET
63 M
Required: enter capacity and head or select pump size.
Liquid flow rate: MAX: 1,000 GPM [62.5 GPM] (at
maximum
speed)
Speed
Maximum Head
Inch- Pound
Metric
*30xHZ*
610 GPM
38.4 L/S
60XHZ
1,000 GPM
63 L/S
Required: enter capacity and head or select pump
size.
Speed
Inch- Pound
Metric
Default
1,800 RPM
1,500RPM
MIN:
1,800 RPM
1,500RPM
MAX:
3,600 RPM
3,000 RPM
*45 PSIG [310 KPA]*, MAX: 45 PSIG [310 KPA]
Design temperature:
*68 DEG F [20 DEG C]*, MAX: 120 DEG F [50 DEG C]
*1.0*, MIN: 0.25, MAX: 5.0
Pump efficiency:
MIN: 10, MAX: 100
Driver type:
*TXXDC*- Standard TEFC motor
WXXDC- Washdown TEFC motor
WVRDC- VFD rated motor only (no controller)
WVCDC- VFD rated motor with controller
Seal type:
SNGW- Single mechanical seal w/ water cooling
DBLW- Double mechanical seal w/ water cooling
7-16
7 Pumps (G10)
Description
Type
Sanitary fluming pump with feeder hopper
FLUME PUMP
For transferring delicate food products, like
mushrooms and cranberries. Uses water as a
protective cushion. Material of construction is
SS304.
Liquid flow rate:
MAX: 4,150 GPM [260 L/S]. Includes water and
product.
Required: enter either diameter; head and
capacity; or head and product rate.
Maximum head decreases as capacity increases.
At the maximum capacity of 4,150 GPM [260 L/
S], the maximum head is 45 FEET [13.7 M].
Product rate:
MAX: based on maximum capacity (4,150 GPM
[260 L/S]), specific gravity, and H20/product
ratio. Required: enter either diameter; head and
capacity; or head and product rate.
Inlet and outlet diameter:
MIN: 4 INCHES [100 MM], MAX: 10 INCHES [250 MM]
Fluid head:
*35* FEET [*10.7* M], MAX: 110 FEET [33.5 M]
Maximum head decreases as capacity increases.
The pump is dead-headed at 110 FEET [35.5 M].
At the maximum capacity of 4,150 GPM [260 L/
S], the maximum head is 45 FEET [13.7 M].
Water to product weight ratio: *10*
Design pressure gauge:
*45 PSIG [310 KPA]*, MAX: 45 PSIG [310 KPA]
Design temperature:
*68 DEG F [20 DEG C]*, MAX: 120 DEG F [50 DEG C]
*1.0*, MIN: 0.2, MAX: 5.0 (of water-product mixture).
Pump efficiency:
MIN: 10, MAX: 100
7 Pumps (G10)
7-17
Centrifugal Pumps (CP) - continued.
Description
Type
FLUME PUMP - continued.
Hopper length: Minimum hopper length depends on
diameter:
Diameter
Minimum Hopper Length
4 INCHES [100 MM]
2.0 FEET [0.610 M]
6 INCHES [150 MM]
3.5 FEET [1.067 MM]
8 INCHES [200 MM]
5.0 FEET [1.524 M]
10 INCHES [250 MM]
6.0 FEET [1.829 M]
Enclosure type:
OPEN- Closed frame unit
*CLOSE*- Open frame unit
7-18
7 Pumps (G10)
Gear Pumps (GP)
For the pumping of viscous fluids, such as polymers and resins. Standard
rotary pumps can pump fluids with viscosities as great as 250,000 CP and
special designs are available to handle viscosities up to 1,000,000 CP.
The principal of operation is that as two rotors rotate, projections on the rotors
mesh and unmesh. They unmesh on the suction side of the pump creating a
cavity which is filled with liquid. As the rotors continue to turn, the liquid is
trapped between the projections of the rotors and the pump casing. The liquid
is carried to the discharge side of the pump in these pockets. At the discharge
side, the rotors mesh and the liquid is squeezed out of the pump.
Includes pump, baseplate, driver (optional).
Description
Standard external gear rotary pump
Type
GEAR
For pumping of viscous fluids to 300 GPM [18 L/
S], such as polymers and resins; standard type
external gear rotary pump.
Includes motor driver.
Material:
*CS*- Carbon steel
CI- Cast iron
SS- Stainless steel
BRONZ- Bronz
Liquid flow rate:
MAX: 300 GPM [18 L/S].
Viscosity:
MAX: 30,000 CSTOKE [30,000 MM2/S];
Default: *32* CSTOKE [*32* MM2/S].
Speed:
MAX: 600 RPM; Default: *90* RPM.
Canned rotor gear pump
Explosion-proof motor, to 570 GPM [35 L/S].
CANNED RTR
Material:
*SS316*
Liquid flow rate:
40 - 570 GPM [3 - 35 L/S]
Speed:
MAX: 1,800 RPM; Default: *1,800* RPM
Viscosity:
Default: *32* CSTOKE [*32* MM2/S]
7 Pumps (G10)
7-19
Gear Pumps (GP) - continued
Description
Type
Mechanical seal gear pump
With mechanical seal, to 480 GPM [30 L/S]. Includes
motor driver.
MECH SEAL
Material:
*GSLCS* (Glass-lined CS)
Liquid flow rate:
Range: 35 - 480 GPM [3 - 30 L/S].
Speed:
MAX: 1,800 RPM; Default: *1,800* RPM.
7-20
7 Pumps (G10)
Piston, Other Positive
Displacement Pumps (P)
Description
Type
Reciprocating simplex with steam driver.
SIMPLEX
Material:
Default: *CS*
Liquid flow rate:
Range: 5.5 - 910 GPM [0.4 - 56 L/S]
Fluid head:
MAX: 1,000 FEET [300 M]
Temperature:
Range: 0.2 - 5.0; Default: *1.0*
Driver power:
Range: 3 - 10 HP [2.22 - 7.5 KW]
Reciprocating duplex with steam driver.
DUPLEX
Material:
Default: *CS*
Liquid flow rate:
MAX: 1,000 GPM [62 L/S]
Fluid head:
MAX: 1,000 FEET [300 M]
Temperature:
Range: 0.2 - 5.0; Default: *1.0*
Driver power:
Range: 2 - 100 HP [1.5 - 7.5 KW]
Triplex (plunger) with pump-motor driver.
TRIPLEX
Material:
Default: *CS*
Liquid flow rate:
MAX: 1,000 GPM [62 L/S]
Fluid head:
MAX: 1,000 FEET [300 M]
Temperature:
Range: 0.2 - 5.0; Default *1.0*
Driver power:
Range: 2 -100 HP [1.5 - 75 KW]
7 Pumps (G10)
7-21
Piston, Other Positive Displacement Pumps (P) - continued
Description
Type
DIAPHRAGM
Diaphragm pump - TFE type.
Includes motor driver. For the low capacity
pumping of hazardous, toxic or abrasive
liquids. Although diaphragm pumps are made
with capacities of 100 GPM, generally they
handle 25 GPM or less. Diaphragm pumps are
also frequently used as metering pumps.
A diaphragm pump is a type of reciprocating
pump. A reciprocating rod flexes a diaphragm
fabricated of metal, rubber or plastic. The
flexing of the diaphragm produces the
pumping action.
The advantage of the diaphragm pump is that
no packing or seals are exposed to the liquid
being pumped.
Material:
*CS*- Carbon steel
SS316- SS316
Liquid flow rate:
Range: 0.012 - 600 GPM [1.3 - 37.5 L/S]
Temperature:
Range: 0.2 - 5.0; Default: *1.0*
Slurry pump.
SLURRY
Material:
Default: *SS316*
Liquid flow rate:
Range: 1.5 - 25 GPM [0.1 - 1.5 L/S]
Range: 0.2 - 5.0; Default: *1.0*
Temperature:
7-22
7 Pumps (G10)
Description
Type
Rotary (sliding vanes) pump. Includes motor driver.
ROTARY
Material:
Defaults*
Liquid flow rate:
Range: 10 - 750 GPM [0.7 - 47 L/S]
Range: 0.2 - 5.0; Default: *1.0*
Temperature:
Material:
BRONZ
Liquid flow rate:
Range: 25 - 450 GPM [1.6 - 28 L/S]
Temperature:
Reciprocating plunger pump.
RECIP MOTR
Includes motor driver. Plunger pumps are used for
pumping hydraulic fluid, hydraulic de-scaling of steel,
water flooding of oil fields, salt water disposal,
pumping of propane, butane and other volatile liquids,
and for process pumping requiring high pressures.
This item is an electric motor driven plunger, power
pump. A power pump is a reciprocating pump driven
through a crankshaft. Although the RECIP-MOTR pump
is driven by an electric motor, a power pump may be
driven by a steam or gas turbine, a gas engine, or a
diesel engine as well. A plunger pump is a
reciprocating pump that displaces liquid from a
cylinder by the reciprocating motion of a long, slender,
solid rod called a plunger. On the back-stroke of the
plunger, the cylinder fills with liquid and on the
forward-stroke, the liquid is expelled. The capacity of a
plunger pump is determined by the diameter, stroke
and number of plungers. Plunger pumps are made
from two to nine plungers and in two basic
configurations, horizontal and vertical depending on
whether the plungers are arranged horizontally or
vertically in the machine. Typically, discharge
pressures of plunger pumps fall in the range from
1,500 to 6,000 PSIG, although pressure as high as
20,000 PSIG can be handled in some.
7 Pumps (G10)
7-23
Description
Type
RECIP MOTR - continued
Material:
Liquid flow rate:
Min: 0.01 GPM [0.4 L/S]
Temperature:
Range: 0.2 - 5.0; Default: *1.0*
Driver power:
MAX: 1,000 HP [750 KW]
High density stock pump with twin intermeshing
screws.
HD STOCK
Casing material:
*SS316*, SS317
Stock flow rate air dried:
Flow rate of air dried (AD) solids in pumped fluid.
MAX: 1,500 TPD [56 TON/H]
MAX: 160 PSIG [1,100 KPA] to 550 TPD [20 TON/H],
else 100 PSIG [688 KPA].
Design temperature:
Consistency air dried:
Percent by weight of air dried (AD) solids in fluid.
Pump efficiency:
Range: 10 - 100
Driver type:
NONE- No driver
Speed:
Default: *1,800* RPM [*1,500* RPM]
*400* PSIG [*2,800* KPA].
7-24
7 Pumps (G10)
Description
Type
Sanitary rotary lobe pump
ROTARYLOBE
Used for a wide range of fluids (low or high viscosity,
non-lubricating or abrasive), this pump forwards
fluids, yet has a low impact on solids and a relatively
constant discharge pressure.
Pump size selection:
Symbol
Nominal Flow Rate / Diameter
GPM/INCHES
L/S MM
06- 15
6 / 1.5
0.37 / 40
15 - 15
15 / 1.5
0.9 / 40
18 - 15
18 / 1.5
1.1 / 40
30 - 15
30 / 1.5
1.8 / 40
60 - 25
60 / 2.5
3.7 / 65
130 - 3
130 / 3
8.2 / 80
220 - 4
220 / 4
13.8 / 100
320 - 6
320 / 6
20.2 / 150
420 - 8
420 / 8
26.5 / 200
520 - 8
520 / 8
32.8 / 200
Required: select pump size or enter capacity and exit
pressure.
Liquid flow rate:
MAX: 520 GPM [32.8 L/S]
pressure.
MAX: 200 PSIG [1,375 KPA]
pressure.
Impeller speed:
MAX: 10 x Hz RPM
*1.0*, MIN: 0.2, MAX: 5.0
Fluid viscosity:
*1.0 CPOISE [1.0 MPA-S]*
Design temperature:
*68 DEG F [20 DEG C]*
Seal type:
*MECH*- Single mechanical seal
ORNG- O-ring seal
Relief cover type:
*STD*- Standard cover
MAN- Manual relief cover
7 Pumps (G10)
7-25
Piston, Other Positive Displacement Pumps (P) - continued.
Description
Type
Sanitary air diaphragm pump
AIR DIAPH
added.
Inlet and outlet diameter:
MIN: 1 INCHES [25 MM DIAM], MAX: 3 INCHES DIAM
[75 MM DIAM]
Enter either inlet/outlet diameter or capacity
and head.
Liquid flow rate:
MAX: 220 GPM [13.7 L/S] at 20 FEET [6 M]
Enter either inlet/outlet diameter or capacity and
head.
Fluid head:
MAX: 210 FEET [64 M] at 60 GPM [3.7 L/S]
MAX: 110 PSIG [750 KPA]
Design temperature:
MIN: 68 DEG F [20 DEG C], MAX: 300 DEG F [148
DEG C]
*1.0*, MIN: 0.2, MAX: 5.0
Pump Efficiencies
7-26
Pump Type
Default Efficiency
Centrifugal Pumps
< 50 GPM = 60%
All Other Pumps
82%
Hi-Density Stock Pump
Calculated using an empirical correlation.
7 Pumps (G10)
7 Pumps (G10)
7-27
7-28
7 Pumps (G10)
8 Towers, Columns
(G6)
Introduction to Towers and Columns
Tower/Column Applications
Tower/Column Internals
Description of Towers/Columns
Materials of Construction
Shell and Head Design
8 Towers, Columns (G6)
8-1
Introduction to Towers and
Columns
Towers are classified according to the type of “internals” in the tower, and
according to the function performed by the tower.
•
Towers may contain trays. If the tower contains trays, the vessel is called a
tray tower, or, synonymously, a tray column.
•
Tower may contain packing. If the tower contains a packing, the vessel is called a
packed tower, or packed column.
•
If the feed to the tower is a hydrocarbon mixture and the tower separates this
mixture into two factions or streams, one stream containing the more volatile
components of the feed and the other stream the less volatile components of the
feed, the tower is called a fractionation tower. Other names for a fractionation
tower are: fractionation column, fractionator, distillation tower and
distillation column.
•
If the feed to the tower is liquid, and the tower removes an undesirable gas which is
dissolved in the feed, the tower is called a stripping tower. Other names for a
stripping tower are stripping column and stripper.
•
If the feed to the tower is a gas mixture containing one or more undesirable
components which are removed within the tower by absorbing them with a suitable
solvent, the tower is called an absorption tower. Other names for an absorption
tower are: absorption column and absorber.
•
If the feed to the tower is a gas or liquid mixture containing one or more
undesirable components, which are removed within the tower by adsorbing them
onto solid catalyst pellets, the tower is called an adsorption tower. Other names for
an adsorption tower are: adsorption column and adsorber.
•
If the feed to the tower is a liquid mixture containing one or more undesirable
components which are removed by absorbing them with another liquid, the tower is
called an extraction tower or extraction column.
Towers are similar to vertical process vessels in that they are erected vertically
and they are cylindrical in shape with heads at each end of the cylinder.
Towers are, however, normally much taller then vertical process vessels.
Typically the length to diameter ratio of a tower ranges from 3:1 to 20:1.
Towers typically range in diameter from 3 to 20 FEET and in height from 20 to
150 FEET.
Tower/Column Applications
Towers are commonly used for the following purposes:
•
Distillation
•
Stripping
•
Absorption
•
Adsorption
•
Extraction.
A description of these items follows.
Distillation — a process which separates a mixture of materials into two or
more desired parts. The device which performs this operation may be called a
8-2
distillation tower, distillation column or fractionator. The operation of a
distillation column depends on the fact that different materials boil at different
temperatures. For example, water boils at 212 DEG F and ethyl alcohol (the
active ingredient in liquor) boils at 173 DEG F. Distillation is not a new
concept. The material which boils at the lower temperature is called the light
or more volatile component. The material with the higher boiling point is called
the heavy or less volatile component. In the case of ethyl alcohol and water,
we are dealing with a two component or binary mixture. This is not the usual
case. More commonly, the feed to a distillation column is a multi-component
mixture. For example, crude oil contains hundreds of different components.
The purpose of distilling crude oil is to separate it into what are called fractions
or cuts. Each fraction or cut is not a pure component, but a mixture of
components which may be used as is or refined further. Crude distillation
normally is used to produce these fractions: raw gasoline, raw kerosene, gas
oil and reduced crude.
Stripping — The process of extracting a material dissolved in a liquid phase
and transferring it into a gas phase is called stripping or desorption. The
stripping process is carried out in a device called a stripping tower or stripping
column. The removal of ammonia from water is an example of the stripping
process. Water with ammonia dissolved in it passes down the stripping tower.
Air passing upward through the tower strips the ammonia from the water and
the ammonia - air mixture exits from the top of the tower.
Absorption — The process of transferring a material from the gas phase to
the liquid phase is called absorption. The liquid into which the gaseous
component dissolves is called the absorbent. The device in which the
absorption process takes place is called an absorption tower, absorption
column or absorber. The removal of carbon dioxide and hydrogen sulfide from
the natural gas with deithanolamine (DEA) is an example of the absorption
process. Natural gas, CO2 and H2S pass upward through the tower. DEA
passing downwards absorbs the CO2 and H2S.
Adsorption — The process of transferring a material from either the gas or
liquid phase to the solid phase is called adsorption. The solid to which the
liquid or gaseous component attached itself is called the adsorbent. The device
in which the adsorption process takes place is usually called an adsorption
tower, adsorption column or adsorber. If the purpose of the adsorber is to
remove water, the term drying tower or dryer is often used.
Extraction — The process of transferring material from one liquid phase to
another immiscible liquid phase is called liquid - liquid extraction, solvent
extraction or simply extraction. Immiscible liquids are liquids which do not
dissolve in each other, for example, oil and water. If the two immiscible liquids
are contacted counter currently, the contacting device is called an extraction
column, extraction tower or extractor.
Tower/Column Internals
Trays — May be divided into two major categories; crossflow trays and
counter flow trays. Crossflow trays get their name because liquid flows across
the tray to a downcomer while vapor rises through perforations in the tray
deck. There are three types of crossflow trays in common use today. They are
the bubble cap, sieve tray, and valve tray. The bubble cap trays were used
almost exclusively until about 1950. Since then, the use of bubble cap trays
has almost disappeared because their complicated construction makes them
8-3
heavy (resulting in heavier and more expensive tray supports) and expensive
to fabricate.
Bubble cap trays get their name because vapor rises through holes in the tray
and is collected underneath bubble caps. Each cap has slots in it through which
the vapor from the tray below bubbles into the liquid on the tray.
Sieve trays are the cheapest trays to fabricate because of their simple design.
They consist of a perforated plate through which vapor rises from the tray
below, a weir to hold a liquid level on the tray, and a downcomer which acts as
a downspout to direct the liquid to the tray below. The operation of the sieve
tray depends on the vapor velocity through the perforations being high enough
to keep the liquid flowing across the tray and not down through the same
perforations the vapor is rising through. The drawback to the sieve tray is that
it has a narrow operating range compared to the bubble cap tray and the valve
tray. Too low a vapor velocity and the liquid falls through the holes to the plate
below - a condition called dumping. Too high a velocity and vapor doesn’t
bubble through the liquid on the tray. Instead, the vapor pushes the liquid
away from the hole so that there is no liquid-vapor contact. This condition is
called coning.
Valve trays have liftable caps which operate like check valves. These caps
make valve trays more expensive than sieve trays but they also increase the
operating range of the tray. At low vapor velocities, the caps close and prevent
dumping.
The other major category of trays is the counterflow type. These trays have no
downcomers. The liquid falls through the same openings in the tray that the
vapor from the tray below rises through. This type of tray is not widely used.
The most popular of the counterflow type tray is the Turbogrid tray.
Packings — The second major category of tower internals is packings.
Packings serve the same purpose as trays; they bring a gas or vapor stream
into intimate contact with a liquid stream. Trays accomplish this by providing a
very large wetted surface area for the gas or vapor to flow by. Packed towers
would normally be selected instead of tray towers in the following instances:
1
For columns less than 2 FEET in diameter, packing is generally cheaper.
2
If highly corrosive fluids are being handled, packings are often
advantageous because they can be made of ceramic, carbon, plastic or
other highly resistant metallic or non-metallic material.
3
Packed towers are low pressure drop devices, therefore, they are often used for
vacuum distillations.
The major disadvantages of packed towers are:
1
They have a narrower operating range than tray towers.
2
A packed tower must have a larger diameter than a tray tower to handle
the same feed rate.
The most common types of packings are: Raschig rings, Berl saddles, Intalox
saddles and Pall rings.
Adsorption towers are packed towers; however, their function is to transfer a
material from the liquid or gas phase onto the surface of the solid adsorbent.
Adsorbents are not packing types. Adsorbents are generally either a granular
material or else spherical or cylindrical shaped pellets. Some common
adsorbents are: Fuller’s earthes (natural clays), activated clay, alumina,
activated carbon and silica gel.
8-4
Description of Towers/Columns
“Towers” and “columns” are interchangeable name for the same device. These
devices have one of two functions. One is to separate a mixture into two or
more desired parts. The other function is to transfer a material from one phase
to another phase.
Towers are classified according to the function performed. Examples are
distillation, stripping or extraction. Towers are also classified by the type of
device installed inside (internals) so the tower can perform its desired
function. Tower internals consist of either trays or packings.
Towers are always erected vertically. They are usually tall and cylindrical in
shape. Sometimes they are designed with the top of the tower one diameter
and the bottom a different (usually larger) diameter. This gives the tower a
“Coke bottle” shape and is called a double diameter tower.
The cylindrically shaped body of the tower is called the shell. The shell is
closed at both ends with dome-shaped covers called heads. There are three
head designs in common use:
•
Torispherical, the most common of which is the ASME flanged and dished
head
•
Ellipsoidal, also called elliptical, elliptical dished or 2:1 ellipsoidal (because
the ratio of the length of the major to the minor axis of this head is 2:1)
•
Hemispherical.
Which kind of head to use is an economic decision. The torispherical head is
the cheapest to fabricate, but is the thickest for a given pressure. The
ellipsoidal head is more expensive to fabricate than the torispherical, but is
thinner at the same pressure. The hemispherical head is the most costly to
fabricate, but is the thinnest for a given pressure. Thus, the material cost
decreases from the torispherical to hemispherical because the head gets
thinner, but the fabricating costs increase. At pressures below 150 PSIG the
torispherical head is generally the cheapest. From 150 PSIG to 500 PSIG, the
ellipsoidal is usually selected. Above 150 PSIG, the hemispherical head
becomes an economically viable alternative.
Openings are provided in the shell and heads of a tower so that process fluids
can enter and leave. Other openings in the tower are provided for drains,
purge connections and sample connections. These openings into the tower are
called nozzles.
Nozzles range in diameter from 1 INCH for small drains, vents and sample
connections to 24 INCHES [609.6 MM] or more for large process connections.
The small (1 INCH) connections are usually made with pipe couplings, not with
welding necks and flanges.
Workers must be able to enter the tower after it is erected to install and
maintain the internals. Openings in the tower provided for this purpose are
called manholes or manways. Manholes are just nozzles large enough for a
man to pass through. Manholes range in diameter from 18 - 48 INCHES [1219
MM].
A tower is normally supported by a steel cylinder the same diameter as the
tower called a skirt. The skirt is welded to the tower at one end and bolted to
the foundation at the other.
8-5
In addition to nozzles, manholes and skirts, other appurtenances may be
attached to the tower. These other externals may include insulation clips for
the support of insulation, lifting lugs which are eyelets to which rigging is
attached so that the tower can be lifted and placed on its foundation, and
various structural steel members for the support of platforms and ladders.
Materials of Construction
The tower shell and heads are usually fabricated out of carbon or low alloy
steel plate.
As the name implies, the primary alloying element in carbon steel is carbon.
All the other alloying elements in carbon steel are limited to concentrations
less than 0.5%. The most common materials of construction for towers are the
carbon steels A515 and A516.
Low alloy steel contain one or more alloying elements besides carbon in
concentrations from 0.5% to 10%. Alloying elements in concentrations greater
than 10% make the steel a high alloy steel.
When extremely corrosive materials are to be handled, the tower may be
fabricated out of a high alloy steel such as one of the stainless steels, a nonferrous metal such as titanium or monel, or a non-metal such as FRP
(fiberglass reinforced polyester). However, because these materials are either
very expensive or else have design limitations such as low strength, claddings
and linings are commonly used for corrosion resistance. Clad plate consists of
a thin layer of corrosion resistant metal permanently bonded to an inexpensive
carbon or low alloy steel backing. Linings differ from claddings in that there is
not a permanent continuous bond between the corrosion resistant material
and the backing material, and the corrosion resistant material is usually not a
metal. Common lining materials are brick, cement, rubber and glass.
Shell and Head Design
Typically, many companies normally require that tower shells and heads be
designed according to the latest edition of Section VIII Division 1 of the ASME
Boiler and Pressure Vessel Code. Towers manufactured in the United States
will carry the ASME code stamp certifying that the vessel has been designed
and fabricated to code standards. Towers manufactured outside the United
States are to be designed and fabricated according to code standards as well,
but need not carry the code stamp.
Towers which are unusually large, or towers which are required to operate at a
very high pressure may be designed according to Section VIII Division 2 of the
ASME Code. Division 2 requires complete stress analysis of the process vessel.
This complete analysis allows the vessel to be designed with much smaller
safety factors. This results in a vessel which has a thinner shell and head and
is therefore cheaper to fabricate than the same vessel designed according to
the rules of Division 1. Since a Division 2 design results in a cheaper vessel,
why aren’t all process vessels designed according to the rules of Division 2?
Again it is a question of economics. A Division 2 design is so complex that the
money spent in extra engineering time for the vessel can easily exceed the
savings realized in the fabrication of the vessel. Only in very large or thick
walled vessels is the economic advantage of a Division 2 clear-cut.
8-6
Pressure/vacuum,
includes vessel
shell, heads,
transition section,
single base
material, lined or
clad, nozzles,
manholes (one
manhole below and
above tray stack or
packed section and
one manhole every
tenth tray or 25
FEET [7.6 M] of
packed height),
stiffening rings if
desired, base ring,
lugs, skirt or legs;
tray clips, tray
supports (if
designated),
distributor piping,
plates, packing (if packing designated); variety of applications for plate and
packed towers: absorption, desorption, distillation or stripping (via kettle or
8-7
thermosiphon reboiler defined separately), extraction; applications for packed
towers: gas and liquid adsorption; sections can be trayed, packed, empty.
Systems with automatic installation bulks (Aspen Capital Cost Estimator and
Aspen Process Economic Analyzer ) generate platforms for towers. A tower
begins with one 360 DEGREE platform for the first 25 FEET [7.6 M], or fraction
thereof, of exposed height, plus one 90 DEGREE platform for every additional
25 FEET [7.6 M], or fraction thereof, of exposed height. If the tower is in a
structure, the system subtracts the height of the structure from the total tower
height (Bottom T-T height + Skirt height) to calculate the total exposed
height. To place a tower in a structure, make the area type OPEN or EX-OPEN
(see Chapter 36 for area type descriptions), or else use the Structure tag
number to assign the tower to the open steel structure (OPN-STL-ST)
available under steel plant bulks.
(See
Single Diameter Towers for tray stacks.)
Description
Type
Packed double diameter tower.
PACKED
Application:
Defines vessel function and related
pipe/instrumentation model.
Default: *ABSORB*
ABSORB- Absorption
DESORB- Desorption
DISTIL- Distillation with thermosiphon reboiler
(not included)
8-8
Double Diameter Towers (DDT) - continued
Description
Type
PACKED - continued
DIS-RB- Distillation with kettler reboiler (not included)
EXTRAC- Extraction
GAS-AD- Gas adsorption
LIQ-AD- Liquid adsorption
STRIPP- Stripping with thermosiphone reboiler (not
included)
STR-RB- Stripping with kettle reboiler (not included)
Base material Bottom:
For clad plate, specify the backing plate material
(cladding is defined below). See Chapter 28
for materials.
Design gauge pressure Bottom.:
Default: Specified top section pressure, or 50 PSIG
[350 KPA]: negative for vacuum.
Design temperature Bottom:
Default: Specified top section temp or 250 DEG F [120
DEG C].
Packing material Bottom:
Default: *NONE*
Packing height Bottom:
Default: *0.0* FEET [*0.0* M]
Cladding material Bottom:
Default: *NONE*
Skirt height:
Default: 1.5 x bottom diameter; enter 0.0 if vessel
hung in OPEN structure.
Manhole diameter Bottom:
Thickness Bottom section:
Corrosion allowance Bottom:
Cladding thickness Bottom:
Stiffening ring spacing Bottom:
if not required.
8-9
Description
Type
PACKED - continued
Base material Top:
(cladding is defined below). See Chapter 28 for
materials. Default: *A 515*
Design gauge pressure Top:
Default: Specified bottom section pressure or 50 PSIG
[350 KPA]; negative for vacuum.
Design temperature Top:
Default: Specified bottom section temperature or 250
DEG F [120 DEG C].
Packing material Top:
Default: *NONE*
Packing height Top:
Default: *0.0* FEET [*0.0* M]
Cladding material Top:
Default: *NONE*
Pipe material Top:
Manhole diameter Top:
Thickness Top section:
Corrosion allowance Top:
Default 0.125 INCHES [3 MM] for CS, 0.0 for other
materials.
Cladding thickness Top:
Stiffening ring spacing Top:
if not required.
Wind or seismic design:
Default: Vessel designed for wind and seismic loads
defined in project basis.
W+S- Wind and seismic design required
WIND- Wind design only
SEIS- Wind/seismic design
NONE- Delete wind and seismic design
8-10
Description
Type
PACKED - continued
Fluid volume:
Max: 100; Default: *20*; For seismic design, fluid
volume as a% of vessel volume (water assumed).
Vacuum design gauge pressure:
case. Default: pressure.
Weld efficiency:
50 - 100; ASME/JIS codes only, where allowed for thin
wall vessels; Default: Area Design Basis.
Stress relief:
Molecular weight Overhead prod:
Default: 50 for distillation and stripping applications;
otherwise 30.
Number body flange sets Bottom:
diameter as vessel.
Number body flange sets Top:
diameter as vessel.
Diameter option:
Defines desired diameter as ID or OD;
ID- Inside diameter
ASME design basis:
Default: *D1NF*, applicable only for
ASME code design.
D1NF- ASME Division 1 - no fatigue analysis
D1F- ASME Division 1 - with fatigue analysis
8-11
Description
Type
Trayed double diameter tower.
Available tray types include: bubble cap, sieve, turbo
grid, valve and clips and supports without trays.
TRAYED
Tray type:
Default: *VALVE*
VALVE- Valve trays
BUBBL- Bubble cap trays
TURBO- Turbo grid trays
SIEVE- Sieve trays
NONE.- No trays
Application:
Defines vessel function and related pipe/
instrumentation model; Default: *DISTIL*
ABSORB- Absorption
DESORB- Desorption
(not included)
DIS-RB- Distillation with kettle reboiler
(not included)
EXTRAC- Extraction
STRIPP- Stripping with thermosiphon reboiler
(not included)
STR-RB.- Stripping with kettle reboiler (not included)
materials. Default: *A 515*.
Design gauge pressure Bottom:
Default: Specified top section pressure, or 50 PSIG
[350 KPA]; negative for vacuum.
Default: Specified top section temperature or 250 DEG
F [120 DEG C].
Bottom tray material or packing:
Specify tray material for trays or packing material for
packed sections. See Chapter 28 for materials.
Default: *A 515*.
No. trays/Packed height Bottom:
Enter number of trays for trayed sections or packing
height for packed sections. Default: *0.0*
8-12
Description
Type
TRAYED - continued
Corrosion allowance Top:
materials.
Cladding thickness Top:
Stiffening ring spacing Top:
if not required.
Default: vessel design for wind and seismic loads
defined in Project Basis.
SEIS- Seismic design only
Fluid volume:
For seismic design; fluid volume as a% of vessel
volume (water assumed); Max: 100; Default: *20*.
Weld efficiency:
Range: 50 - 100; ASME/JIS codes only, where allowed
for thin wall vessels; Default: Area Basis.
Stress relief:
Molecular weight Overhead prod:
Default: 50 for distillation and stripping applications;
otherwise - 30.
Number body flange sets Bottom:
diameter as vessel.
Number body flange sets Top:
diameter as vessel.
8-13
Description
Type
TRAYED - continued
Diameter option:
ID- Inside diameter
ASME design basis:
Applicable only for ASME code design.
See following entries for fatigue data.
D2F- ASME Division 2 with fatigue analysis
Start Stop cycles x 1000:
ASME fatige only. Thousands of start-up cycles during
the full equipment life; Min: 0.02;
Default: *1.0*.
Pressure cycles x 1000:
ASME fatigue only. Thousands of deviations from
design pressure during equipment life.
Default: *0*.
Pressure amplitude:
ASME fatigue only. Amplitude of pressure deviation as
percent of design pressure. Default: *0*.
Number of hydrostatic tests:
ASME fatigue only. Number of hydrostatic tests during
the full equipment life. Default: *20*.
Temperature cycles x 1000:
design temperature in equipment life. Default: *0*.
Temperature amplitude:
ASME fatigue only. Amplitude of temperature deviation
as a percent of design temperature.
Tray thickness:
Default: 0.1875 INCH [4.5 MM].
8-14
Description
Type
Multiple Diameter Trayed or Packed
Double-diameter tower with multiple sections. Each
section can be trayed or packed.
Trayed double diameter tower.
For Trayed Sections:
Tray type:
Default: *VALVE*
VALVE - Valve trays
BUBBL - Bubble cap trays
TURBO - Turbo grid trays
SIEVE - Sieve trays
NONE. - No trays
Application:
pipe/instrumentation model; Default: *DISTIL*
ABSORB - Absorption
DESORB - Desorption
DISTIL - Distillation with thermosiphon reboiler
(not included)
DIS-RB - Distillation with kettle reboiler
not included)
EXTRAC - Extraction
GAS-AD - Gas adsorption
LIQ-AD - Liquid adsorption
STRIPP - Stripping with thermosiphon reboiler
(not included)
STR-RB. - Stripping with kettle reboiler
(not included)
For Bottom section:
for materials.
Default: *A 515*.
8-15
Description
Type
Multiple Diameter Trayed or Packed - continuedDiameter Bottom section:
Diameter of Bottom section
Bottom tangent to tangent height:
Enter either Capacity or Diameter and Height
Base material thickness including corrosion
allowance
Design gauge pressure Bottom:
Default: Specified top section pressure, or
50 PSIG [350 KPA]; negative for vacuum.
Default: Specified top section temperature or
250 DEG F [120 DEG C].
For Middle section:
Base material Middle:
(cladding is defined below). See
Chapter 28 for materials.
Default: *A 515*.
Design gauge pressure Middle:
Default: Specified middle section pressure, or
Design temperature Middle:
Default: Specified middle section temperature or
250 DEG F [120 DEG C].
For Top section:
Base material Top:
for materials.
Default: *A 515*.
Design gauge pressure Top:
Design temperature Top:
Default: Specified top section temperature or
250 DEG F [120 DEG C].
Diameter option:
OD - Outside diameter
ID - Inside diameter
8-16
Description
Type
Multiple Diameter Trayed or Packed - continuedHead Type:
ELLIP - 2:1 Ellipsoidal
HEMI - Hemispherical
TORI - Torispherical (ASME)
Skirt height:
Default: 1.5 x bottom diameter; enter 0.0 if
vessel hung in OPEN structure.
Skirt thickness:
Default: System calculated
Demister thickness:
SS304 mist pad 12 PCF [192 KG/M3] with top
and bottom support grids. Def. 0
Transition height-Bottom-Middle:
Transition height between bottom and
middle sections.
Transition height-Middle-Top:
Transition height between middle and top sections.
If pressure and vacuum entered, design is for
worst case. Default: pressure design.
Jacket design gauge pressure:
Jacket pressure or thickness required to
obtain jacket.
Default: no jacket.
Jacket type:
FULL - full jacket
PIPE - half-pipe jacket
Default: FULL
Jacket thickness:
Jacket pressure or thickness required to obtain
jacket.
Default: no jacket.
Jacket material:
See Chapter 28 for materials. Default: *CS*.
Default: vessel design for wind and seismic loads
W+S - Wind and seismic design required
WIND - Wind design only
SEIS - Seismic design only
NONE - Delete wind and seismic design
8-17
Description
Type
Multiple Diameter Trayed or Packed - continuedFluid volume:
For seismic design; fluid volume as a percent
of vessel volume (water assumed)
Max: 100
Default: *20*.
Tower Section Details:
Note: Clicking the red arrow in the Tower Section
Details field opens the Tower internal data form, on
which to enter details about the bottom, middle and
top sections of the tower.
For each section:
Name:
The name of the section.
Base material:
For clad plate, specify the backing plate
material (cladding is defined below). See
Chapter 28 for materials.
Diameter:
Enter the diameter of the vessel.
Vessel tangent to tangent height:
Thickness:
allowance.
50 PSIG [350 KPA]: negative for vacuum.
Design temperature:
Default: Specified top section temp or
250 DEG F [120 DEG C].
Corrosion allowance:
Default: 0.125 INCHES [3 MM] for CS, 0.0 for
other materials.
Cladding material:
Default: *NONE*.
Cladding thickness:
is specified; otherwise: 0.0.
8-18
Description
Type
Multiple Diameter Trayed or Packed - continuedSECTION - TRAYS
Number of trays:
Enter number of trays. Min 2.
Tray type:
Default: *VALVE*
VALVE- Valve tray
SIEVE- Sieve trays
NONE- No trays
Tray material:
See Chapter 28 for materials. Default: *A285C*.
Tray spacing:
Range: 12 - 30 INCHES [305 -760 MM];
Tray thickness:
Default: *0.187* INCHES [*4.50*]
Max: 0.375 INCHES [9.00 MM].
SECTION - PACKINGS
Packing height Section 1:
Max: Tangent to tangent height less 1.0 FEET
[0.3 M].
Packing material(1):
Packing height Section 2:
Max: Tangent to tangent height less height
of packing No. 1.
Packing material(2):
Jacket option:
*NO*- Jacket not required
YES- Jacket is required
Number of manholes:
Default: *1*.
Manhole diameter:
Default: *18* INCHES[*450* MM].
Stiffening ring thickness:
Default stiffeners designed for vacuum only;
enter 0.0 if not required.
Number of body flange sets:
Number of sets (pairs) of body flanges of the
same diameter as the vessel.
Pipe material:
See a list of piping materials.
8-19
Pressure/vacuum includes vessel shell, heads, single base material (lined or
clad), nozzles, manholes, jacket and nozzles for heating or cooling medium,
base ring, lugs, skirt or legs; tray clips, tray supports (if designated),
distributor piping, plates, packing (if packing designated); variety of
applications for plate and packed towers: absorption, desorption, distillation or
stripping (via kettle or thermosiphon reboiler defined separately), extraction;
applications for packed towers: gas and liquid adsorption; trayed, packed,
empty.
Systems with
automatic installation
bulks (Aspen Capital
Cost Estimator and
Aspen Process
Economic Analyzer )
generate platforms for
towers. A tower begins
with one 360 DEGREE
platform for the first 25
FEET [7.6 M], or
fraction thereof, of
exposed height, plus
one 90 DEGREE
platform for every
additional 25 FEET [7.6
M], or fraction thereof,
of exposed height. If
the tower is in a
structure, the system
subtracts the height of
the structure from the
total tower height (Bottom T-T height + Skirt height) to calculate the total
exposed height. To place a tower in a structure, make the area type OPEN or
EX-OPEN (see Chapter 36 for area type descriptions), or else use the
Structure tag number to assign the tower to the open steel structure (OPNSTL-ST) available under steel plant bulks.
If the number of platforms is greater than or equal to six, then the number of
manholes is equal to one plus the number of platforms. If the number of
platforms is less than six, the number of manholes is equal to one plus
8-20
approximately one for every 18 trays (for small towers, tray spacing is about
12 INCHES, so there would be one manhole for about every 18 FEET).
Description
Type
Packed single diameter tower.
PACKED
If a packing type is not specified, a packed column is
designed and costed with distributor and support
plates for average density packing.
Application:
instrumentation model; Default: *ABSORB*
ABSORB- Absorption
DESORB- Desorption
DISTIL - Distillation with thermosiphon reboiler
(not included)
(not included)
EXTRAC- Extraction
(not included)
Shell Material:
for materials.
Default: *A 515*.
If pressure and vacuum entered, design is
for worst case. Default: pressure *15* PSIG
[*100* KPA].
If pressure and vacuum entered, design is
for worst case. Default: pressure.
Design Temperature:
otherwise material: 650 DEG F [340 DEG C].
Packing Type:
If packing type is not specified, no packing will
be provided. See Chapter 28 for packing materials.
Total Packing Height:
Max: tangent to tangent height less 1.0 FEET
[0.3 M].
Demister Thickness:
Max: 12.0 INCHES [300 MM].
SS304 mist pad 12 PCF [192 KG/M3] with top
and bottom support grids.
8-21
Single Diameter Towers (TW) - continued
Description
Type
PACKED - continued
Cladding Material:
Default: *NONE*.
Skirt Height: Enter 0.0 skirt height if tower hung in
OPEN structure; Default: 1.5 x diameter.
Wind or Seismic Design: Default: Vessel designed
for wind and seismic loads defined in Project Basis.
Fluid Volume:
volume (water assumed). Max: 100; Default: *20*.
Manhole Diameter:
Max: 48 INCHES [1,200 MM].
Default: 0.125 INCHES [3 MM] for CS; 0.0 for other
material. Double if jacketed.
diameter as vessel.
Weld Efficiency:
ASME/JIS Codes only, where allowed for thin wall
vessels; Default: Area Basis; Range: 50 - 100.
Stress Relief:
Cladding Thickness:
specified, otherwise - 0.0.
if not required.
Default: No jacket.
Jacket Type:
Default: *FULL*.
FULL- Full jacket
PIPE.- Half-pipe jacket
8-22
Description
Type
PACKED - continued
Jacket Thickness:
Default: No jacket.
Jacket Material:
Head Type:
ELLIP- 2:1 ellipsoidal
HEMI- Hemispherical
TORI- Torispherical (ASME)
Molecular Weight Overhead Prod:
Default: 50 for distillation and stripping applications,
otherwise 30.
Diameter Option:
Defines desired diameter as ID or OD; Default: See
Area Design Basis.
ID- Inside diameter
ASME Design Basis:
Start Stop Cycles x 1000:
the full equipment life; Min: 0.02; Default: *1.0*.
Pressure Cycles x 1000:
design pressure during equipment life. Default: *0*.
Pressure Amplitude:
Number of Hydrostatic Tests:
Temperature Cycles x 1000:
Temperature Amplitude:
ASME fatigue only. Amplitude of temperature
deviation as a percent of design temperature.
8-23
Description
Type
Trayed single diameter tower.
TRAYED
Tray Type:
Default: *VALVE*
VALVE- Valve tray
SIEVE- Sieve trays
NONE- No trays
Application:
instrumentation model; Default: *DISTIL*.
ABSORB- Absorption
DESORB- Desorption
(not included)
(not included)
EXTRAC- Extraction
(not included)
Shell Material:
(cladding is defined below). Default: *A 515*.
Default: 15 FEET [4.5 M] plus tray stack height.
case. Default: pressure *15* PSIG [*100* KPA].
Design Temperature:
otherwise material: 650 DEG F [340 DEG C].
Tray Material:
Number of Trays:
Min: 2
8-24
Description
Type
TRAYED - continued
Tray Spacing:
Range: 12 - 30 INCHES [305 -760 MM]; Default: *24*
INCHES [*600* MM].
Demister Thickness:
Max: 12 INCHES [300 MM]
Cladding Material:
Default: *NONE*.
Skirt Height:
Enter 0.0 skirt height if tower hung in OPEN structure;
Default: 1.5 x diameter.
Wind or Seismic Design:
Fluid Volume:
Manhole Diameter:
Default: 0.125 INCHES [3 MM] for CS; 0.0 for other
material. Double if jacketed.
diameter as vessel.
Weld Efficiency:
ASME/JIS Codes only, where allowed for thin wall
vessels; Range: 50 - 100; Default: Area Basis.
Stress Relief:
CODE, YES, NO; Default: See Area Design Basis.
Cladding Thickness:
if not required.
Jacket Design Gauge Pressure: Jacket pressure or
thickness required to obtain jacket. Default: No
jacket.
8-25
Description
Type
TRAYED - continued
Jacket Type:
Default: *FULL*
FULL- Full jacket
Jacket Thickness:
Default: No jacket.
Jacket Material:
Head Type:
HEMI- Hemispherical
TORI- Torishpherical (ASME)
Molecular Weight Overhead Prod:
Default: 50 for distillation and stripping applications,
otherwise 30.
Diameter Option:
Area Design Basis.
ID- Inside diameter
Tray Thickness:
Default: *0.187* INCHES [*4.50* MM];
Max: 0.375 INCHES [9.00 MM]
ASME Design Basis:
Start Stop Cycles x 1000:
the full equipment life; Min: 0.02; Default: *1.0*.
Pressure Amplitude:
8-26
Description
Type
TRAYED - continued
Temperature Cycles x 1000:
Temperature Amplitude:
ASME fatigue only. Amplitude of temperature
deviation as a percent of design temperature.
Tray stack only, for single- and double-diameter
towers.
TRAY STACK
Optional tray types include: bubble-cap, turbo
grid, seive and valve.
Tray Material:
Number of Trays: Min: 1.
Tray Type:
SIEVE- Sieve trays
VALVE- Valve trays
Tray Thickness:
Default: *0.187* INCHES [*4.50* MM];
Max: 0.375 INCHES [9.00 MM]
Tray Spacing:
Range: 12 - 30 INCHES [305 - 750 MM];
Default: 24 INCHES [600 MM].
Direct contact heat exchanger tower includes
distributors, packing supports, nozzles; may include
packing.
DC HE TW
Shell Material:
materials.
Default: *A 515*.
Gas Flow Rate Inlet:
Range: 30,000 - 300,000 LB/H
[13,610 - 136,000 KG/H]; Enter either flowrate or
diameter and height.
Vessel Diameter:
Enter either flowrate or diameter and height.
8-27
Description
Type
DC HE TW - continued
case. Default: pressure 15 PSIG [100 KPA].
Design Temperature:
other material: 650 DEG F [340 DEG C].
Enter maximum gas temperature.
Packing Type Section 1:
Default: *68PVC*. See Chapter 28 for packing
materials.
Packing Height Section 1:
Max: Tangent to tangent height less 1.0 FEET [0.3 M].
Default: None for OPEN top, else 68PVC.
Max: Tangent to tangent height less height of packing
No. 1.
Cladding Material:
Default: *NONE*.
Skirt Height:
Enter 0.0 skirt height if tower hung in OPEN
structure; Default: 1.5 x diameter.
WIND- Wind display only
Fluid Volume:
For seismic design, fluid volume as a% of vessel
Manhole Diameter:
8-28
Description
Type
DC HE TW - continued
material, double if jacketed.
diameter as vessel.
Weld Efficiency:
vessels; Default: See Area Basis; Range: 50 - 100%.
Stress Relief:
Cladding Thickness:
if not required.
Default: No jacket.
Jacket Type:
Default: *FULL*
FULL- Full jacket
Jacket Thickness:
Jacket pressure or thickness required to obtain
jacket. Default: No jacket.
Jacket Material:
Head Type:
HEMI- Hemispherical
OPEN- Open top/TORI bottom
Diameter Option:
Area Design Basis.
ID- Inside diameter
8-29
Description
Type
Temperature swing adsorption unit includes vessel
TS ADSORB
pair(s), distributors, packing supports, and valve skid;
may include heater (steam or electric), packing.
Shell Material:
materials.
Default: *A 515*.
Gas Flow Rate Inlet:
Enter either flowrate or diameter and height; Range:
30,000 - 300,000 LB/H [13,610 - 136,000 KG/H].
Vessel Diameter:
Number of Vessel Pairs:
Number of vessel pairs in configuration, one vessel per
pair absorbing at a time.
case. Default: pressure 15 PSIG [100 KPA].
Design Temperature:
other material: 650 DEG F [340 DEG C].
See Chapter 28 for packing materials; Default:
*13XMS*.
Max: Tangent to tangent height less 1.0 FEET [0.3 M].
Default: *ALMNA* (Alumina).
Max: Tangent to tangent height less height of packing
No. 1.
Cladding Material:
Default: *NONE*.
Skirt Height:
Enter 0.0 skirt height if tower hung in OPEN structure;
Default: 1.5 x diameter.
8-30
Description
Type
TS ADSORB - continued
WIND- Wind design only`
Fluid Volume:
Manhole Diameter:
diameter as vessel.
Weld Efficiency:
vessels; Range: 50 - 100%; Default: See Area Basis.
Stress Relief:
Cladding Thickness:
if not required.
Default: No jacket.
Jacket Type: Default: *FULL*
FULL- Full jacket
Jacket Thickness:
Default: No jacket.
Jacket Material:
8-31
Description
Type
TS ADSORB - continued
Head Type:
HEMI- Hemispherical
OPEN- Open top/TORI bottom
Heater Type:
*ELEC*- Electric heater
STEAM- Steam heater
NONE- No heater
Applies to steam gas heater only
Diameter Option:
ID- Inside diameter
8-32
8-33
8-34
8-35
8-36
8-37
8-38
9 Vacuum Systems
(G6)
Condensers (C)
Ejectors (EJ)
Vacuum Pumps (VP)
9 Vacuum Systems (G6)
9-1
Condensers (C)
Barometric condenser
Description
Type
Barometric for condensing of motive steam between
ejector stages.
BAROMETRIC
Material:
Default: *CS*
Water flow rate:
Range: 200 - 5,000 GPM [15 - 315 L/S]
Material:
CI
Water flow rate:
Range: 40 - 5,000 GPM [3 - 315 L/S]
Material:
RBLCS (rubber lined carbon steel)
Water flow rate:
Range: 200 - 3,000 GPM [12 - 180 L/S]
9-2
Ejectors (EJ)
100 PSIG [690 KPA] steam
Description
Type
One stage of non-condensing ejection.
SINGLE STG
Single stage ejectors may be used to produce
pressures as low as 2 INCHES Hg ABS, but are
normally used in the pressure range from atmospheric
to 3 INCHES Hg ABS. Ejectors are used to generate
low pressure for vacuum distillation, vacuum
crystallization and evaporation and to produce chilled
water.
Ejectors use a high pressure motivating fluid, usually
steam, to produce a vacuum. The single stage ejector
consists of three basic parts: nozzle, mixing chamber
or suction head, and diffuser. Although ejectors can be
fabricated from a variety of material, usually the
nozzle is stainless steel and the mixing chamber and
diffuser are cast iron or steel. Ejectors are easily
recognized by the long thin hour-glass shape of the
diffuser.
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
HAST- Hastelloy
Air ejection rate:
Range: 10 - 10,000 LB/H [4.6 - 4,530 KG/H]
Suction absolute pressure:
Range: 20 - 400 MM HG [2,670 - 53,300 PA]
.TWO STAGE
Two ejection stages with barometric intercondenser
Two stage ejectors are used to produce suction
pressures from 4 to 0.5 INCHES Hg ABS. Two stage
ejectors have the same process applications as single
stage ejectors.
This item is a two stage ejector with a barometric type
intercondenser. A two stage ejector is simply two
single stage ejectors arranged in series. Two stages
can produce a higher vacuum than a single stage
ejector. The first stage evacuates the equipment item
to which it is attached and compresses these gases
and vapors to an intermediate pressure.
The motive steam and condensable vapors ejected by
the first stage are condensed in the barometric
condenser to reduce the load on the second stage. The
second stage ejector takes the non-condensable
gasses from the first stage and compresses them to
atmospheric pressure so that they may be released to
the atmosphere.
9-3
Ejectors (EJ) - continued
Description
Type
TWO STAGE - continued
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
HAST- Hastelloy
Air ejection rate:
Range: 10 - 150 LB/H [4.6 -68 KG/H]
Range: 10 - 200 MM HG [1,340 - 26,600 PA]
Non-condensing two single stage ejectors without
2 STAGE
intercondenser. A two stage non-condensing ejector is
less expensive than a two stage condensing ejector on
an installed basis. The non-condensing ejector may be
used for an application where the condensing ejector
is used. Therefore, the non-condensing ejector is
preferred where the lower initial capital investment
out-weighs the higher operating cost due to the higher
steam consumption.
This item is a two stage non-condensing ejector. Two
single stage ejectors are arranged in series without an
intercondenser. Hence, the second stage condenser
must handle the motive steam from the first stage
ejector and the gases evacuated from the process
vessel. This results in a larger second stage ejector
and increased steam consumption over a two stage
condensing unit.
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
HAST- Hastelloy
Air ejection rate:
Range: 10 - 120 LB/H [4.6 - 50 KG/H]
Range: 5 - 100 MM HG [670 - 13,3000 PA]
9-4
Description
Type
Four stages of ejection with barometric condenser
4 STAGE B
between third and fourth ejector.
Four stage ejectors are used to produce suction
pressures from 4 to 0.2 MM Hg ABS. Four stage
ejectors are used to produce suction for vacuum
distillation, vacuum crystallizers and vacuum
evaporators.
This item is a four stage ejector with one barometric
condenser between the third and fourth ejectors. The
condenser is used only between those stages where
the condensing temperature of the steam is greater
than the temperature of the cooling water available.
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
HAST- Hastelloy
Air ejection rate:
Range: 10 - 110 LB/H [4.6 - 48 KG/H]
Range: 0.5 - 10 MM HG [67 - 1,330 PA]
Four stages of ejection with barometric condensers,
between second and third and between third and
fourth ejector. Four stage ejectors are used to produce
suction pressure from 4 to 0.2 MM Hg ABS. Four stage
distillation, vacuum crystallizers, and vacuum
evaporators.
This item is a four stage ejector with two barometric
condensers. Four ejectors are arranged in series with
one condenser between the second and third ejectors
and the other between the third and four ejectors.
Condensers are used only between those ejectors
where the condensing temperature of the steam is
greater than the temperature of the cooling water
available.
4 STAGE
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
HAST- Hastelloy
Air ejection rate:
Range: 10 - 110 LB/H [4.6 - 48 KG/H]
Range: 0.25 - 5.0 MM HG [33 - 660 PA]
9-5
Description
Five stages of ejection with barometric condenser
between fourth and fifth ejector.
Five stage ejectors are used to produce suction
pressures from 0.4 to 0.02 MM Hg ABS. Five stage
distillation, vacuum crystallizers and vacuum
evaporators.
This item is a five stage ejector with one barometric
condenser between the fourth and fifth ejectors.
Type
5 STAGE B
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
HAST- Hastelloy
Air ejection rate:
Range: 10 - 110 LB/H [4.6 - 48 KG/H]
Range: 0.5 - 1.0 MM HG [7 - 130 PA]
9-6
Vacuum Pumps (VP)
Includes pump, motor and drive unit.
Description
Type
Water-sealed vacuum pump.
Ultimate pressure: 500 MM HG [66,660 PA].
Water-sealed 500 MM HG [PA] vacuum, explosion
proof motor.
WATER SEAL
Material:
Default: *CS*
CS- Carbon steel
SS316- SS316
Range: 30 - 4,000 CFM [55 - 6,750 M3/H]
Mechanical oil-sealed vacuum pump.
MECHANICAL
First stage: 0.01 MM HG [1.35 PA]
Second stage: 0.0003 MM HG [0.04 PA].
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Range: 30 - 700 CFM [55 - 1,150 M3/H]
Number of stages:
Mechanical booster includes motor and drive.
Ultimate pressure 0.0001 MM HG [0.0135 PA].
MECH BOOST
Material:
Default: *CS*
CS- Carbon steel
Range: 120 - 2,000 CFW [205 - 3,375 M3/H]
9-7
9-8
10 Vessels
(G10)
Vertical Tanks (VT)
10 Vessels (G10)
10-1
Horizontal vessels are commonly used as settling drums, surge tanks, reactors
and distillate drums. A settling drum is used for phase separation between two
immiscible liquids. The L/D ratio of a settling drum is normally four. A surge
tank or surge drum is used to maintain a constant flowrate of liquid to a
downstream piece of equipment when the flowrate of liquid from the upstream
piece of equipment is fluctuating. The fluctuations in flow rate are absorbed by
the surge drum by allowing the liquid level in this drum to rise and fall.
Horizontal drums are frequently filled with catalyst and used as reactors.
Placing catalyst in horizontal vessels allows shallow bed depths and large
cross-sectional areas. A typical example of horizontal vessels being used as
reactors is the Claus reactor. A distillate or reflux drum provides space for
overhead condensables from a distillation column to separate from vapors.
Surge drums and distillate drums are normally vertical. If there is settleable
water in the feed to these vessels, however, the vessel is erected with a
water pot.
The horizontal vessel is a pressure vessel fabricated according to the rules of
the specified code (i.e., Section VIII Division 1 of the ASME Code) and erected
in the horizontal position. Although the horizontal vessel may be supported by
lugs in an open steel structure, the more usual arrangement is for the vessel
to be erected at grade and supported by a pair of saddles.
Cylindrical, pressure/vacuum, code design and construction, includes heads,
single wall (base material, clad/lined), saddles/lugs, nozzles and manholes.
Description
Type
Horizontal pressure/vacuum drum.
Use minus pressure for vacuum design.
HORIZ DRUM
The capacity excludes the volume of the heads. If
both the vessel dimensions and capacity are specified,
the system-calculated capacity must agree with the
specified capacity to within plus or minus 10% to
avoid an error condition.
10-2
10 Vessels (G10)
Horizontal Tanks (HT) - continued
Description
Type
HORIZ DRUM - continued
To secure desired vessel size, specify the diameter and
height directly. A value must be specified if vessel
diameter and/or vessel height (or length) are not
specified. If vessel diameter and height (or length) are
specified, the vessel volume is calculated from these
dimensions. If only vessel capacity is specified, a
straight side length-to-diameter ratio is chosen by the
system, considering cost and practicability.
(Default ratio is 2:1.)
Application:
piping/instrumentation model. Default: *blank*blankStandard continuous process vessel BATCH- Batch
process vessel
STORAGE- Storage vessel
RECVR- Receiver
KO- Knock-out drum
Shell material:
(Cladding is defined below.) See Chapter 28 for
materials.
Default: *A 515*.
Liquid volume:
Enter either capacity or diameter and length. The
capacity excludes the volume of the heads.
If both the vessel dimensions and capacity are
specified, the system-calculated capacity must agree
with the specified capacity to within plus or minus
10% to avoid an error condition.
height directly.
A value must be specified if vessel diameter and/or
vessel height (or length) are not specified. If vessel
diameter and height (or length) are specified, the
vessel volume is calculated from these dimensions.
If only vessel capacity is specified, a straight side
length-to-diameter ratio is chosen by the system,
considering cost and practicability.
10 Vessels (G10)
10-3
Description
Type
Vessel diameter:
Enter either capacity or diameter and length. A value
must be specified if vessel capacity is not specified. If
both capacity and height (or length) are specified, the
diameter is calculated from these values.
Vessel tangent to tangent length:
Enter either capacity or diameter and length. A value
both vessel capacity and diameter are specified, the
height (or length) is calculated from these values.
case; Default: *15* PSIG [*100* KPA] pressure.
Design temperature:
Default: 650 DEG F [340 DEG C] ferrous material; 250
DEG F [120 DEG C] other material.
Default: design temperature. The operating
temperature is used in the calculation of piping and
insulation thickness.
Cladding material:
Manhole diameter:
Max: 48 INCHES [1,200 MM]; Default: *18* INCHES
[*450* MM].
Number of manholes:
Default: *1*.
Allowance for internals:
Specify an allowance for internals as a percent of basic
vessel weight. Default: *0.0*. This value adjusts
vessel weight and cost accordingly.
Diameter of drip leg:
Drip leg (boot) diameter and height must be specified
if required.
Height of drip leg:
Drip leg (boot) diameter and height must be specified
if required.
Base material thickness:
materials.
10-4
10 Vessels (G10)
Description
Type
Weld efficiency:
vessel; Default: Area Basis. Range: 50 - 100.
Stress relief:
Cladding thickness:
specified, otherwise: 0.0.
Stiffening ring spacing:
if not required.
Head type:
If no value is specified, the system selects the tori
spherical type and calculates its thickness. If the head
is thicker than the vessel shell, the system selects the
2:1 ellipsoidal type head thickness. If the head is still
thicker than the shell, the system selects the
hemispherical type head.
HEMI- Hemispherical
diameter as vessel.
Diameter option:
Defines desired diameter as ID or OD; Default - see
Area Design Basis.
ID- Inside diameter
Multi-wall design for high pressure service with total
MULTI WALL
wall thickness of individual, thin, heat-shrunk cylinders
(maximum 2 INCHES [50 MM] thick) heat shrunk,
pressure vacuum design and construction according to
user-designated design code standard.
This item is a horizontal process vessel, the total wall
thickness of which is made up of individual cylinders.
Each individual cylinder is no more than two inches
thick. The composite is made as follows. A cylinder is
fabricated with a diameter slightly larger than the
innermost cylinder.
10 Vessels (G10)
10-5
Description
Type
MULTI WALL - continued
This cylinder is expanded thermally, slipped over the
inner cylinder and as it cools, a tight shrink fit is
obtained. This procedure is repeated until the total
wall thickness is built up.
Application:
Defines vessel function and related piping/
instrumentation model. Default: *blank*blankStandard continuous process vessel
BATCH- Batch process vessel
RECVR- Receiver
KO- Knock-out drum
Shell material:
materials. Default: *A 515*.
Liquid volume:
Enter either capacity or diameter and length.
Vessel diameter:
case. Default: *15* PSIG [*100* KPA].
Design temperature:
Default: design temperature.
Cladding material:
See Chapter 28; for cladding materials.
Manhole diameter:
Default: *18* INCHES [450 MM];
Max: 48 INCHES [1,200];
Number of manholes: Default: *1*.
Specify an allowance for internals as a percent of
basic vessel weight. Default: *0.0*.
Drip leg (boot) diameter and length must be specified
if required.
10-6
10 Vessels (G10)
Description
Type
Height of drip leg:
if required.
material.
Weld efficiency:
vessels; Default: Area Basis. Range: 50 - 100.
Stress relief: Default: See Area Design Basis.
Cladding thickness:
if not required.
Head type:
HEMI- Hemispherical
diameter as vessel.
Diameter option:
Area Design Basis.
ID- Inside diameter
Jacketed horizontal pressure/vacuum drum.
JACKETED
Application:
instrumentation model.
Default: *blank*
blank- Standard continuous process vessel
RECVR- Receiver
KO- Knock-out drum
10 Vessels (G10)
10-7
Description
Type
Shell material:
For clad plate, specify the backing plate material. See
Chapter 28 for materials. Default: *A 515*.
Liquid volume:
Vessel diameter:
case; Default: *15* PSIG [*100* KPA].
case; Default: pressure.
Design temperature:
DEG F [120 DEG C] other materials.
Cladding material:
Default: *90* PSIG [*620* KPA].
Jacket type:
Default: *FULL*
FULL- Full jacket
Jacket material:
Manhole diameter:
Default: *18* INCHES [450 MM]; Max: 48 INCHES
[1,200];
vessel weight. Default: *0.0*.
if required.
Height of drip leg:
if required.
10-8
10 Vessels (G10)
Description
Type
Weld efficiency:
vessels; Default: Area Basis. Range: 50 - 100.
Stress relief:
Cladding thickness:
if not required.
Head type:
HEMI- Hemispherical
diameter as vessel.
Diameter option:
Area Design Basis.
ID- Inside diameter
Sanitary horizontal drum
SAN TANK
Stainless steel material for sanitary storage. As a
sanitary tank, it is built to sanitary standards,
including polished stainless steel. The tank is not
a pressure vessel.
Shell material: SS304,*SS316*
Liquid volume:
MAX: 9,000 GALLONS [34 M3]
Vessel diameter:
MAX: 10 FEET [3 M]
10 Vessels (G10)
10-9
10-10
10 Vessels (G10)
Description
Type
SAN TANK - continued
Vessel length:
MAX: 15 FEET [4.5 M]
*68 DEG F [20 DEG C]*
Head type:
*TORI*- Torispherical (ASME)
CON15- 15 degree cone head
Jacket type:
*NONE*- No jacket
DMPLE- 90 PSIG [620 KPA] dimple jacket
Crude Oil Desalter
Horizontal pressure/vacuum drum.
The capacity excludes the volume of the heads. If both
the vessel dimensions and capacity are specified, the
system-calculated capacity must agree with the
specified capacity to within plus or minus 10% to avoid
an error condition.
height directly. A value must be specified if vessel
diameter and/or vessel height (or length) are not
specified. If vessel diameter and height (or length) are
specified, the vessel volume is calculated from these
dimensions. If only vessel capacity is specified, a
Default ratio is 2:1.)
Shell material:
materials.
Default: *A 515*.
Vessel diameter:
A value must be specified if vessel capacity is not
specified. If both capacity and height (or length) are
specified, the diameter is calculated from these
values.
10 Vessels (G10)
10-11
Description
Type
Crude Oil Desalter - continued
Vessel diameter:
A value must be specified if vessel capacity is not
specified. If both capacity and height (or length) are
values.
Enter either capacity or diameter and length. A
value must be specified if vessel capacity is not
specified. If both vessel capacity and diameter are
specified, the height (or length) is calculated from
these values.
case;
Default: *15* PSIG [*100*KPA] pressure.
case.
Default: pressure.
Design temperature:
Default: 650 DEG F [340 DEG C] ferrous material;
250 DEG F [120 DEG C] other material.
Default: design temperature. The operating
temperature is used in the calculation of piping
and insulation thickness.
allowance.
materials.
Cladding material:
CLAD MATLS See Chapter 28 for cladding materials.
SS304
SS316
SS321
SS347
SS410
SS430
304L
316L
NI200
NI201
MONEL
INCNL
-continued10-12
10 Vessels (G10)
Description
Type
Crude Oil Desalter - continued
Cladding thickness:
is specified; otherwise: 0.0
Vessel Internals
basic vessel weight.
Default:*0.0*. This value adjusts vessel weight
and cost accordingly.
Number of electrostatic plates:
Min > 0
Transition Sectn (Middle-Top)
Head type:
If no value is specified, the system selects the
torispherical type and calculates its thickness.
If the head is thicker than the vessel shell, the
system selects the 2:1 ellipsoidal type head
thickness. If the head is still thicker than the
shell,the system selects the hemispherical type
head.
ELLIP - 2:1 ellipsoidal
Weld efficiency:
vessel; Default: Area Basis. Range: 50 - 100.
Stress relief:
Diameter option:
Defines desired diameter as ID or OD; Default - see
Area Design Basis.
Manhole diameter:
Max: 48 INCHES [1,200 MM]; Default: *18*
INCHES [*450* MM].
Number of manholes:
Default: *1*.
10 Vessels (G10)
10-13
Vertical Tanks (VT)
Vertical process vessels are typically used as either surge drums or knock out
drums. When used as surge drums, they act like shock absorbers, maintaining
a constant flowrate of liquid out of the vessel regardless of the flowrate into it.
If liquid flows in faster than the constant rate it flows out, the vessel fills with
liquid. If liquid flows in slower than the constant rate it is removed, then the
liquid level drops. The liquid level is constantly fluctuating in order to absorb
these variations in flow and maintain a constant flowrate out. When a vertical
process vessel is used as a knock out drum, a mixture of gas and liquid flows
into the vessel and this mixture is separated into its gas and liquid components
within the vessel. The gas then flows out the top of the vessel and the liquid
flows out the bottom.
Vertical process vessels, as their name indicates, are erected in the vertical
position. They are cylindrical in shape with each end capped by a domed cover
called a head. The length to diameter ratio of a vertical vessel is typically 3:1.
Typically, vertical process vessels hold less than 5000 GALLONS.
Vertical tanks include: process, storage applications liquid, gas, solid
processing and storage; pressure/vacuum code design for process and certain
storage vessel types; includes heads, single wall, saddles, lugs, nozzles,
manholes, legs or skirt, base ring, davits where applicable.
Description
Type
Pressure/Vacuum Service
CYLINDER
Cylindrical vertical pressure/vacuum vessel.
Application:
instrumentation model. Default: *blank*
RECVR- Receiver
KO- Knock-out drum
Shell material:
Default: *A 515*.
10-14
10 Vessels (G10)
Vertical Tanks (VT) - continued
Description
Type
CYLINDER - continued
Liquid volume: Enter either capacity or diameter and
height. The capacity excludes the volume of the
heads. If both the vessel dimensions and capacity are
specified, the system calculated capacity must agree
with the specified capacity to within plus or minus
10% to avoid an error condition. To secure desired
vessel size, specify the diameter and height directly. A
value must be specified if vessel diameter and/or
vessel height (or length) are not specified. If vessel
diameter and height (or length) are specified, the
vessel volume is calculated from these dimensions.
(Default is 2:1.) If only vessel capacity is specified, a
Vessel diameter:
Enter either capacity or diameter and height. A value
both vessel capacity and height (or length) are
values. If both vessel capacity and diameter are
specified, the height (or length) is calculated from
these values.
See Diameter.
case; Default: *15* PSIG [*100* KPA].
case; Default: pressure.
Design temperature:
Default: 650 DEG F [340 DEG C] ferrous material, 250
10 Vessels (G10)
10-15
Description
Type
Skirt height:
Skip if legs required, enter 0.0 if hung in OPEN
structure; Default: 1.5 x diameter. If the capacity is
10,000 GALLONS [37 M3] or less, the vessel is
designed with 4-feet [1.25 M] pipe legs. For a capacity
greater than 10,000 GALLONS [37 M3], the vessel is
designed with a skirt. The skirt height is calculated as
1.5 x vessel diameter, with minimum and maximum
calculated heights of 4 - 32 FEET [1.25 - 9.5 M].
Vessel leg height:
Skip if skirt required, enter 0.0 if hung in OPEN
structure; Default: *4* FEET [1.25 M].
See Skirt Height.
Fluid volume:
Manhole diameter: Max: 48 INCHES [1,200 MM];
Default: 18 INCHES [450 MM].
Number of manholes:
Default: *1*.
Default: *0.0*; Specify an allowance for internals as a
percent of basic vessel weight.
Demister thickness:
Default: 0.125 INCHES [3 MM for CS, 0.0 for other
materials.
diameter as vessel.
Weld efficiency:
vessels; Defaults: Area Basis. Range: 50 - 100.
10-16
10 Vessels (G10)
Description
Type
Stress relief:
Cladding material:
If no cladding material is specified, the system
assumes that the vessel is not clad regardless of any
input for cladding thickness.
Cladding thickness:
specified, otherwise 0.0. See Cladding Material.
if not required.
Head type:
If no value is specified, the system selects the
torispherical type head and calculates the thickness. If
the head is thicker than the vessel shell, the system
selects the 2:1 ellipsoidal type head and recalculates
the head thickness. If the head is still thicker than the
shell, the system selects the hemispherical type head.
HEMI- Hemispherical
Head thickness Top:
Head thickness Bottom:
Diameter option:
Area Design Basis.
ID- Inside diameter
ASME design basis:
Applicable only for ASME code design. See following
entries for fatigue data. Default: *D1NF*.
Start stop cycles x 1000:
ASME fatigue only. Thousands of start-up cycles
during the full equipment life. Range: 5.00 - 0.02.
10 Vessels (G10)
10-17
Description
Type
Pressure amplitude:
ASME fatigue only. Amplitude of process deviation as
ASME fatigue only. Amplitude of temperature as a
percent of design temperature. Default: *0*.
Multi-wall design for high pressure service. Total wall
thickness of individual thin heat shrunk cylinders
(maximum 2 INCH [50 MM] thick each).
MULTI WALL
Application:
RECVR- Receiver
KO- Knock-out drum
Shell material:
See Chapter 28 for materials. Default: *A 515*.
Liquid volume:
Vessel diameter:
worst case.
10-18
10 Vessels (G10)
Description
Type
Design temperature:
Skirt height:
structure; Default: 1.5 x diameter.
Vessel leg height:
Skip if skirt required, enter 0.0 if hung in OPEN
structure; Default: *4* FEET [*1.25* M].
Fluid volume:
Max: 100; Default: *20*; For seismic design; fluid
volume as a% of volume (water assumed).
Manhole diameter:
Number of manholes:
Default: *1*.
Demister thickness:
materials.
diameter as vessel.
Weld efficiency:
10 Vessels (G10)
10-19
Description
Type
Stress relief:
Default: see Area Design Basis.
Cladding material:
Cladding thickness:
if not required.
Head type:
HEMI- Hemispherical
Head thickness Top:
Diameter option:
Defines desired diameter as ID or OD; Default: see
Area Design Basis.
ID- Inside diameter
ASME design basis:
Default: *D1NF*.
during the full equipment life.
Range: 5.00 - 0.02.
Default: *0*.
10-20
10 Vessels (G10)
Description
Type
Pressure amplitude:
Jacketed, cylindrical, vertical pressure/vacuum vessel. JACKETED
Application:
RECVR- Receiver
KO- Knock-out drum
Shell material:
(Cladding is specified below.) Default: *A 515*.
Liquid volume:
Vessel diameter:
Design temperature:
10 Vessels (G10)
10-21
Description
Type
Jacket type:
Default: *FULL*
FULL- Full jacket
Jacket material:
Skirt height:
structure; Default: *1.5 x diameter*.
Vessel leg height:
Skip if skirt required. Enter 0.0 if hung in OPEN
structure; Default: *4* FEET [*1.25* M].
Fluid volume:
Max: 100; Default: *20*; For seismic design; fluid
volume as a% of vessel volume (water assumed).
Manhole diameter:
Demister thickness:
diameter as vessel.
Weld efficiency:
10-22
10 Vessels (G10)
Description
Type
Stress relief:
Cladding material:
Cladding thickness:
if not required.
Head type:
HEMI- Hemispherical
Head thickness Top:
Diameter option:
Area Design Basis.
ID- Inside diameter
ASME design basis:
Default: *D1NF*.
Range: 5.00 - 0.02.
10 Vessels (G10)
10-23
Description
Type
Default: *0*.
Pressure amplitude:
Number of hydrostatic Tests:
High Pressure Gas/Liquid Storage
SPHERE
Sphere pressure/vacuum design to 3000 PSIG [20500
KPA].
This item is used by chemical, rubber, petroleum and
paper industries for storing large volumes of
anhydrous ammonia, betana, butane and other gases
at high temperature.
A spherical tank is elevated and supported by legs
fabricated from structural steel columns or pipe.
Sphere sizes range as high as 90 FEET in diameter and
are typically constructed of high strength steel. These
tanks are commonly used for high pressure storage of
gases and volatile liquids, typically in the range of 5 250 PSIG. Storing volatile liquids at high pressures
raises the boiling point of the liquid and therefore
minimizes or eliminates that need for costly
refrigeration equipment to liquify the material being
stored.
Uses Type 16 foundation (Individual Column Footing).
Shell material:
10-24
10 Vessels (G10)
Description
Type
SPHERE - continued
Liquid volume:
Enter either capacity or diameter.
Vessel diameter:
Enter either capacity or diameter.
-15 - 3,000 PSIG [-100 - 20,5000];
Default: 15 PSIG [100 KPA].
Design temperature:
Max: 1,500 DEG F [815 DEG C];
Manhole diameter:
Number of manholes:
Default: *1*.
materials.
Cladding material:
Cladding thickness:
Diameter option:
Area Design Basis.
ID- Inside diameter
ASME design basis:
Default: *D1NF*.
10 Vessels (G10)
10-25
Description
Type
SPHERE - continued
Range: 5.00 - 0.02.
Pressure amplitude:
Spheroid to 750000 GALLONS [2840 M3]. Field
erected.
SPHEROID
This item is commonly used for storage of gasolines
and other volatile liquids.
Spheroids vary in shape and size, but generally fall
into one of the following categories:
•
Hemispheriod: Spherical segments comprising the
roof and bottom of the tank are joined to a
cylindrical middle section. Hemispheriods are used
for pressures up to 5 PSI and capacities to 25,000
barrels. For capacities to 50,000 barrels the roof
and bottom are noded.
• Hortonspheriod: Spherical segments are joined
together in a somewhat elliptical shape.
Hortonspheroids are capable of handling storage at
pressure from 5 to 30 PSIG.
Hortonspheroids and hemispheroids are designed to
rest on a prepared grade conforming to the shape of
the bottom (usually sand).
10-26
10 Vessels (G10)
Description
Type
SPHEROID - continued
Spheroidal shaped tanks are often more economical
than cylindrical pressure vessels for storage at
pressures greater than 0.5 PSI.
Uses Type 16 foundation (Individual Column
Footing).
Shell material:
Liquid volume:
Range: 60,000 - 750,000 GALLONS [230 - 2,840 M3];
Vessel diameter:
Vessel height:
Range: 0.0 - 15 PSIG [0.0 - 100 KPA];
Design temperature:
Manhole diameter:
Number of manholes:
Default: *1*.
Default: Specify an allowance for internals as a
percent of basic vessel weight. Default: *0.0*.
materials.
Cladding material:
10 Vessels (G10)
10-27
Description
Type
SPHEROID - continued
Cladding thickness:
Diameter option:
Default - see Area Design Basis.
ID- Inside diameter
Near-Atmospheric Liquid Storage
STORAGE
Field erected storage tank.
Note on Painting: The system assumes that once the
tank is assembled in the field it will be sandblasted
and primed inside and out, and a finish coat applied
on the outside only. Use Bulk Adjustments to override
these values.
The available roof types are FLAT, FLOAT, CONE, LIFT,
OPEN, INFLT, and INCN.
Flat roof tank
Use minus pressure for vacuum design. Field erected.
Floating roof tanks are frequently used in the storage
of kerosene and jet fuels. Floating roofs may be
installed inside a tank with a fixed roof or used as a
tank’s only
cover. Typically constructed from polyurethane foam
blocks or nylon cloth impregnated with rubber or
plastic, floating roofs are designed to completely
contact the surface of the storage products and
thereby eliminate the vapor space between the
product level and the fixed roof.
Floating roof tank
This feature makes floating roofs desirable for the
following reasons:
1. Reduction of evaporation and breathing
losses.
2. Reduction of tank corrosion.
3. Increased safety from fire or explosion.
10-28
10 Vessels (G10)
Description
Type
STORAGE - continued
Floating root tanks are suitable for storage of products
having vapor pressures from 2 to 15 PSIA. Products
that boil at temperatures under the normal range of
atmospheric conditions should not be stored in floating
roof tanks.
Cone roof tanks are used for storage of low pressure
products (e.g., oil, diesel and asphalt.) Cone roof
tanks are usually field fabricated out of carbon steel.
Roofs are sloped upward to the center at a slight
angle. Typically, ranging from 50,000 - 1,000,000
GALLONS capacities, they are used for storage of low
vapor pressure products (less than 2 PSIA) when
evaporation looses and breathing losses are not
considered important.
Lifter roof tanks are generally field fabricated. They
have a minimum capacity of 40,000 GALLONS [152
M3]. Lifter roof tanks can be specified with pressure
from 0 - 0.05 PSIG
[0 - 0.3 KPA] and a maximum temperature of 250
DEG F [120 DEC C]. The default temperature is *68*
DEG F [*20* DEG C].
Cone roof tank
Lifter roof tank
Open top tanks are designed and constructed
according to user-generated design code standards.
Open top tanks have a maximum temperature of 250 Open top tank
DEG F [120 DEC C]. The default temperature is *68*
DEG F [*20* DEG C].
Shell material: For clad plate, specify the backing
plate material (cladding is defined below). See
Chapter 28 for materials. Default: *A285C*.
Liquid volume : Enter either liquid volume or
diameter and height.
Vessel diameter: Enter either capacity or diameter
and height.
Vessel height: Enter either capacity or diameter and
height.
Roof type:
Default: *FLAT*
FLAT- Flat roof tank
CONE- Cone roof tank
10 Vessels (G10)
10-29
Description
Type
STORAGE - continued
FLOAT- Floating roof tank
LIFT- Lifter
OPEN- Open roof tank
INFLT- Internal floater with flat roof
INCN- Internal floater with cone roof
Bottom type:
Default: *FLAT*
FLAT- Single flat bottom
DBL- Double bottom
0.0 - 2.5 PSIG [0.0 - 17 KPA];
Default: *0.05* PSIG [*0.35* KPA].
Design temperature:
Manhole diameter:
basic vessel weight. Default: *0.0*.
other materials.
Cladding material:
Cladding thickness:
Default: *0.125* INCHES [*3* MM] if cladding
material is specified; otherwise: *0.0*.
Range: 0.2 - 5.0; Default: *1.0*.
Diameter option:
Area Design Basis.
ID- Inside diameter
Flame arrestor diameter:
Range: 1.0 - 8.0 IN DIAM [25.0 - 200.0 MM DIAM].
Conservation vent diameter:
Range: 1.0- 8.0 IN DIAM [25.0 - 200.0 MM DIAM].
10-30
10 Vessels (G10)
Description
Type
Cryogenic storage tank - double wall, superinsulated. CRYOGENIC
Shell material:
See Chapter 28 for materials. Default: *SS304*.
Liquid volume:
Range: 300.0 - 60,000.0 GALLONS
[1.20 - 227.00 M3].
Vessel diameter:
If both pressure and vacuum are entered, design is for
worst case. Default: 250.0 PSIG [1,720 KPA].
If both pressure and vacuum are entered, design is for
worst case. Default: pressure.
Design temperature:
Default: -320.0 DEG F [-195 DEG C].
Min: -14.70 PSIG [-100.0 KPA];
Default: -14.70 PSIG [-100.0 KPA]
Jacket material:
Skirt height:
Skip if legs are required. Enter ‘0.0’ if hung in OPEN
structure. Default: 1.5 x diameter.
Vessel leg height:
Skip if legs are required. Enter ‘0.0’ if hung in OPEN
structure. Default: 1.5 x diameter.
Fluid volume:
volume (water assumed).
Manhole diameter:
Max: 48.0 INCHES [1,200.0 MM];
Default: 18.0 INCHES [450.0 MM]
10 Vessels (G10)
10-31
Description
Type
CRYOGENIC - continued
vessel height.
materials.
Weld efficiency:
vessels. Range: 50 - 100; Default: Area Basis.
Stress relief:
NO- No stress relief
Default stiffeners designed for vacuum only, enter
‘0.0’ if not required.Head type:
HEMI- Hemispherical
Diameter option:
ID- Inside diameter
Flat bottom dome top. FRP to 30000 GALLONS [113
M3], HAVEG to 7000 GALLONS [26 M3].
Fiberglass Reinforced Plastic Storage Tank: Filamentwound with a biosphere - a polyester resin (e.g., Atlac
282). Flat bottom and dome top under 2.5 PSIG [16.7
KPA], otherwise dished heads.
PLAST TANK
Haveg Storage Tank.
Material:
Default: *FRP*
FRP- FRP
HAVEG- Haveg
Liquid volume:
Volume or diameter + height required input Range:
1,000 - 30,000 GALLONS [3.8 - 113 M3]
10-32
10 Vessels (G10)
Description
Type
PLAST TANK - continued
Vessel diameter:
Volume or diameter + height input.
Max: 12.0 FEET [93.6 M].
Vessel height:
Volume or diameter + height required input.
Range: 0.00 - 15.00 PSIG [0 - 100 KPA];
Temperature:
Wooden storage tanks to 50000 GALLONS [1890 M3].
WOOD TANK
Material: Default: *CYPRS*
CYPRS- Cypress
REDWD- Redwood
PINE- Pine
FIR- Fir
Liquid volume:
Range: 800 - 50,000 GALLONS [3.1 - 189 M3].
Vessel diameter:
Range: 0.0 - 0.05 PSIG [0.0 - 0.3 KPA].
Temperature:
Near-Atmospheric Gas Storage
GAS HOLDER
Telescoping gas holder.
Low pressure gas vessel.
Shell material:
Gas volume:
Vessel diameter:
Vessel height:
10 Vessels (G10)
10-33
Description
Type
GAS HOLDER - continued
Range: 0.0 - 2.5 PSIG [0.0 - 17 KPA];
Design temperature:
Manhole diameter:
Number of manholes:
Default: *1*.
Cladding material: See Chapter 28 for materials.
Cladding thickness:
Diameter option:
Default: - See Area Design Basis.
ID- Inside diameter
Atmospheric Solid/Liquid Storage
CONE BTM
Cone bottom, flat top storage bin.
Shell material:
Liquid volume:
Vessel diameter:
Vessel height:
10-34
10 Vessels (G10)
Description
Type
CONE BTM - continued
Min: 0.0 PSIG [0.0 KPA];
Default: 0.05 PSIG [0.35 KPA].
Design temperature:
Default: 68 DEG F [20 DEG C] to 0.05 PSI [0.35 KPA];
else 650 DEG F [340 DEG C] ferrous, 250 DEG F [120
DEG C] other.
Vessel leg height:
Enter ‘0.0’ if bin hung in OPEN structure;
Default: *4* FEET [*1.25* M].
Manhole diameter:
other materials.
diameter as vessel.
Stress relief:
Default: See Area Design Basis
Cladding material:
Cladding thickness:
Default *0.125* INCHES [*3* MM] if cladding material
is specified; otherwise: *0.0*.
Head thickness Top:
10 Vessels (G10)
10-35
Description
Type
CONE BTM - continued
Diameter option:
ID- Inside diameter
ASME design basis:
Default: *D1NF*.
Start Stop cycles x 1000:
Range: 5.00 - 0.02.
Default: *0*.
Pressure amplitude:
design temperature in equipment life.
Default: *0*.
Live bottom storage bin.
LIVE BTM
Shell material:
Solid volume:
10-36
10 Vessels (G10)
Description
Type
LIVE BTM - continued
Vessel diameter:
MAX: 15 FEET [4.69 M]
Vessel height:
Design temperature:
Vessel leg height:
Enter ‘0.0’ if bin hung in OPEN structure;
Manhole diameter:
other materials.
diameter as vessel.
Stress relief:
Cladding material:
Cladding thickness:
Default *0.125* INCHES [*3* MM] if cladding material
is specified; otherwise: *0.0*.
Diameter option:
ID- Inside diameter
10 Vessels (G10)
10-37
Description
Type
Tile Chests
Tile chests provide tile lined tanks for storage of
liquids, suspensions or slurries. Although tile chests
are used in the chemical industry, they
are predominantly used in pulp and paper mills for
storing fiber suspensions at various stages of
processing. Chests can be rectangular or cylindrical
and may be concrete or metallic. Various designs are
available depending on the nature of the fluid — high
density, low density.
Tile Chests, rectangular concrete include the following CHEST REC
options:
•
Single tile chest
•
Group of tile chests
•
One chest in a group of chests.
Grouping option: PARTGRP is used for one chest in
assemblage, WHLGRP to define an entire assemblage.
Default: *PARTGRP*.
SINGLE- Tile chest is a single stand-alone item
PARTGRP- One chest of a multi-group assemblage
WHLGRP- Entire multi-group assemblage
Inside length:
Enter either chest dimensions or capacity.
Vessel height:
Inside width:
Chest volume:
Enter either chest dimensions (length height, width) or
capacity; Min: 30000 GALLONS (114M3);
Max: 1300000 GALLONS (4921 M3). If Grouping
Option is WHLGRP, enter capacity of entire group;
otherwise enter capacity of this chest.
Tile or lining type:
Default: *25RSB*
25RSB- 2.5 INCHES [62 MM] red shale brick
10-38
10 Vessels (G10)
Description
Type
CHEST REC - continued
Tile or lining:
Percent of chest surface to be lined,
100% = one side; 200% = inside + outside. Max:
200; Default: 100.
Configuration:
Default: *OPEN*
OPEN- Open top chest
CLOSED- Chest has a roof
Installation option:
Default: *GRADE*
GRADE- Tile chest is constructed on grade
STRUCT- Tile chest is within a structure
Capacity of group:
For PARTGRP chest only, capacity of entire group;
Default: 4x chest capacity.
Number of chests in group:
For WHLGRP chest only, enter number of chests in
entire assemblage. Default: *4*.
Number of partitions lengthwise:
Number of full length partitions parallel to length
dimension (may be fraction).
Number of partitions widthwise:
Number of width wide partitions parallel to width
dimension (may be fraction).
Soil type:
SOFT CLAY- Bearing: 2000 PSF [100 KN/M2]
FIRM CLAY- Bearing: 4000 PSF [200 KN/M2]
WET SAND- Bearing: 4000 PSF [200 KN/M2]
SAND+CLAY- Bearing: 4000 PSF [200 KN/M2]
DRY SAND- Bearing: 600 PSF [300 KN/M2]
SAND- Bearing: 8000 PSF [400 KN/M2]
GRAVEL- Bearing: 12000 PSF [600 KN/M2]
SOFT ROCK- Bearing: 16000 PSF [800 KN/M2]
HARDPAN- Bearing: 20000 PSF [1000 KN/M2]
MED-ROCK- Bearing: 30000 PSF [1400 KN/M2]
HARD ROCK.- Bearing: 80000 PSF [3800 KN/M2]
Product density:
Default: *62.4* PCF.
Exclude excavation:
Exclude portion of calculated quantity if not required
or common with other items. Max: 100; Default:
*0.0*.
10 Vessels (G10)
10-39
Description
Type
CHEST REC - continued
Footings exclusion:
Exclude portion of calculated quantity if not required or
common with other items. Max: 100; Default: *0.0*.
Floor exclusion:
Wall length exclusion:
Wall width exclusion:
Tile Chests, Cylindrical
CHEST CYL
Low density tile chest with a capacity range of 3000 to
300000 GALLONS [12 to 1135 M3]. Chest is available
in concrete or metallic materials of construction. If the
user enters no dimensions (diameter, height, width,
length), the capacity range is 3000 to 300000
GALLONS [12 to 1135 M3].
High density tile chest with a capacity range of 30000
to 1300000 GALLONS [114 to 4921 M3]. Chest is
available in concrete or metallic materials of
construction.
Shape symbol:
Default: *CYLLD*
CYLLD- Cylindrical chest, low density stock
CYLHD- Cylindrical chest, high density stock
Inside diameter:
Chest dimensions or capacity required.
Vessel height:
Chest dimensions or capacity required.
Chest volume:
Enter either dimensions (diameter, height) or
capacity; Min: 3000 GALLONS [12 M3]; Max: 300000
GALLONS [1135 M3]
10-40
10 Vessels (G10)
Description
Type
CHEST CYL - continued
Default: *25RSB*
25RBS- 2.5 INCH [62 MM] red shale brick
45RSB- 4.5 INCH [112 MM] red shale brick
Tile or lining:
Percent of chest to be lined. 100% = one side; 200%
= inside + outside. Max: 200; Default: *100*.
Configuration:
Default: *OPEN*
OPEN- Open top chest
CLOSED- Chest has a roof
Installation option:
Default: *GRADE*
GRADE- Tile chest is constructed on grade
STRUCT- Tile chest is within a structure
Soil type:
SOFT CLAY- Bearing: 2000 PSF [100 KN/M2]
FIRM CLAY- Bearing: 4000 PSF [200 KN/M2]
WET SAND- Bearing: 4000 PSF [200 KN/M2]
SAND+CLAY- Bearing: 4000 PSF [200 KN/M2]
DRY SAND- Bearing: 600 PSF [300 KN/M2]
SAND- Bearing: 8000 PSF [400 KN/M2]
GRAVEL- Bearing: 12000 PSF [600 KN/M2]
SOFT ROCK- Bearing: 16000 PSF [800 KN/M2]
HARDPAN- Bearing: 20000 PSF [1000 KN/M2]
MED-ROCK- Bearing: 30000 PSF [1400 KN/M2]
HARD ROCK.- Bearing: 80000 PSF [3800 KN/M2]
Product density:
Default: *62.4* PCF [1,000 KG/M3].
Exclude excavation:
or common with other items. Max: 100;
Default: *0.0*.
Footings exclusion:
or common with other items. Max: 100;
Default: *0.0*.
Floor exclusion:
or common with other items. Max: 100; Default:
*0.0*.
10 Vessels (G10)
10-41
Description
Type
Shell material:
CHEST MTL
(Cladding is defined below.) ©©Default: *A285C*.
Liquid volume:
Vessel diameter:
Vessel height:
Default: *25RSB*
Tile or lining:
Percent of chest surface to be lined. 100% = one side;
200% = inside + outside. Max: 200;
Default: *100*.
Roof type:
Default: *FLAT*
FLAT- Flat roof tank
CONE- Cone roof tank
FLOAT- Floating roof tank
LIFT- Lifter
OPEN- Open top tank
INFLT- Internal floater with flat roof
INCN- Internal floater with cone roof
Range: 0 - 2.5 PSIG [0 - 17.0 KPA];
Ignore this field for open top tanks.
Design temperature:
Manhole diameter:
Default: *18* INCHES [450.0 MM].
Number of manholes:
Default: *1*.
10-42
10 Vessels (G10)
Description
Type
CHEST MTL
other materials.
Cladding material:
Cladding thickness:
Default: *0.125* INCHES [*3* MM] for cladding
material, otherwise *0.0*.
Specific gravity:
Range: 0.2 - 5.0; Default: *1.0*.
Diameter option:
Bottom type:
Default: *FLAT*
FLAT- Single flat bottom
DBL- Double bottom
Sanitary vertical cylindrical vessel
SAN TANK
Since this is a sanitary item, the tank is built to
sanitary standards, including polished stainless steel.
This is not a pressure vessel.
Shell Material:
SS304,*SS316*
Application:
The application symbol defines vessel function and
related pipe/instrum. model.
*SURGE*- Surge tank
MIX- Mixing tank
Liquid Volume:
MAX: 5,000 GALLONS [18.9 M3]
Vessel Diameter:
MAX: 9.25 FEET [2.8 M]
Vessel Height:
MAX: 10 FEET [3 M]
MIN: 68 DEG F [20 DEG C]
Cover type:
*OPEN*- Open top
FLAT- Loose flat top
FIXED- Fixed flat top with bridge
DISH- Dished top with manway and agitator nozzle
10 Vessels (G10)
10-43
Description
Type
SAN TANK - continued
Bottom type:
WELL- Well bottom
SLOPE- Sloped bottom
TORI- Torispherical bottom
*CON15*- 15 degree cone bottom
CON30- 30 degree cone bottom
Jacket type:
*NONE*- No jacket
DMPLE- 90 PSIG [620 KPA] dimple jacket
LNG Tank
A Full Containment Double Walled Tank implies that
both the inner steel tank and the outer prestressed
concrete shell with reinforced concrete spherical dome
are independently capable of resisting the Design Load
Conditions and allow for their special characteristics,
since failure of either can lead to leakage of LNG
gaseous fumes which are both toxic and highly
flammable.
DESIGN LOADS
Wind force adjustment:
Additional adjustment for wind force specified in
project civil design specs. roject civil design specs.
Min: 0
Max: 2
Default: 1
Seismic force adjustment:
project civil design specs. roject civil design specs.
Min: 0
Max: 2
Default: 1
Min: >0
Default: 4.21 PSIG
Design blast pressure:
Min: 0
Default: 2.18 PSIG
Roof live load:
Min: 0
Default: 50 PSF
-continued-
10-44
10 Vessels (G10)
Description
Type
LNG Tank -continued
INNER STEEL TANK
LNG tank volume:
Minimum Volume = 1,320,500 Gallons [5,000 M^3]
Maximum Volume = 52,835,000 Gallons [200,000
M^3]
Min: >0 Gallons
Tank diameter:
Enter either volume or diameter and height
Min: >0 FEET
Tank height:
Min: >0 FEET
Shell Material:
9% Ni steel is typically used in cryogenic storage
applications
Default: A 553
Min: >0 INCHES
Max: 2 INCHES
Min: 0.2
Max: 5
Default: .0476
Design temperature:
Default: -274 F
Default: Design operating temperature
OUTER CONCRETE TANK
Tank diameter (ID):
Min: >0 FEET
Tank height):
Min: >0 FEET
Wall thickness:
Prestressed concrete wall thickness, inches [mm]
Min: 6 INCHES
Concrete type:
B - Standard concrete
C - Higher grade concrete
D - Chemical resistant concrete
Default - as specified in unit area civil specs or
project civil specs.
-continued-
10 Vessels (G10)
10-45
Description
Type
LNG Tank - continued
SUBMERGED PUMPS
Number of pumps:
Min: >0
Default: 1.
Casing material:
I-1: Case: CI; impeller/wear parts: CI
I-2: Case: CI; impeller/wear parts: Bronze
S-1: Case: CS; impeller/wear parts: CI
S-3: Case: CS; impeller/wear parts: A436
S-4: Case: CS; impeller: CS; wear parts: CI
S-5: Case: CS; impeller.: CS; wear parts: 12%Cr
S-6: Case: CS; impeller/wear parts: 12% Cr
S-8: Case: CS; impeller/wear parts: SS316
S-9: Case: Monel-lined CS; impeller/wear:Monel
C-6: All parts: 12% Cr
A-7: All parts: SS304
A-8: All parts: SS316
D-1: All parts: Duplex
CAST MATLS...: See a list of casting materials.
Default: A-7
Liquid flow rate:
Min: >0 GPM
Default: 1,300 GPM
Fluid head:
Min: >0 FEET
Maximum head: 1000 FT [ 300 M] at 30xHZ;
3800 FT [1150 M] at 60xHZ.
Default: 800 FEET
Speed:
Min: 1800 RPM
Max: 3600 RPM
Additional Notes:
1. The civil and steel volumetric bulks are included in
the equipment cost.
2. A pile foundation will automatically be designed if
required. The soil type, pile type, and pile
parameters are specified in the unit area civil specs or
project civil specs.
3. The inner steel tank freeboard is calculated based
on the inner tank height, diameter, and seismic
horizontal acceleration. The seismic horizontal
acceleration is specified in the project civil specs.
-continued-
10-46
10 Vessels (G10)
Description
Type
LNG Tank continued
4. The inner steel tank is checked for overturning
stability.
5. The foundation concrete type is based on the unit
area civil specs or project civil specs.
6. The following steel plates are assumed as ¼” thick:
Primary bottom, secondary bottom, secondary corner
protection, and vapor barrier.
7. The bottom foam insulation is assumed as 3’-6”
thick.
8. The tank lid foam insulation is assumed as 2’-0”
thick.
9. If an external civil data file is specified, adjustments
may be made to the labor hours as follows:
•
Concrete dome roof = Foundation type 4 (Mass
pour)
•
Prestressed concrete roof ring beam =
Foundation type 12 (Columns and beams)
•
Prestressed concrete walls = Foundation type 13
(Walls)
•
Inner tank concrete ring foundation = Foundation
type 9 (Circular ring foundation for large tanks)
•
Outer tank foundation = Foundation type 4 (Mass
pour)
10 Vessels (G10)
10-47
10-48
10 Vessels (G10)
11 Crushers, Mills and Stock
Treatment
(G6)
Crushers (CR)
Flakers (FL)
Mills (M)
Stock Treatment (ST)
11 Crushers, Mills and Stock Treatment (G6)
11-1
Crushers (CR)
Includes motor and drive unit.
Description
Type
Cone crusher for secondary and fine crushing for hard CONE
and medium hard materials such as limestone, stone
and rock.
The cone crusher is a type of gyratory crusher. A
conical head is gyrated by means of an eccentric
driven through gears and a countershaft. The gyratory
motion causes the conical head to approach and
recede from the walls of the crushing chamber. The
material receives a series of rapid blows as it passes
through the crushing cavity.
Material:
Default: *CS*.
Mantle diameter:
Range: 20 - 84 INCHES [510 - 2,130 MM].
Crusher type:
Default: *STAND*
STAND- Standard head
SHORT- Short head
11-2
Crushers (CR) - continued
Description
Type
Primary and secondary crushing of hard and medium
hard materials such as limestone, stone and rock.
GYRATORY
A conical head is gyrated by means of an eccentric
driven through gears and a countershaft. The gyratory
motion causes the conical head to approach and
recede from the walls of the crushing chamber. The
material receives a series of rapid blows as it passes
through the crushing cavity.
Material:
Default: *CS*.
Mantle diameter:
Range: 20 - 120 INCHES [510 - 3,045 MM].
Crusher type:
Default: *PRIME*
PRIME- Primary crushing
SECOND- Secondary crushing
Overhead eccentric jaw crusher for primary and
ECCENTRIC
secondary crushing of hard, tough and abrasive
materials, such as quartz, rock, glass and ferroalloys.
Includes hydraulic toggle, motor and motor drive
sheave and V belts.
A moving jaw opens and closes against a vertical or
slightly inclined fixed jaw by means of a toggle to
crush the feed material. In single-toggle machines the
moving jaw has an almost circular motion at the
upper-end of the jaw plate and an elliptical movement
at the lower-end. This motion causes the jaw plates to
wear faster than double-toggle machines but also
assists the flow of material through the crushing
chamber. The trend is towards single-toggle machines
because the increased wear is usually outweighed by
the lower initial cost of the single-toggle machine.
Material:
Default: *CS*.
Crusher flow rate:
Range: 25 - 1,620 TPH [23 - 1,460 TON/H].
Product size:
Range: 1 - 16 INCHES [25 - 400].
11-3
Description
Type
Swing jaw crusher for primary and secondary
JAW
crushing of hard and/or abrasive materials such
as quartz rock, glass and ferroalloys.
A moving jaw is opened and closed by means of
a pair of toggles against a vertical or slightly
inclined fixed jaw crushing the feed material.
(See ECCENTRIC crusher for additional
information.)
Material:
Default: *CS*.
Crusher flow rate:
Range: 70 - 610 TPH [65 - 550 TON/H].
Product size:
Range: 2 - 8 INCHES [50 - 200 MM].
Rotary crusher for coarse, soft materials, such
as gypsum, phosphate rock, pitch, mica,
cocoanut shells.
ROTARY
A toothed cone rotates inside a toothed shell.
The clearance between the teeth on the cone
and the teeth on the shell determines the
product size.
Material:
Default: *CS*.
Driver power:
Range: 2 - 25 HP [1.5 - 18.5 KW].
Single roll crushers are manufactured in light,
medium and heavy duty constructions for the
primary crushing of friable materials such as
coal; medium hard materials such as coal,
phosphate rock and shale; and hard materials
such as cement rock, iron ore and limestone.
S ROLL LT
Single roll crusher for light duty primary and
secondary crushing for coal and other friable
materials.
Material:
Default: *CS*.
Crusher flow rate:
Range: 140 - 1,470 TPH
[128 - 1,330 TON/H].
Product size:
Range: 2 - 6 INCHES [50 - 150 MM].
11-4
Description
Type
S ROLL LT - continued
Single roll crusher for medium duty primary and/or
materials.
Material:
Default: *CS*.
Crusher flow rate:
Range: 105 - 840 TPH [95 - 760 TON/H].
Product size:
Range: 2 - 8 INCHES [50 - 200 MM].
S ROLL MED
S ROLL HVY
Single roll crusher for heavy duty primary and/or
materials.
Material:
Default: *CS*.
Crusher flow rate:
Range: 175 - 1,000 TPH [160 - 900 TON/H].
Product size:
Range: 2 - 8 INCHES [50 - 200 MM].
Sawtooth crusher. Size reduction in tearing via toothed SAWTOOTH
rollers for lumpy and friable materials, such as
plastics, shale, charcoal, shells and bark.
The particles are crushed between two rollers with
sawtooth-like projections.
Material:
Default: *CS*.
Driver power:
Range: 5 - 40 HP [4 - 30 KW].
Reversible hammermill for secondary reduction of hard REV-HAMR
and medium hard minerals, stone, rock, limestone,
low-silica ores/chemicals.
Tertiary reduction of friables materials in closed circuit
crushing.
Material:
Default: *CS*.
Crusher flow rate:
Range: 20 - 450 TPH [18 - 408 TON/H].
11-5
Description
Type
Non-reversible hammermill for secondary crushing of HAMMER
bituminous and sub-bituminous coals, lignite, gypsum MED
and some medium-hard minerals.
Material:
Default: *CS*.
Crusher flow rate:
Range: 15 - 40 TPH [13 - 36 TON/H].
Non-reversible hammermill for hard materials (cement SWING HAMR
rock, limestone).
Material:
Default: *CS*.
Crusher flow rate:
Range: 30 - 180 TPH [27 - 160 TON/H].
Rotary breaker for simultaneous sizing and cleaning of BRADFORD
run-of-mine coal.
Material:
Default: *CS*.
Crusher flow rate:
Range: 450 - 1,500 TPH [400 - 1360 TON/H].
Single rotor impact breaker for primary and secondary S IMPACT
breaking of non-abrasive quarry rock and similar
materials.
Crusher flow rate:
Range: 250 - 1,000 TPH [225 - 900 TON/H].
Fine and medium crushing of soft non-abrasive
materials.
PULVERIZER
Material:
Default: *CS*.
Crusher flow rate:
Range: 300 - 8,500 LP/H [140 - 3,855 KW].
Driver power:
Range: 3 - 75 HP [2.22 - 55].
11-6
Description
Type
Ring granulator for primary and secondary crushing of ROLL RING
bituminous and sub-bituminous coals, lignite, gypsum
and some medium hard minerals.
Heavy cast steel rings, toothed and/or plain, at the
end of rotating arms crush solid material by a
combination of impact breaking and rolling
compression.
Material:
Default: *CS*.
Crusher flow rate:
Range: 50 - 2,000 TPH [45 - 1,800 TON/H].
Flakers (FL)
Includes motor and drive.
Description
Type
Drum flaker to 200 SF [18 M2] of surface.
DRUM
Material:
Default: *CS*.
Surface area:
Range: 10 - 250 SF [1 - 23 M2].
Mills (M)
Includes mill, motor, bearings, gears, lube system and vendor-supplied
instruments.
Description
Type
Attrition mill to 300 HP [224 KW].
ATTRITION
Material:
Default: *CS*.
Driver power:
Range: 5 - 300 HP [4 - 224 KW].
Driver speed:
Max: 3,600 RPM
11-7
Mills (M) - continued.
Description
Type
Wet or dry autogenous mills.
AUTOGENOUS
Material:
Default: *CS*.
Application:
Default: *WET*
WET- Wet grinding
DRY- Dry grinding
Ball mill includes initial ball charge.
BALL MILL
Material:
Default: *CS*.
Application:
Default: *WET*
WET- Wet grinding
DRY- Dry grinding
Rod mill includes initial rod charge.
Material:
Default: *CS*.
Application:
Default: *WET*
WET- Wet grinding
DRY- Dry grinding
ROD MILL
Micro-pulverizer to 30 HP [22 KW].
MIKRO PULV
Material:
Default: *CS*.
Driver power:
Range: 7.5 - 30 HP [5.5 - 22 KW].
Driver speed:
Max: 3,600 RPM
Roller mill to 400 HP [300 KW].
ROLLER
Material:
Default: *CS*.
Application:
Default: *WET*
WET- Wet grinding
DRY- Dry grinding
Rod charger for rod mill.
11-8
ROD CHARGR
Stock Treatments (ST)
Description
Type
Refiners are used for the refining of fibers either from REFINER
Kraft pulping or secondary fiber operations.
The refiner is a double-disk type with rotor and stator
in a quick opening hinged housing. The shaft is
supported on anti-friction grease-lubricated bearings,
packing box, electro-mechanical plate positioning. Also
included is the drive consisting of the gear box, electric
motor, coupling and guard.
Material:
Default: *SS316*
SS316- SS316
SS304- SS304
Stock flow rate:
Enter stock flow rate (bone dry) or plate diameter.
Range: 5 - 2000 TPD [.20 - 75 TON/H].
Plate diameter:
Enter stock flow rate (bone dry) or plate diameter.
Range: 12 - 60 INCHES [305 - 1,520 MM].
CSF - ml of water:
CSF = Canadian Standard Freeness.
Default: *120*.
Deflakers reduce and disperse flakes into finer size,
and are mainly used in pulp mill operations.
The unit can be designed for a wide range of capacities
and solids concentration. Due to the intermeshing
stator and rotor design, the unit can also be used in
high shear mixing operations. Two designs are
available:
• Plate type — includes stator and rotor plate tackles
DEFLAKE DK
housed in a body with quick hinged door opening
for easy maintenance, electric motor driver,
coupling, packing seal, external rotor/stator
adjustment mechanism, built in junk trap.
Material:
Default: *SS316*
SS316- SS316
SS304- SS304
Hydraulic capacity:
Enter hydraulic capacity or rotor diameter.
Range: 5.0 - 2000 GPM [0.3 - 125.0 LS].
11-9
Stock Treatments (ST) - continued
Description
Type
DEFLAKE DK - continued
Rotor diameter:
Enter hydraulic capacity or rotor diameter.
Range: 4 - 30 INCHES [100 - 750 MM].
Deflaker speed:
Default: *1,800* RPM.
Range: 1 - 10; Default: *4*.
• Concentric conical type — includes shell and plug
tackles housed in body, electric motor driver,
external rotor/stator adjustment mechanism, built
in junk trap and lube oil system.
DEFLAKE CN
Material:
Default: *SS316*
SS316- SS316
SS304- SS304
Hydraulic capacity:
Range: 5 - 2,000 GPM [0.3 - 125.0 L/S].
Deflaker speed:
Default: *1,800* RPM.
Range: 1 - 10; Default: *4*.
11-10
12 Drying Systems
(G6)
Crystallizers (CRY)
Evaporators (E)
Air Dryers (AD)
Dryers (D)
Drum Dryers (DD)
Rotary Dryers (RD)
12 Drying Systems (G6)
12-1
Crystallizers (CRY)
Description
Type
Batch vacuum crystallizer unit for small scale
production of crystals. Includes cone bottom agitated
tank, steam jet ejectors and direct contact condenser
to 8200 GALLONS [25.8 M3].
BATCH VAC
Energy requirements are lower for a batch vacuum
unit than for a continuous vacuum unit, however, for
the same capacity, batch units must be larger than
continuous units and are therefore more expensive.
A warm saturated solution is fed to a cone bottom
tank. The pressure in the tank is then reduced using
stream-jets. The solution flashes and the flashed
solvent is condensed in a direct contact condenser.
The non-condensables which pass through the direct
contact condenser are vented to the atmosphere by
the steam-jet equipment. While the solution is
flashing, agitators in the crystallizer keep the forming
crystals in the suspension and keep the contents of the
tank at a uniform concentration. When the
supersaturation of the flashed solution has been
removed (by the formation of the crystals), the tank is
emptied.
Material:
*CS*.
CS- Carbon steel
RBLCS- Rubber-lined CS
SS304- SS304
Liquid volume:
Range:
850 - 8,200 GALLONS [2.7 - 25.8 M3].
Mechanical scraped-surface crystallizer, jacketed,
spiral ribbon scraper, trough, stacked in lengths of 40
FEET [12 M]. Includes motor and drive.
MECHANICAL
For the relatively small-scale production of crystals
from a supersaturated solution. The scraped-surface is
used where a slight change in the temperature of a
solution means a large change in its solubility. When
the required rate of heat removal is greater then
200,000 BTU/HR, the scraped surface crystallizer is
usually not economical.
The scraped-surface crystallizer consists of a 24-inch
wide trough with a semi-circular bottom, a cooling
jacket on the outside and a spiral ribbon scraper/mixer
the length of the trough.
12-2
Crystallizers (CRY) - continued
Description
Type
MECHANICAL - continued
Crystals growing on the walls off the trough are
scraped off and suspended in the mother liquor. These
units are manufactured in lengths of 10 to 40 FEET. If
lengths greater than 40 are required, the units are
stacked one on top of another and the solution
cascades from one level to the next.
Material:
*CS*, CI
CS- Carbon steel
CI- Cast iron
Length:
Range: 20 - 1,000 FEET [6.1 - 300 M]
Material:
SS (Stainless steel)
Length:
Range: 20 - 550 FEET [6.1 - 165 M]
Oslo growth type crystallizer to 6,900 TPD [260
OSLO
TONH]. Large scale crystal production. Includes
interconnecting piping, recirculating pump and
accessories.
This piece of equipment, also called a growth
crystallizer or classified-suspension crystallizer,
operates in the following manner. The feed stream
plus a recycle stream of saturated solution are
pumped through a heat exchanger and heated. The
solution enters a vaporization chamber and a portion
of the solvent is flashed, thus cooling the solution and
raising the concentration of the solute. This
supersaturates the solution. The supersaturated
solution is then fed to the bottom of a suspension or
crystallizing chamber where it contacts already formed
crystals. Through the formation of new crystals and
the growth of existing crystals, the supersaturation of
the solution is removed. Additionally, as the solution
moves upward through the suspension chamber, the
small crystals are carried upward while the large
crystals settle to the bottom, thus classifying the
crystals by size. The large crystals are removed from
the bottom of the suspension chamber while the
solution, no longer saturated, is mixed with fresh feed,
fed to the heat exchanger, and the events described
above are repeated.
Material:
Default: *CS* (Carbon steel)
Crystallizer rate:
Max: 6,900 TPD [260 TON/H]
12-3
Evaporators (E)
Description
Type
Agitated falling film evaporator to 150 SF [13 M2]
includes motor and drive.
FALL FILM
Material:
Default: *SS304*
SS304- SS304
SS316- SS316
Heat transfer area:
Range: 4 - 150 SF [0.4 - 13 M2]
Forced circulation evaporator to 10000 SF [925 M2]
FORCED CIR
includes interconnecting piping, circulating pumps and
drivers.
Material:
Heat transfer area:
Range: 100 - 10,000 SF [10 -925 M2]
Tube material:
CS tubes with CS shell, Cu. or Ni tubes with CI shell.
CS- Carbon steel
CU- Copper
NI- Nickel
Material:
CI (Cast iron)
Heat transfer area:
Range: 155 - 8,000 SF [14 - 740 M2]
Tube material:
CS tubes with CS shell, Cu or Ni tubes with CI shell.
CS- Carbon steel
CU- Copper
NI- Nickel
Long tube rising film evaporator to 35 SF [3.2 M2]
includes interconnecting piping.
LONG TUBE
Material:
SS steel tubes with SS shell.
Heat transfer Area:
Range: 18 - 35 SF [1.7 - 3.2 M2]
12-4
Evaporators (E) - continued
Description
Type
Long tube vertical evaporator to 50000 SF [4640 M2] LONG VERT
variety of tube and shell materials.
Karbate tubes with rubber-lined CS shell, CU tubes
with other shell materials.
Material:
Surface area:
Range: 400 - 50,000 SF [38 - 4,640 M2]
Material:
CI (Cast iron)
Surface area:
Range: 100 - 25,000 SF [10 - 2,320 M2]
Material:
CU
Surface area:
Range: 200 - 3,000 [19 - 275 M2]
Material:
RBLCS
Surface area:
Range: 100 - 2,700 SF [10 - 250 M2]
Standard vertical tube evaporator to 7000 SF
[650 M2]
STAND VERT
CS tubes with CS shell, Cu tubes with CI shell, Pb shell
with Pb-lined CS shell.
Material:
Surface area:
Range: 100 - 6,000 SF [10 - 555 M2]
Material: CI (Cast iron)
Surface area:
Range: 100 - 6,000 SF [10 - 555 M2]
Material: PBLCS (Lead-lined CS)
Surface area:
Range: 200 - 7,000 SF [19 - 650 M2]
12-5
Evaporators (E) - continued
Description
Type
Standard horizontal tube evaporator to 10000 SF [920 STAND HOR
M2].
CS tubes with CS shell, Cu tubes with CI shell.
Material:
Default: *CS*
Surface area:
Range: 100 - 10,000 SF [10 - 920 M2]
Material:
CI (Cast iron)
Surface area:
Range: 100 - 6000 SF [10 - 555 M2]
12-6
Description
Type
Agitated thin film evaporator with explosion-proof
motor and drive.
THIN
FILM
Material:
Default: *SS316*
Heat transfer area:
Range: 0.95 - 27 SF [0.1 - 2.5 M2]
Packaged system including condenser and stand.
WFE SYSTEM
Material:
Default: *SS316*
Heat transfer area:
Range: 0.2 - 12 SF [0.02 - 1.1 M2]
12-7
Air Dryers (AD)
Description
Type
Dual tower, desiccant type, for drying of air to -40
DEG F [-40 DEG C] dew point; includes desiccant.
AIR DRYER
Material:
Gas flow rate:
Max: 50,000 CFM [84,900 M3/H]
12-8
Dryers (D)
Includes solid materials.
Description
Type
Atmospheric tray batch dryer.
ATMOS TRAY
Material:
Default: *CS*
Tray area:
Range: 30 - 200 SF [2.8 - 18.5 M2]
Material:
SS
Tray area:
Range: 30 - 250 SF [2.8 - 23 M2]
Vacuum tray batch dryer.
VAC TRAY
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Tray area:
Range: 40 - 200 SF [3.8 - 18.5 M2]
Agitated pan batch dryer for sensitive materials.
PAN
Material:
Default: *CS*
CS- Carbon steel
304CD- CS clad with 304 SS
316CD- CS clad with 316 SS
Surface area:
Range: 12 - 180 SF [1.1 - 16.7 M2]
Diameter:
Range: 3 - 10 FEET [0.9 - 3.0 M]
Pan depth:
Range: 18 - 36 INCHES [450 - 900 MM]
Driver power:
Range: 3 - 40 HP [2.22 - 30 KW]
12-9
Dryers (D) - continued
Description
Type
SPRAY
Continuous spray drying system. Includes supports,
heater, filter, atomizer, fan, driver, instrumentation,
interconnecting piping, cyclone and accessories to
9000 LB/H [4080 KG/H] evaporative capacity (water).
Material:
Default: *CS*
Evaporation rate:
Range: 700 - 9,000 LB/H [320 - 4,080 KG/H]
12-10
Drum Dryers (DD)
Description
Type
Single atmospheric drum dryer for drying of solids on
web material.
on steam-heated rotating drum.
SINGLE ATM
Material:
Default: *CS*
Tray area:
Range: 10 - 200 SF [1 - 18 M2]
Double atmospheric drum dryer for drying of solids on DOUBLE ATM
web material on pair of steam heated drums.
Material:
Default: *CS*
Tray area:
Range: 25 - 400 SF [2.4 - 35 M2]
Single vacuum rotary drum dryer for drying of
sensitive solids under vacuum.
SINGLE VAC
Material:
Default: *CS*
Tray area:
Range: 10 - 200 SF [1 - 18 M2]
Rotary drum cooker-cooler.
S COOKCOOL
Use to blanch foods like pasta or corn, cook foods like
meats or poultry, or cool foods like bagged soup.
Material:
SS304, *SS316*
Dryer drum diameter:
12-11
Drum Dryers (DD) - continued
Description
Type
S COOKCOOL - continued
Only 60 INCH (1525 MM) and 72 INCH (1825
MM) diameters are available.
Food flow rate: MAX: 303,000 LB/HR (137,437
KG/HR) at default product density 50 LB/CF (800
KG/M3). The maximum capacity any model can
handle depends upon the product density, and is
thus volumetric in nature; densities higher than
the default can realize capacities above 303,000
lb/hr (137,437 KG/HR), while densities lower
than the default realize maximum capacities
below 303,000 lb/hr (137,437 KG/HR).
Cooler length: MIN: 4 FEET [1.2M] for 60 INCH
[1,525 MM] and 8 FEET [2.4 M] for 72 INCH
[1,825 MM] drum dia., MAX: 16 FEET [4.8 M]
Product density: MIN: 50 PCF, MAX: 303,000 LB/
HR [137,437 KG/HR] at product density 50 LB/CF
(800 KG/M3).
Cook time: If drum diameter is specified, default
cooking time is 1 MINUTE, which is the minimum
allowable cooking time, and therefore the
cooking time that results in the maximum
allowable capacity. If capacity is specified, the
default cooking time is computed based on the
capacity, cooker length, and drum diameter.
MIN: 1 MINUTE, MAX: 12 MINUTES.
Driver power:
Default: based on drum diameter, food capacity
and cooker length.
Driver type:
*WVRDC*- Washdown, VFD rated, direct drive,
CS
WVCDC- Washdown, VFD controlled, direct drive,
CS
12-12
Rotary Dryers (RD)
Description
Type
Direct contact of hot gas with moist solids with
maximum surface area of 2000 SF [185 M2].
DIRECT
Material:
Default: *CS*
Surface area:
Range: 100 - 2,000 SF [10 - 185 M2]
Indirect contact of hot gases with moist solids with
maximum surface area of 2000 SF[185 M2].
INDIRECT
Material:
Default: *CS*
Surface area:
100 - 2,000 SF [10 - 185 M2]
Jacketed rotary vacuum dryer with explosion-proof
motor.
Maximum capacity of 500 CF [14.1 M3].
JAC VACUUM
Material:
Default: *CS*
CS- Carbon steel
SS316- SS316
Flow rate:
8 - 500 CF [0.25 - 14.1 M3]
Conical rotary vacuum dryer with maximum capacity
of 400 CF.
[11.3 M3].
VACUUM
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Flow rate:
3 - 400 CF [0.1 - 11.3 M3]
12-13
Description
Type
Atmospheric tray dryer with painted steel chamber.
ATM SYSTEM
Material:
Default: *SS316*
Tray surface area:
Range: 80 - 300 SF [7.5 - 27.5 M2]
Batch tray dryer with vacuum and no trays.
VACUUM
Material:
Default: *CI*
Tray surface area:
Range: 20 - 75 SF [1.9 - 6.9 M2]
Material:
SS304
Tray surface area:
Range: 20 - 80 SF [1.9 - 7.0 M2]
Turbo tray drying system with auxiliaries except
heating system.
TURBO
Material:
Default: *CS*
Tray surface area:
Range: 60 - 20,000 SF [6 - 1,850 M2]
Heating medium:
Default: *blank*
H-AIR- Hot air
STEAM- Steam
blank- Other heating medium
Batch tray dryer with vacuum pump and condenser.
VAC SYSTEM
Material:
Default: *CI*
Tray Surface Area:
Range: 13 - 70 SF [1.3 - 6.5 M2]
12-14
13 Solids Conveying
(G10)
Conveyors (CO)
Definitions and Samples of Conveyor Section Types
Cranes (CE)
Feeders (FE)
Hoists (HO)
Scales (S)
13 Solids Conveying (G10)
13-1
Conveyors (CO)
Description
Type
Open belt conveyor for transporting solid materials
over long distances. Because the belt material is
reinforced rubber, materials at temperatures above
150 DEG F are normally not handled.
Includes grade-level support steel, belt tensioning
device, motors and drives.
OPEN BELT
An endless moving belt is used to transport solids
either horizontally or on an incline. The belt may be
flat, but is typically troughed in order to increase the
carrying capacity of the belt.
Belt Width:
Range: 18 - 120 INCHES [450 - 3,000 MM]
Product Density:
MAX: 20
0 PCF [3,200 KG/M3];
Driver Power per Section:
Driver power per section if conveyor has multiple
sections.
13-2
Conveyors (CO) - continued
Description
Type
OPEN BELT - continued
Conveyer Speed:
MIN: 20 FPM [370 M/H]
Vertical lift (+) or drop (-): Difference in elevation
between feed and discharge: lift (positive), drop
(negative). Default: *0.0* FEET [*0.0* M]
Height Grade Section:
Grade section has this uniform, nominal height for
entire length. Default: *6* FEET [*2* M].
Length Grade Section:
Default length = conveyor length, if length of other
two section type = 0.0.
Height Slope Section:
Slope section varies from grade section height to this
designated height.
Length Slope Section:
two section types = 0.0.
Height Above Grade Section:
Above grade section varies from slope section height
to this designated height.
Length Above Grade Section:
Cantilever Length:
Cantilever length may be specified only for the end of
an elevated section. Default: *0.0* FEET [*0.0* M]
Tower Bent Spacing:
Tower (bent) spacing applies to elevated sections only.
Gallery Enclosure:
Default: *NO GALLERY*
GALLERY- Gallery enclosure for conveyor and walks
NO GALLERY- No gallery enclosure
Number of Motors:
Default: 1 per MILE [1 per 1.6 KM]
Number of Walkways:
Default: 1 if no gallery, 2 if conveyor has gallery
enclosure.
Walkway Width:
Default: 36 INCHES [910 MM] if no gallery, 54 INCHES
[1370 MM] if gallery enclosure.
13-3
Description
Type
Same as open belt conveyor but enclosed with
corrugated sheet
CLOSED
BLT
metal canopy enclosing the belt to protect the belt and
the materials from the elements. Canopy is also used
to control dust when transporting material with fines.
Belt Width:
Range: 18 - 120 INCHES [450 - 3,000 MM]
Product Density:
MAX: 200 PCF [3,200 KG/M3];
Driver Power per Section:
Driver power per section if conveyor has multiple
sections.
Speed:
MIN: 20 FPM [370 M/H]
Vert Lift (+) or drop (-): Difference in elevation
(negative). Default: 0.0 FEET [0.0 M].
Height Grade Section:
Grade section has this uniform, nominal height for
entire length. Default: *6* FEET [*2* M]
Length Grade Section:
Height Slope Section:
Slope section varies from grade section height to this
designated height.
Length Slope Section:
Height Above Grade Section:
Above grade section varies from slope section height
to this designated height.
Length Above Grade Section:
Cantilever Length:
Cantilever length may be specified only for the end of
an elevated section. Default: *0.0* FEET [*0.0* M]
Tower Bent Spacing:
Tower (bent) spacing applies to elevated sections only.
13-4
Description
Type
CLOSED BLT - continued
Gallery Enclosure:
Default: *NO GALLERY*
GALLERY- Gallery enclosure for conveyor and walks
NO GALLERY- No gallery enclosure
Number of Motors:
Default: 1 per MILE [1 per 1.6 KM]
Number of Walkways:
Default: 1 if no gallery, 2 if conveyor has gallery
enclosure.
Walkway Width:
Default: 36 INCHES [910 MM] if no gallery, 54 INCHES
[1370 MM] if gallery enclosure.
13-5
Definitions and Samples of Conveyor
Section Types
Section 1: A conveyor section at uniform nominal height (H1) above grade. The
section on “post-type” legs and has a total length L1.
Section 2: A conveyor section where height varies from the nominal grade height (H1)
to some elevation above grade (H2). The section is supported on “bents” or
“tower-type” supports and has a total length L2.
Section 3: A conveyor section where height varies from one elevated height (H2) to a
second elevated height (H3). The section is supported on “bents” or “tower-type”
supports and has a total length L3.
Samples of Combined Sections
Sections 1, 2 and 3
13-6
Section 1 and 3
Description
Apron to 50 FEET [15 M] includes motor and drive,
open pans mounted between endless chains, not
enclosed (open), and floor-mounted support steel.
Type
APRON
The apron conveyor is suitable for conveying coarse
solids. The open apron conveyor is limited to material
temperatures less than 600 DEG F.
Material:
Default: *CS*
Conveyer Length:
Range: 7 - 50 FEET [2.2 - 15 M]
Conveyer Width:
Range: 18 - 54 INCHES [450 - 1,350 MM]
Conveyer Flow Rate:
Range: 20 - 200 TPH [18.5 - 142 TON/H]
Driver Power:
Range: 2 - 20 HP [1.5 - 15 KW]
Product Density:
MAX: 200 PCF [3,200 KG/M3];
Pneumatic conveying system for moving granular
materials horizontally and vertically to areas that are
either far away or otherwise hard to reach
economically with mechanical conveyors. Includes
TEFC motor, blower, base, coupling, check valve,
instrumentation and filter piping.
PNEUMATIC
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
AL- Aluminum
Conveyer Length:
Range: 100 - 1,200 FEET [30 - 360 M]
Tube Diameter:
Range: 3 - 4 INCHES [75 - 100 MM]
Conveyer Flow Rate:
Range: 2 - 15 TPH [2 - 13 TON/H]
Product Density:
Range: 20 - 60 PCF [325 - 960 KG/M3];
13-7
Description
Type
Roller conveyor for moving firm flat-bottomed unit
loads, (e.g., drums, pallets and boxes). Inclines or
declines should not be more than 5o. Especially
suitable for conveying unit loads in a curved path.
Rollers supported in frame.
ROLLER
Material:
Conveyer Length:
Range: 4 - 25 FEET [1.3 - 7.5 M]
Conveyer Width:
Range: 12 - 20 INCHES [300 - 500 MM]
Roller Spacing:
Range: 3 - 4 INCHES [75 - 100 MM]
Screw conveyor for conveying granular or fine solids SCREW
horizontally or up an incline. Screw conveyor capacity,
however, decreases rapidly as the angle of incline
increases. Includes motor, drive and helical screw in
U-shaped trough.
The crew conveyor consists of a helical screw inside
an enclosed U-shaped trough. As the screw rotates,
the material is moved forward. Screw conveyors are
inexpensive, easy to maintain and can easily be made
dust-tight.
Material:
Default: *CS*
CS- Carbon steel
SS305- SS305
SS316- SS316
Conveyer Length:
Range: 10 - 1,000 FEET [3.1 - 300 M]
Screw Diameter:
Range: 6 - 24 INCHES [155 - 600 MM]
Product Density:
MAX: 100 PCF [1,600 KG/M2]
Vibrating conveyor for moving granular materials
horizontally or on slight incline. Includes motor and
drive, carrying trough, support base and drive
springs.
VIBRATING
The material being transported should have a high
friction factor on steel as well as a high internal
friction factor. Material must be dense so that air
resistance will not retard the flight of the solid particle
as it is thrown forward, and the material should not
aerate.
13-8
Description
Type
VIBRATING - continued
Friable materials can be handled because the
movement of the material is gentle. The conveyor can
be made dust-tight and materials of construction may
be used to allow the handling of materials at
temperatures up to 2000 DEG F.
A vibrating conveyor consists of a carrying trough,
supporting base, drive springs and a drive system. The
drive system and springs impart an oscillating motion
to the trough which causes the material to move
forward in a hopping motion.
Material:
Pan Width:
Range: 12- 36 INCHES [300 - 900 MM]
Spaced bucket centrifugal discharge elevator includes
motor, drive and bucket contents discharged by
centrifugal motion.
CENT BKT L
For the vertical lifting of free-flowing fine or small lump
materials such as coal, sand and dry chemicals. This
elevator should not be used for materials that are
degraded by breakage or for fluffy materials.
This equipment item consists of evenly spaced buckets
attached to an endless belt or chain enclosed in a
supporting casing. This is called a centrifugal
discharge elevator because the contents of the
buckets are thrown into the discharge chute by
centrifugal force as the bucket rounds the head shaft.
Material:
Conveyer Length:
Range: 12 - 120 FEET [4 - 36 M]
Bucket Width:
Range: 6 - 16 INCHES [150 - 400 MM]
Conveyer Flow Rate:
Range: 16 - 156 TPH [14.5 - 141 TON/H]
Product Density:
MAX: 100 PCF [1,600 KG/M3];
13-9
Description
Type
Continuous bucket elevator, buckets closely spaced
with back of preceding bucket serving as gravity
discharge chute for dumping bucket. Includes motor
and drive.
CONT BKT L
The slower speed and gentler discharge make this
type of elevator more suitable for materials which are
degraded through breakage, and for fluffy materials.
This equipment item is the same as the spaced bucket
centrifugal discharge elevator except buckets are
closely spaced with the back of the preceding bucket
serving as a discharge chute for the bucket with is
dumping as it rounds the head shaft. Close bucket
spacing allows the same capacity to be achieved as
slower elevator speeds.
Thus, bucket discharge is by gravity rather than
centrifugal force.
Material:
Conveyer Length:
Range: 12 - 100 FEET [4 - 36 M]
Bucket Depth:
Range: 8 - 24 INCHES [200 - 600 MM]
Conveyer Flow Rate:
Range: 40 - 216 TPH [36 - 195 TON/H]
Product Density:
MAX: 100 PCF [1,600 KG/M3];
Sanitary horizontal conveyor
S BELTCONV
Material:
*SS304*, SS316
Conveyer length:
Range: 6 - 20 FEET [1.8 - 6 M]
Belt width: Available sizes:
18 INCH [450 MM]
24 INCH [600 MM]
30 INCH [750 MM]
36 INCH [900 MM]
Conveyer type:
*INSPC*- Inspection type conveyor
BIDIR- bi-directional type (reversing belt conveyor)
Driver power: Default *1* HP
Driver type:
*WVRDC*- Washdown, VFD rated, direct drive, CS
WVCDC- Washdown, VFD controlled, direct drive, CS
13-10
Description
Type
Sanitary vertical conveyor
S VERTICAL
Material:
*SS304*, SS316
Vertical lift (+) or drop (+): MIN: - 40 FEET [-12.2 M];
MAX: 40 FEET [12.2 M] Difference in elevation
(negative)
18 INCH [450 MM]
24 INCH [600 MM]
30 INCH [750 MM]
36 INCH [900 MM]
Length of lead-in section:
Default and MIN: *2* FEET [.6 M]
Length of the conveyor at feed end before lift or drop
Length of lead-out section: Default and MIN: *2* FEET
[.6 M]
Length of the conveyor at discharge end before lift or
drop
Driver power:
Default *1* HP
Driver type:
Sanitary vibratory conveyor
S VIBRATRY
Material:
*SS304*, SS316
Conveyer length:
Range: 6 - 40 FEET [1.8 - 12.2M]
18 INCH [450 MM]
24 INCH [600 MM]
30 INCH [750 MM]
36 INCH [900 MM]
Belt support:
*NONE*- No belt support will be provided
BSUP- Belt support will be provided
13-11
Description
Type
S VIBRATRY - continued
Driver type:
Number of lane dividers: Default *0*; MAX: 2
Dewatering screen:
*NONE*- De-watering screen pair not included
DWAT- De-watering screen pair included
Pneumatic gate:
*NONE*- Full-width pneumatic screen not included
PNUM- Full-width pneumatic screen included
Discharge type:
*NONE*- No discharge exists
DROP- Drop-out type discharge
BIAS- Bias type discharge
Sanitary incline conveyor
S INCLINE
Material: *SS304*, SS316
Length of incline section: MIN: 2 FEET [.600 M];
MAX: 40 FEET [12.2 M]
Belt width:
Available sizes:
18 INCH [450 MM]
24 INCH [600 MM]
30 INCH [750 MM]
36 INCH [900 MM]
Length of lead-in section: Default and MIN: *2* FEET
[.6 M]
Length of the conveyor at feed end before lift or drop
Length of lead-out section: Default and MIN: *2* FEET
[.6 M]
Length of the conveyor at discharge end before lift or
drop
Driver type:
13-12
Cranes (CE)
Description
Type
BRIDGE CRN
Travelling bridge crane includes trolley, hoists,
bridge, bridge rail, end trucks and drivers; not
included are building crane supports or travelling
rails (see Plant Bulk — Steel - Mill Building) to
200 TONS [175 TON].
Material:
Crane Capacity:
Range: 5 - 200 TONS [5 - 175 TON]
Includes hoist trolley and track beam to 30 TONS HOIST
[25 TON].
Material:
Crane Capacity:
Range: 0.5 - 30 TONS [0.5 - 25 TON]
Description
Type
Freight elevator for lifting personnel, equipment and
supplies in process buildings and open steel
structures. Capacity to 10 TONS [10 TON] and 200
FEET [60 M] lift. Includes geared motor drive at 150
FPM [2750 M/H].
FREIGHT
Elevator Capacity:
Range: 2 - 10 TONS [2 - 10 TON]
Height:
Range: 20 - 200 FEET [7 - 60 M]
Elevator for lifting personnel and small tools in process PASSENGER
buildings and open steel structures. Capacity to 5
TONS [5 TON] and 200 FEET [60 M] lift. Includes
geared variable stage drive at 2 00 FPM [3650 M/H].
Elevator Capacity:
Range: 1 - 5 TONS [1 - 5 TON]
Height:
Range: 20 - 200 FEET [7 - 60 M]
13-13
Feeders (FE)
Description
Type
Volumetric belt feeder to 4800 CFH [135 M3/H].
BELT
Material:
Feeder Rate:
Range: 120 - 4,800 CFH [3.5 - 135 M3/H]
Bin activator.
BIN ACTVTR
Material:
Diameter:
Range: 3 - 15 FEET [1.0 - 4.5 M]
Rotary vane feeder with diameter to 36 INCHES [900
MM]. Includes motor and drive.
ROTARY
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Rotary Feeder Diameter:
Range: 3 - 36 INCHES [80 - 900 MM]
The model assumes 40 LBS/CF for capacity
related calculations.
The model also assumes that each diameter unit
has a maximum volumetric capacity. For
example, a 4 INCH diameter has 0.013 CF/rev
and a 20 INCH diameter has 2.7 CF/rev.
The model calculations handle the following
two cases:
If Rate (LBS/H) and RPM are not specified then:
For Dia <= 20, RPM=45
For Dia > 20, RPM=30
Assume 50% fill, so Rate is:
CF/Rev*RPM*0.5*(40 LBS/CF)*(60 Min/Hr)
If Rate is specified then:
RPM = Rate/(40 LBS/CF)/(CF/rev)/(60 Min/Hr)
Horsepower is estimated from diameter. For
example, a 3 INCH diameter has 0.333 HP and a
30 INCH diameter has 5.0 HP.
13-14
Feeders (FE) - continued
Description
Type
Vibrating feeder.
VIBRATING
(includes hopper)
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Length:
Range: 5 - 14 FEET [1.6 - 4.2 M]
Feeder Width:
Range: 12 - 72 INCHES [3.5 - 1,800 MM]
Loss-in-weight. Gravimetric weigh belt for free-flowing WT LOSS
feeding/proportioning of solids. Includes motor and
variable speed drive.
Material:
Default: *CS*
Flow Rate:
Range: 5 - 2,400 LB/H [2.3 - 1,085 KG/H]
DUMPER
Sanitary dumper.
Lifts vats, combos, and tubs. Heavy duty stainless
steel construction is non-corrosive to withstand rigors
of daily washdown. Material of construction is SS316.
Dump height:
MIN: 3 FEET [0.914 M]; MAX: 17 FEET [5.18 M] for
INLIN lift, 14 FEET [4.26 M] for OFF lift.
Container type:
*55GD*- 55 GALLON [0.2 M3] drum
140GD- 140 GALLON [0.5 M3] drum
CTOTE- Corrugated tote
WOODC- Wood crate
3642B- SS bin 36 x 42 INCHES [914 x 1066 MM]
FBOX- Fiber box 18 x 18 x 36 INCHES [457 x 457 x
914 MM]
13-15
Description
Type
DUMPER - continued
Lift type:
*INLIN*- Inline hydraulic lift
OFF- Offset electric lift
Retainer hold down:
*MAN*- Manual mechanism
AUTO- Automatic mechanism
AUTOB- Automatic mechanism and hydraulic box
retainer
Hydraulic power pack:
*NONE*- External hydraulic power pack
INCL- Self-contained hydraulic power pack
Sanitary bulk bag unloader
SACK DUMP
Sack size:
*1,500 LBS [681 KG], MAX: 4,000 LBS [1,814 KG]
Discharge type:
*GRAV*- Gravity discharge
SCREW- Flexible screw conveyor
Control type:
*MAN*- Manual control
LIW- Loss-in-weight control
Frame loading type:
*FORK*- Fork lift loading
HOIST- Electric hoist and trolley
Sanitary screw feeder
SAN SCREW
Includes a hopper with a screw feeder to convey dry,
fine, or wet solids. The screw feeder is controlled as
specified by the user. Material of construction is
SS316.
Flow rate:
Enter mass rate/vol. rate
MAX: 5600LB/H [2540KG/H] at 35PCF[560KG/M3] DRY-VOL
Volumetric rate:
Enter mass rate or vol. rate; MAX varies with density,
product and control type.
MAX: 160 CFH [4.5 M3/H]
13-16
Description
Type
SAN SCREW - continued
Product density:
*35 |PCF [560 |KG/M3]
Product type:
*FINE*- Fine powders only
DRY- Dry particulates; fine, coarse powders
WET- Wet, dry particulates; fine, coarse
powder
Control type:
*VOL*- Volumetric control
LIW- Loss-in-weight control
Extended auger length:
*12 |INCHES [304 MM]*, MIN: 12 |INCHES
[304 MM]
Enclosure type:
*WASH*- Washdown enclosure
EXPR- Explosion-proof enclosure
Sanitary weigh belt feeder
SAN BELT
Provides flow control for food and other solid
materials not requiring total material
containment. Material of construction is SS316.
Flow Rate:
MAX: 90,000 LB/H [40,800 KG/H]
Required: enter rate or width.
Feeder Width:
Two available widths: 12 INCHES [300 MM], 24
INCHES [600 MM]. Required: enter rate or
width.
Enclosure type:
*CLOSE*- Closed frame unit
OPEN- Open frame unit
13-17
Hoists (HO)
Description
Type
5-speed electric hoist with motor driven trolley. The
HOIST
trolley suspends the hoist from an I-beam. The hoist is
propelled along the I-beam by the motor driven
trolley. An electric hoist used for repetitive or
high-speed lifting.
Material:
Hoist Capacity:
Range: 1 - 12 TONS
[1 - 10 TON]
Single speed electric hoist, no trolley. Used for
repetitive or high-speed lifting.
1 SPEED
Material:
Hoist Capacity:
Range: 1 - 14 TONS
[1 - 12 TON]
5-speed electric hoist, no trolley. Used for repetitive or 5 SPEED
high-speed lifting.
Material:
Hoist Capacity:
Range: 1 - 13 TONS
[1 - 11 TON]
HAND GT
Hand hoist, geared manual pull-chain driven trolley.
For intermittent service, especially maintenance work.
Material:
Hoist Capacity:
Range: 1 - 12 TONS [1 -10 TON]
Hand hoist, manually-pulled trolley. The hoist is
moved to a new position on the I-beam by manually
pulling the trolley. For intermittent service, especially
for maintenance work.
HAND PT
Material:
Hoist Capacity:
Range: 1 - 12 TONS
[1 - 10 TON]
13-18
Hoists (HO) - continued
Description
Type
Hand hoist, no trolley. The hand hoist without trolley is HAND NT
a portable lifting device which is suspended from a
hook and operated by a hand chain. For intermittent
service, especially for erection and maintenance work.
Material:
Capacity:
Range: 1 - 18 TONS [1 - 16 TON]
Beam scale to 2000 LBS [900 KG].
BEAM SCALE
Material:
Scale Capacity:
Range: 300 - 2,000 LBS [135 - 900 KG]
Conveyor belt scale.
BELT
Material:
Belt Width:
Range: 18 - 72 INCHES [450 - 1,800 MM]
Bench, dial, and beam to 3000 LBS [1350 KG].
BENCH
Material:
Scale Capacity:
MAX: 3,000 LBS [1,350 KG]
Floor, dial, and beam full frame to 8000 LBS [3600
KG].
FULL FRAME
KG].
Material:
Scale Capacity:
MAX: 8,000 LBS [3,600 KG]
Floor, dial, and beam semi-frame to 8000 LBS [3600
KG].
SEMI FRAME
Material:
Scale Capacity:
MAX: 8,000 LBS [3,600 KG]
13-19
Description
Type
Tank scale, weigh bridge and saddles 150000 LBS
[68000 KG].
TANK SCALE
Material:
Scale Capacity:
Range: 10,000 - 150,000 LBS [4,500 - 68,000 KG]
Track scale, for weighing rail cars to 300 TONS [265
TON].
TRACK
Material:
Weight Capacity in Tons:
Range: 150 - 300 TONS [130 - 265 TON]
Truck scale, for weighing trucks/lorries to 60 TONS
[54 TON].
TRUCK
Material:
Range: 30 - 60 TONS [25 - 54 TON]
SAN FLOOR
The sanitary floor scale is a deck provided in a
frame, located inside a small pit so that the top
of the scale is flush with the floor. Weigh cells
and instrumentation in the frame measure the
weight and display it on a nearby local panel.
Material of construction is stainless steel.
Scale Capacity:
MAX: 10,000 LBS [4,500 KG]
Platform Size:
3X3- 3x3 FEET [0.9x0.9 M] platform
4X4- 4X4 FEET [1.2x1.2 M] platform
13-20
Description
Type
SAN FLOOR - continued
Local digital indicator:
*INCL*- Includes logical digital indicator
NONE- Remote indicator only
Deck surface:
*PLAIN*- Glass bead sandbase
TREAD- Tread plate
Deck lift:
*AUTO*- Automatic deck lift
NONE- No deck lift
Floor installation:
*NEW*- No floor alteration necessary
EXIST- Alter the existing floor
13-21
Scales (S)
Description
Type
Beam scale to 2000 LBS [900 KG].
BEAM SCALE
Material:
Scale Capacity:
Range: 300 - 2,000 LBS [135 - 900 KG]
Conveyor belt scale.
BELT
Material:
Belt Width:
Range: 18 - 72 INCHES [450 - 1,800 MM]
Bench, dial, and beam to 3000 LBS [1350 KG].
BENCH
Material:
Scale Capacity:
MAX: 3,000 LBS [1,350 KG]
KG].
FULL FRAME
Material:
Scale Capacity:
MAX: 8,000 LBS [3,600 KG]
Floor, dial, and beam semi-frame to 8000 LBS [3600
KG].
SEMI FRAME
Material:
Scale Capacity:
MAX: 8,000 LBS [3,600 KG]
Tank scale, weigh bridge and saddles 150000 LBS
[68000 KG].
TANK SCALE
Material:
Scale Capacity:
Range: 10,000 - 150,000 LBS [4,500 - 68,000 KG]
13-22
Scales (S) - continued
Description
Type
Track scale, for weighing rail cars to 300 TONS [265
TON].
TRACK
Material:
Range: 150 - 300 TONS [130 - 265 TON]
Truck scale, for weighing trucks/lorries to 60 TONS [54 TRUCK
TON].
Material:
Range: 30 - 60 TONS [25 - 54 TON]
SAN FLOOR
The sanitary floor scale is a deck provided in a frame,
located inside a small pit so that the top of the scale is
flush with the floor. Weigh cells and instrumentation in
the frame measure the weight and display it on a
nearby local panel.
Scale Capacity: MAX: 10,000 LBS [4,500 KG]
Platform Size:
3X3 - 3x3 FEET [0.9x0.9 M] platform
4X4 - 4X4 FEET [1.2x1.2 M] platform
Local digital indicator:
*INCL* - Includes logical digital indicator
NONE - Remote indicator only
Deck surface:
*PLAIN* - Glass bead sandblasted
TREAD - Tread plate
Deck lift:
*AUTO* - Automatic deck lift
NONE
- No deck lift
Floor installation:
*NEW* - No floor alteration necessary
EXIST - Alter the existing floor
13-23
13-24
14 Separation Equipment
(G7)
Centrifuges (CT)
Filters (F)
Thickeners (T)
Screens (VS)
14 Separation Equipment (G7)
14-1
Centrifuges (CT)
Description
Type
Atmospheric suspended basket.
ATM SUSPEN
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Driver Power:
Range: 2 - 30 HP [1.5 - 22 KW]
Automatic batch filtering centrifuge to 60 INCHES
[1520 MM].
BATCH AUTO
Material: Default: *CS*
CS- Carbon steel
SS316- SS316
HASTC- Hastelloy C
Centrifuge diameter:
Range: 24 - 60 INCHES [610 - 1,520 MM]
Centrifuge capacity:
Range: 3 - 30 CF [0.085 - 0.84 M3]
14-2
Centrifuges (CT) - continued.
Description
Type
Batch bottom-suspended filtering centrifuge with
diameter to 48 INCHES [1210 MM].
BATCH BOTM
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Range: 20 - 48 INCHES [510 - 1,210 MM]
Batch bottom-driven centrifuge, top unloading,
explosion-proof motor with diameter to 56 INCHES
[1420 MM].
TOP UNLOAD
Material:
Default: *CS*
CS- Carbon steel
RBLCS- Rubber-lined carbon steel
SS316- SS316
HASTC- Hastelloy C
Centrifuge capacity:
Range: 2 - 20 CF [0.06 - 0.56 M3]
Range: 18 - 56 INCHES [460 - 1,420 MM]
Batch bottom-driven centrifuge, bottom unloading,
fixed speed hydraulic driver with diameter to 56
INCHES [1420 MM].
BOT UNLOAD
Material:
Default: *SS316*
Range: 12 - 56 INCHES [305 - 1,420 MM]
Batch top-suspended filtering centrifuge with diameter BATCH TOP
to 50 INCHES [1260 MM].
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
RBLCS- Rubber-lined carbon steel
Range: 20 - 50 INCHES [510 - 1,260 MM]
14-3
Centrifuges (CT) - continued
Description
Type
High speed disk clarifier centrifuge, stack of rotating
conical disks to shorten sedimentation path, batch
removal of solids and diameter to 20 INCHES [500
MM].
DISK
Material:
Default: *CS*
Range: 10 - 20 INCHES [250 - 500 MM]
Reciprocating conveyor, with continuous filtering
RECIP CONV
centrifuge for free-draining granular solids, horizontal
bowl, removal by reciprocating piston and diameter to
50 INCHES [1250 MM].
Material:
Range: 15 - 50 INCHES [375 - 1,250 MM]
Material:
Range: 20 - 50 INCHES [500 - 1,250 MM]
Scroll conveyor with continuous filtering centrifuge,
solids removal by scroll conveyor and diameter to 75
INCHES [1875 MM].
SCROLL CON
Material:
Range: 15 - 75 INCHES [375 - 1,875 MM
Material:
Range: 15 - 50 INCHES [375 - 1,250 MM]
Solid bowl with diameter to 54 INCHES [1370 MM].
SOLID BOWL
Material:
Default: *CS*
CS- Carbon steel
SS316- SS316
Bowl diameter:
Range: 18 - 54 INCHES [460 - 1,370 MM]
Dowl length:
Range: 28 - 132 INCHES [720 - 3,350 MM]
14-4
Centrifuges (CT) - continued
Description
Type
Screen bowl with diameter to 54 INCHES [1370 MM].
SCREEN BWL
Material:
Default: *CS*
CS- Carbon steel
SS316- SS316
Bowl diameter:
Range: 18 - 54 INCHES [460 - 1,370 MM]
Bowl length:
Range: 28 - 132 INCHES [720 - 3,350 MM]
High speed tubular sedimentation centrifuge, bottom TUBULAR
entry, batch solids removal and diameter to 6 INCHES
[150 MM].
The following rates are shown to assist in selecting the
proper equipment item, however, rates outside this
range may be input.
TPH = 110-325, TON/H = 91-263.
Material:
Bowl diameter:
Range: 4 - 6 INCHES [105 - 150 MM]
Continuous filtration vibratory centrifuge with solids
VIBRATORY
removal by vibratory screen for dewatering of coarse
solids with screen diameter to 56 INCHES [1420 MM].
Material:
Screen diameter:
Range: 48 - 56 INCHES [1,220 - 1,420 MM]
Inverting filter centrifuge.
INVERTING
Material: Default: *SS316*
Centrifuge diameter: Range: 12 - 52 INCHES [305 1,320 MM]
Centrifuge capacity: Range: 0.2 - 12 CF [0.0056 0.34 M3]
14-5
Description
Type
Centrifugal precipitator includes driver and
interconnecting piping with flow rate to 10,000 CFM
[16,990 M3].
CENTRF PRE
Material:
Default: *CS*
Gas flow rate:
Range: 500 - 10,000 CFM [850 - 16,990 M3/H]
Cloth bay baghouse includes hopper bottom, airlocks CLOTH BAY
and electrical motor shakers. Cloth area to 12,000 SF
[1,110 M2].
Fabric filters are used for high efficiency 99+%,
cleaning of small particles (less than one micron).
Fabric filters are an excellent choice where feed
conditions may vary because efficiency is unaffected
by varying flowrates, particulate loading, or particle
size distribution. Baghouses are not a good choice if
the gas contains free moisture or if condensation will
occur in the baghouse. Baghouses are limited to a
maximum temperature of 550 DEG F.
Shaker type filters are generally used for:
• Low CFM
• Low particulate loading
• Intermittent operation.
Pulse type units are used for:
• Large CFM
• High particulate loading
• Continuous operation.
The “cloth bay” dust collector is commonly called a
baghouse or fabric filter. Dust laden gas is ducted into
a rectangular (small units may be cylindrical)
enclosure. The dirty gas must pass through cloth
tubes or bags to get out of the baghouse. Baghouses
are characterized by the method used to clean the
filter bags. Two options are available - shaker and
pulse type cleaning, which are a function of the air-tomedia ratio.
14-6
Dust Collectors (DC) - continued
Description
Type
CLOTH BAY - continued
The air-to-media ratio, also called the air-to-cloth
ratio, is the CFM of gas passing through one square
foot of filter fabric. Shaker type baghouses are limited
to air-to-media ratios of less than 4:1. Dirty gas flows
from the inside to the outside of the filter bags in a
shaker type unit. In order to remove the collected
dust, the flow of dirty gas is stopped and an electric
motor shakes the bags.
Pulse type units have their filter bags supported over a
cylindrical wire cage and dirty gas flows from the
outside of the bags to the inside. Pulse type units
operate with air-to-cloth ratios from 4:1 to 15:1. Filter
bags are cleaned by injecting a pulse of compressed
air into the bags being cleaned. The pulse of air
expands the bags violently and throws off the dust
collected on the bag’s outside surface. The pulse type
baghouse does not have to be taken off-line for
cleaning.
With both types of baghouse, the dust is collected in
hopper bottoms and removed through an airlock.
The air-to-media ratio, also called the air-to-cloth
ratio, is the CFM of gas passing through one square
foot of filter fabric. Shaker type baghouses are limited
to air-to-media ratios of less than 4:1. Dirty gas flows
from the inside to the outside of the filter bags in a
shaker type unit. In order to remove the collected
dust, the flow of dirty gas is stopped and an electric
motor shakes the bags.
Pulse type units have their filter bags supported over a
cylindrical wire cage and dirty gas flows from the
outside of the bags to the inside. Pulse type units
operate with air-to-cloth ratios from 4:1 to 15:1. Filter
bags are cleaned by injecting a pulse of compressed
air into the bags being cleaned. The pulse of air
expands the bags violently and throws off the dust
collected on the bag’s outside surface. The pulse type
baghouse does not have to be taken off-line for
cleaning.
With both types of baghouse, the dust is collected in
hopper bottoms and removed through an airlock.
14-7
Description
Type
CLOTH BAY - continued
Today, most filter bags are manufactured from
synthetic fibers. The materials in most common use
are acrylics, nylon 6, nylon 66, “nomex” nylon,
“Teflon,” polypropylene and polyesters (e.g.,
“dacron”). The baghouses in the system have
polyester bags. Polyester has moderate all-around
chemical resistance and good strength and abrasion
resistance. Polyester may be used at a minimum
continuous service temperature of 300 DEG F.
Material:
Surface Area:
Range: 100 - 12,000 SF [10 - 1,110 M2]
Flow rate:
Enter surface area, flow rate, or boiler capacity (coalfired boiler aplx. only)
Air/media ratio:
Range: 1 - 4 CFM/SF [19 - 70 M2/H/M2]
Air temperature:
Boiler capacity:
Max: 3,400 MMBTU/H [1,000 MEGAW]
Baghouse with injected pulsed air Compressor for air
pulse injection not included.
PULSE SHKR
Material:
Surface Area:
Range: 100 - 6,000 SF [10 - 557 M2]
Flow Rate:
Max: 250,000 CFM [420,000 M3/H]
Air/media ratio:
Range: 5 - 15 CFM/SF [91 - 270 M3/H/M2]
Air temperature:
Boiler capacity:
14-8
Description
Type
Cyclone for gas/solid separation. Diameter to 60 CYCLONE
INCHES [1,500 MM].
Collection efficiency varies with particle size.
From the table above we see that cyclones are a good
choice for medium size particles. Cyclones can be
fabricated from a wide variety of internals and can also
be refractory lined. Therefore cyclones can be used for
the removal of particles from corrosive and/or high
temperature (1,800 DEG F) gas streams.
The cyclone has a cylindrically shaped upper section
and long tapering conical lower section. Dirty gas
enters the top section through a tangential nozzle.
This imparts a swirling motion to the gas. The
entrained particles are thrown to the wall of the
cyclone by centrifugal force. The particles descend by
gravity along the wall to the bottom of the cone where
they are discharged.
The gas spirals downward to the bottom of the cone
then reverses direction and moves upward to the gas
exit at the top center of the cyclone. Increasing the
diameter of a cyclone increases its capacity but
capacity of a single cyclone is limited to about 50,000
CFM. When larger flowrates must be handled several
cyclones are arranged in parallel.
Material Selection:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Diameter:
Range: 3 - 60 INCHES [75 - 1,500 MM]
Flow Rate:
Range: 70 - 40,000 CFM [120 - 67,900 M2/H]
Pressure drop:
Default: *2.5* IN-H20 [*625* PA] to *27,000*
CFM [*45,870* M3/H]; or *6* IN-H20 [*1,500* PA]
Air Temperature:
14-9
Description
Type
Multiple cyclone with flow rate to 20,000 CFM [33,980 MULT CYCLO
M3/H].
Material:
Gas flow rate:
Range: 900 - 20,000 CFM [1,530 - 33,980 M2/H]
High voltage electrical precipitator
ELC H VOLT
Gas flow rate:
Min: 600 CFM [1,020 M3/H]
Required: gas flow rate or boiler capacity
(for coal-boiler application only)
Boiler capacity:
Max: 3,400 MMBTU/H [1,000 MEGAW]
Required: gas flow rate or boiler capacity (for coalboiler application only)
Removal efficiency:
Min: 80.0%; Max: 99.99%
Required: removal efficiency or particle load (for coalboiler application only)
Particle size (microns):
Default: *0.600* microns
Particle resistance x10E10:
Default: *2* OHM-IN [*5* OHM-CM]
SO3 Concentration (ppm): Default: *4.50* ppm
Low voltage electrical precipitator
ELC L VOLT
Material:
Gas flow rate:
Range: 600 - 20,000 CFM [1,020 - 33,980 M3/H]
Washer dust collector
WASHERS
Material:
Default: *CS*
Gas flow rate:
Range: 600 - 20,000 CFM [1,020 -33,980 M3/H]
Air temperature:
14-10
Filters (F)
Description
Type
Cartridge filter to 1,200 GPM [75 L/S] with 5 micron
cotton filter.
CARTRIDGE
Cartridge filters are generally used as a final filtering
element for the removal of small particles, such as
pipe scale, down to 10 microns
in size from a liquid stream containing a low
concentration of these solids.
A cartridge filter consists of a tank containing one or
more filter elements or cartridges which are tubes of
wound natural or synthetic fibers. Liquid flows through
the cartridges and the suspended solids are trapped
by the fibers. As the filter gets dirtier, pressure drop
builds to a point where the cartridges must be
replaced. The cartridges are disposable. They are not
cleaned and reused.
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Liquid flow rate:
Range: 30 - 1,200 GPM [1.9 - 75 L/S]
Pressure leaf-dry filter with leaf area to 600 SF [55
M2].
LEAF DRY
Material:
Default: *CS*
CS- Carbon steel
SS316- SS316
Surface area:
Range: 50 -600 SF [4.7 - 55 M2]
Pressure leaf-wet filter with leaf area to 600 SF [55
M2].
LEAF WET
Material:
Default: *CS*
CS- Carbon steel
SS316- SS316
Surface area:
Range: 50 - 600 SF [4.7 - 55 M2]
14-11
Filters (F) - continued
Description
Type
Automatic plate and frame filter with capacity to 50 CF PLATE
[1.4 M3].
FRAM
Material:
Default: *RBLCS*
RBLCS- Rubber-line CS
PPLCS- Polyprop. lined CS
SS316- SS316
Frame capacity:
Range: 10 - 50 CF [0.3 - 1.4 M3]
Plate size:
Range: 36 - 48 INCHES [900 - 1,200 MM];
Default: 48 INCHES [1,2000 MM]
Disk Filter. General Features: The filter is a vacuum
type (from drop leg), consisting of segmented disks
with polypropylene filter bags, suction valve, vat
(optional) with stiffeners, discharge trough, drive
motor, base plate, rotor and bearing support. The
following variations are available.
ROTY DISK
Standard Disk Filter (for general chemical industry) —
This filter additionally includes a paddle agitator for
the vat, worm and gear reducer for filter drum, air
blow discharge mechanism and cleaning showers.
Thickener (as in pulp and paper mills) — includes the
general features and in addition, has repulper, flushing
pipe, hood with mounting flange, inspection and
service doors, knock off and cleaning showers
(including nozzles, header, hoses, valves). The filtrate
valve (double solution type) and the drive reducer is a
helical gear.
Material:
Default: *CS*
CS- Carbon steel
SS316- SS316
RBLCS- Rubber lined CS
EPLCS- Epoxy lined CS
Application:
Default: *MD RATE*
LO RATE- Low filtration rate
MD RATE- Medium filtration rate
HI RATE- High filtration rate
THCKNR- Used as a thickening device
14-12
Description
Type
ROTY DISK - continued
Solid flow rate:
Enter solid flow rate or surface area.
Surface area:
Range: 100 - 900 SF [10 - 80 M2]
Solids handling rate:
Default: 0.30 TPD/SF [0.12 TPH/lM2]
Number of disks:
Min: 1; Default: *3*.
Liquid flow rate:
Flowrate of feed stream
Percent of solids in the feed stream.
Range: 0.50 - 5.00; Default: *15*.
Tank or vat material:
Default: *NONE*
NONE- No vat will be provided
CS- Carbon steel vat
SS316- Stainless steel vat
Drum Filter. General Features: The filter is a vacuum ROTY DRUM
type (from drop leg), multi compartment cylinder shell
with internal filtrate piping with polypropylene filter
cloth, feed box with inlet and drain nozzles, suction
valve, rake-agitated vat (optional) with stiffeners,
discharge trough, driver consisting of rotor, drive
motor base plate, worm, gear reducer and two pillow
block bearing with supports. In addition to the
standard filter, the following variations are available.
Thickener (as in pulp and paper mills) — includes the
above general features and, in addition, has repulper,
flushing pipe, hood with mounting flange, inspection
and service doors, knock off and cleaning showers
(including nozzles, header, hoses, valves). The
distinguishing features are air-assisted scraper
discharge, filtrate valve (double solution type), steel
filter cloth and the drive reducer is a helical gear.
Brown Stock and Bleach Washers — in addition to the
thickener features, the washers have multiple showers
for washing.
Lime Mud Filter and Dregs Washer — essentially
includes the same general features as the general
washer, but with pre-coat for easier filtration.
14-13
Description
Type
ROTY DRUM - continued
Material: Default: *CS*
CS- Carbon steel
SS316- SS316
EPLCS- Epoxy lined CS
Application: Default: *MD RATE*
LO RATE- Low filtration rate
MD RATE- Medium filtration rate
HI RATE- High filtration rate
THCKNR- Used as a thickening device
Solid flow rate:
Surface area:
Range: 100 - 2,000 SF [10 - 185 M2]
Solids handling rate:
Default: 0.50 TPD/SF [0.20 TPH/lM2]
Number of disks:
Min: 1; Default: *3*.
Liquid flow rate:
Flowrate of feed stream
Range: 0.50 - 5.00; Default: *20*.
Tank or vat material: Default: *NONE*
NONE- No vat will be provided
CS- Carbon steel vat
SS316- Stainless steel vat
Scroll discharge centrifugal filter for dewatering fine
solids (0 to 28 mesh) or medium coarse solids (.375
INCH [10 MM] to 28 mesh).
SCROLL
Material:
Feed size selection:
FINE- Fine solids
MEDIUM- Medium solids
Sewage filter with area to 600 SF [55 M2].
SEWAGE
Material:
Default: *CS*
Surface area:
Range: 100 - 600 SF [10 - 55 M2]
14-14
Description
Type
Sparkler with area to 110 SF [10 M2].
SPARKLER
Material:
Default: *SS316*
SS316- SS316
Surface area:
Range: 8 - 110 SF [
0.75 - 10.2 M2]
Sparkler volume:
Range: 0.5 - 15 CF [0.02 - 0.4 M3]
Sparkler diameter:
Range: 18 - 33 INCHES [450 - 825 MM]
Tubular fabric filters (bank of three) with automatic or TUBULAR
manual cleaning/backwashing. Flow rate to 3400 GPM
[210 L/S].
For filtering liquid streams such as cooling tower water
and tank car loading lines. The wide selection of filter
media available allows particles from 1 micron to
2,000 microns in size to be removed. Because tubular
filters can be backwashed, liquid streams with high
solids concentrations can be handled.
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Liquid flow rate:
Range: 100 - 3,400 GPM [6.5 - 210 L/S]
Mesh size:
Range: 60 - 700 MESH
Mode of operation:
Automatic cleaning and backwashing option available.
Default: *NONE*
NONE- No auto operation
AUTO- Auto clan/backwash
White water filter including centrifugal screening
basket, internal showers and distributors.
WHITEWATER
Liquid flow rate:
Maximum flow varies: 4750 GPM [300 L/S]
at 0.001 consistency, 2500 GPM [157 L/S] at 0.1.
Range: 0.001 to 0.1; Default: 0.1
14-15
Description
Type
Compressed gas filter
Removes particulates from compressed gas. Supplied
with standard 10 micron filter.
Min: 0.25 PSIG [1.75 KPA]; Max: 720 PSIG [4,965
KPA]
Specified inlet pressure dictates maximum gas flow
rate and pressure drop.
Gas flow rate and Pressure Drop:
Maximum gas flow rate, which varies with inlet
pressure (see chart), is at standard conditions.
COMPRSGAS
Design gauge pressure
Inlet
Gas flow rate MAX*
150 PSIG [1,033 KPA]
60,000 CFM [103,000 M3/H]
275 PSIG [1,895 KPA
86,500 CFM [146,900 M3/H]
720 PSIG [4,956 KPA]
155,000 CFM [263,000 M3/H]
*at MAX Pressure Drop
Temperature: Default: *60* DEG F [*15.5* DEG C];
Max: 100 DEG F [37.5
DEG C]. Maximum gas flow rate is achieved at 60 DEG
F.
Pressure drop: Range varies with temperature and
inlet pressure. The following defaults and MIN/MAX
values are applicable only to air at default temperature
of 60 DEG F [15.5 DEG C]. For other gases and/or
other temperatures, appropriate molecular weight and
temperature corrections will be applied to the pressure
drop.
Default
MIN
MAX
Design gauge pressure Inlet range of 0.25 PSIG [1.75 KPA] - 150 PSIG [1,033 KPA]
0.0175 psi
[0.00012 N/mm2]
0.0175 psi
[0.00012 N/mm2]
2.0 psi
[0.01379 N/mm2]
Design gauge pressure Inlet range of 150 PSIG [1,033 KPA] - 275 PSIG [1,895 KPA]
0.25 psi
[0.00172 N/mm2]
0.25 psi
[0.00172 N/mm2]
3.0 psi
[0.02068 N/mm2]
Design gauge pressure Inlet range of 275 PSIG [1,895 KPA] - 720 PSIG [4,956 KPA]
0.50 psi
[0.00345 N/mm2]
0.50 psi
[0.00345 N/mm2]
5.0 psi
[0.03447 N/mm2]
Molecular weight:
Default gas is air with a molecular weight of 28.96.
14-16
Description
Type
Sanitary in-line metal trap
METAL TRAP
Protects against iron contamination and reduces
abrasive wear to equipment by trapping particles via
gravity and magnetic separating action. Material of
construction is SS316.
added.
Pipe diameter:
MIN: 2 INCH [50 MM], MAX: 4 INCH [100 MM].
Standard sizes:
INCHMM
250
380
4100
Sanitary fluming reclaim reel
RECL REEL
Sometimes used with a fluming pump and dewatering
shaker. Water from the shaker will be forwarded to the
fluming reclaim reel so that the reclaim reel can
remove solids that weren’t removed by the shaker.
Fluming rate:
MAX: 1,200 GPM [75 L/S]
Distribution header:
NONE- Not included
*INCL*- Included
Cover option:
INCL- Included
Culinary (sterile) air filter
SAN AIR
Keeps rust and other such matter out of the product.
Air flow rate:
Enter actual flow rate or pipe size; MAX: 4340 CFM
[7373M3/H] at 100 PSIG [689.4KPA].
Pipe diameter:
MIN: 0.5 INCH [15 MM], MAX: 8 INCH [200 MM]
Standard sizes:
INCHMM
0.515
125
14-17
Description
Type
SAN AIR - continued
250
380
4100
6150
8200
MIN: 100 PSIG [680 KPA]
Number of stages:
*1*, MIN: 1, MAX: 3
Sanitary pipe filter
SAN PIPE
Removes fine particles from a given liquid or gas.
Pipe diameter:
MIN: 1 INCHES [25 MM], MAX: 4 INCHES [100 MM].
-For size LONG and type INLIN, range is 1.5 IN
[40MM] - 3 INCHES [75 MM].
-For type BASKT, MIN is 2 INCHES.
Standard sizes:
INCHES MM
1.0
25
1.5
40
2.0
50
2.5
65 (not available for BASKT)
3.0
80
4.0
100 (not available for INLIN)
Style:
*INLIN*- In-line filter
BASKT- Basket filter - for dia. >= 2 INCHES [50 MM]
If pipe diameter is 4 INCHES [100 MM], BASKT is the
only available type. Otherwise, default is INLIN.
Body size:
*SHORT*- Short body
LONG- Long body
14-18
Description
Type
Sanitary filter press
SAN PRESS
Takes in liquid through internal ports located in every
frame and the two heads, then passes the liquid
through the filter media and into the plates, and finally
releases the liquid through the head.
Any two must be entered: total area, plate size,
number of plates. The third is computed accordingly.
Plate material:
SS304, *SS316*
Total plate area:
The maximum total area, entered in square feet (SF)
or square meters (M2), depends on the plate type and
plate size, and is internally calculated and checked.
Plate size:
Available sizes of round plates:
INCHES MM
12
300
18
450
24
600
Flow Diagram
Available sizes of square plates:
INCHES MM
12 7/8
300
18 7/8
450
24
600
Note:24 INCH (600 MM) plate size available for
HYDRL (hydraulic) closure type only.
14-19
Description
Type
SAN PRESS - continued
Number of plates:
The maximum number of plates depends upon the
plate size:
Plate Size
Square
MAX No.
Round
of Plates
12 INCH [300 MM] 127/8 INCH [300 MM]
15
18 INCH [450 MM] 187/8 INCH [450 MM]
25
24 INCH [600 MM]
40
24 INCH [600 MM]
Plate thickness:
*1 INCH [25 MM]*; MIN: 1 INCH [25 MM]; MAX: 2
INCHES [50 MM]. These (that is, the MIN and the MAX
values) are the only standard plate thicknesses
available.
Head and stand material:
CS- Carbon steel
Plate type:
*ROUND*- Round plates
SQUAR- Square plates
Feed pump type:
*PD *- Positive displacement pump
CNTRF- Centrifugal pump
NONE- No feed pump included
Hydraulic closure:
*HYDRL*-Hydraulic closure
MANUL-Manual closure (not available for 24 INCH
[600 MM] plate size)
14-20
Description
Type
Culinary (sterile) steam filter
SAN STEAM
Used primarily for cleaning factory or plant steam to
reduce the levels of boiler feed chemicals, rust, pipe
scale, and other contaminates. Material of construction
is SS316.
Flow rate:
MIN: 215.0 LB/H [97.5 KG/H]; MAX: 36,100 LB/H
[16,375 KG/H]. The Minimum/maximum flow rates are
computed and depend upon the steam pressure. Those
given above are at the default steam pressure of 100
PSIG [680 KPA].
Enter either flow rate or pipe diameter.
Pipe diameter:
MIN: 0.75 INCHES [20 MM]; MAX: 8 INCHES [200
MM]. Standard sizes are shown under Filter
diameter.
Enter either flow rate or pipe diameter.
Body Diameter: Determined by Pipe Diameter.
Pipe diameter
Inch-Pound
0.75 INCHES
1 INCHES
2 INCHES
3 INCHES
4 INCHES
6 INCHES
8 INCHES
Metric
20 MM
25 MM
50 MM
80 MM
100 MM
150 MM
200 MM
Filter body diameter
Inch-Pound
1.5 INCHES
2.5 INCHES
4 INCHES
8.6 INCHES
10.7 INCHES
12.8 INCHES
16 INCHES
Metric
38.1 MM
63.5 MM
101.6 MM
218.44 MM
271.78 MM
325.12 MM
406.4 MM
Body length:
If pipe diameter is entered, system selects a filter body
length from the above table. If user enters a length, it
is printed, but the underlying design value is still
provided by the table.
Steam pressure-gauge:
*100 PSIG [680 KPA]*
14-21
Description
Type
Sanitary pipe strainer
SAN STRAIN
Removes large particles as a process stream passes
through the strainer’s perforated plate or screen mesh.
Pipe diameter:
MIN: 1 INCH [25 MM], MAX: 4 INCHES [100 MM], with
the following exceptions:
-For BASKT style, MIN is 2 INCHES [50 MM].
-For size LONG and INLIN style, MAX is 3 INCHES
[80MM].
Standard sizes:
INCHMM
125
1.540
250
2.5*65*
380
4100
*BASKT style is not available in this size
Style:
*INLIN*- In-line filter
BASKT- Basket filter - for dia. >= 2 INCHES [50 MM].
Not available for 2.5 IN [65 MM] pipe diameter.
Note: for pipe diameter of 4 INCHES [100 MM],
BASKT is the only available style; otherwise, the
default style is INLIN.
Body size:
*SHORT*- Short body
LONG - Long body
Configuration:
*SINGL*- Single filter
TWIN- Twin filters
14-22
Description
Type
Filter Sediment Removal
SEDIMENT REMOVAL
Cartridge filter to 1,200 GPM [75 L/S] with 5 micron
cotton filter.
Cartridge filters are generally used as a final filtering
element for the removal of small particles, such as
pipe scale, down to 10 microns in size from a liquid
stream containing a low concentration of these solids.
A cartridge filter consists of a tank containing one or
more filter elements or cartridges which are tubes of
wound natural or synthetic fibers. Liquid flows through
the cartridges and the suspended solids are trapped by
the fibers. As the filter gets dirtier, pressure drop
builds to a point where the cartridges must be
replaced. The cartridges are disposable. They are not
cleaned and reused.
Shell Material:
Def.: mat'l selection from design temp.(Ref. proj.
equipment design basis). Specify backing plate
mat'l if clad plate
Default: *CS*
CS - Carbon steel
SS - Stainless steel
A516
A515
A204C - C-.5Mo
A387B - 1Cr - .5Mo
SS304 - SS304
SS316 - SS316
SS321 - SS321
SS347 - SS347
304L - 304L
316L - 316L
NI - Nickel
INCNL - Inconel
MONEL - Monel
HAST - Hastelloy
TFELS - Teflon lined CS
GSLCS - Glass lined CS
CS... - See list of carbon steel materials
H-T STL... - See list of heat treated steel materials
LOW ALLOY STL... - See list of low alloy steel
materials
HI ALLOY STL... - See list of hi alloy steel materials
NON FERROUS... - See list of non-ferrous materials
LINED CS MATLS... - See list of lined steel materials
-continued on next page-
14-23
Description
Type
Sediment Removal Filter - continued Vessel Diameter:
allowance.
materials.
Default gauge pressure:
worst case.
Default: pressure design.
worst case.
Default: pressure design.
Design temperature:
Default: 650 DEGF[340 DEGC] ferrous mat'l;250
DEGF[120 DEGC] mat'l;
Default: Design temperature
Skirt height:
Min > 0
Skip if legs reqd, enter 0.0 if hung in OPEN
structure; default 1.5 x diameter
Skirt thickness:
Min > 0
Default: system calculated;
Vessel leg height:
Min 0
Skip if skirt reqd, enter 0.0 if hung in OPEN
structure; default 4 FEET [1.25 M]
Fluid volume:
Min: 0
Max: 100
Default: 20
For seismic design; fluid volume as a % of vessel
volume (water assumed).
Min: 0
Default: 0
Specify an allowance for internals as a percent
of basic vessel weight.
-continued on next page-
14-24
Description
Type
Sediment Removal Filter - continued Weld efficiency:
Min: 50
Max: 100
ASME/JIS/DIN only, where allowed for thin wall
vessels; default: Area Basis.
Stress relief:
Min: 0
Default: 1
diameter as vessel.
Head type:
ELLIP - 2:1 Ellipsoidal
Head thickness Top:
Min: >0
allowance.
Min: >0
allowance.
Diameter option:
Defines desired diameter as ID or OD, default - see
Area Design Basis.
14-25
Description
Type
Centrifugal cleaners/wet cyclones used for removal of PULP STOCK
contaminants in fluids using centrifugal force. Includes
the body, supporting legs, two reject valves per
cyclone, reject chamber/grit pot, automatic or manual
control of rejected materials and a header for multiple
cyclones. Separate material specifications are allowed
for the top and conical section. Sizing and scaling
features allow contaminants to be separated by size
and density/type. Linear or radial configurations are
available.
Main section material:
Default: *SS316*
SS316- SS316
316L- 316 L
CS- Carbon steel
CERML- Light ceramic liner on CS
CERMM- Medium ceramic liner on CS
CERMH- Heavy ceramic liner on CS
CERMV- Very heavy ceramic liner on CS
ABRPL- Abrasion resistant plate
REPRB- Replaceable rubber liner on CS
LS304- Replaceable SS304 on CS
Cyclone diameter:
Enter diameter or liquid flow rate.
Range: 4 - 30 INCHES [100 - 750 MM]
Liquid flow rate:
Enter diameter or liquid flow rate.
Application:
Default: *AUTO*
AUTO- Automatic cleaner discharge
MANL- Manual cleaner discharge
Configuration:
Default: *LIN*
LIN- Linear manifold
RAD- Radial manifold
Number of cyclones per manifold:
Default: *1*
Cone section material:
Default: *SS316*
SS316- SS316
316L- 316 L
CS- Carbon steel
14-26
Separation Equipment (SE) - continued
Description
Type
PULP STOCK - continued
CERML- Light ceramic liner on CS
CERMM- Medium ceramic liner on CS
CERMH- Heavy ceramic liner on CS
CERMV- Very heavy ceramic liner on CS
CERMC- Ceramic
ABRPL- Abrasion resistant plate
REPRB- Replaceable rubber liner on CS
Containment size:
Default: *MEDIUM*
SMALL- Small debris, less then 40 microns
MEDIUM- Medium debris, 40 - 400 microns
LARGE - Large debris, 400 - 4000 microns
Containment density:
Default: *MEDIUM*
LIGHT - Light weight debris: asphalt, sand, ink
MEDIUM- Medium weight debris: clay, heavy sand
HEAVY- Heavy weight debris: metal clips, foil
VHEAVY- Very heavy debris: nuts, bolts, rock
Water-only cyclones for separation of light and heavy
minerals or particle size separation. Cyclones may be
linear or radial manifold and may be lined with
replaceable liners. Cyclone diameter to 30 INCHES
[760 MM].
WATER CYCL
Material:
Default: *CS*
CS- Carbon steel
CERML- Light ceramic liner
CERMM- Medium ceramic liner
CERMH- Heavy ceramic liner
CERMV- Very heavy ceramic liner
ABRPL- Abrasive resistant plate
REPRB- Replaceable rubber lining
LS304- Replaceable SS304 lining
LS316- Replaceable SS316 lining
Cyclone diameter:
Diameter is for individual cyclone, group manifolding linear or radial. Range: 4 - 30 INCHES [105 - 760 MM]
Configuration:
Default: *LIN*
LIN- Linear manifold
RAD- Radial manifold
14-27
Separation Equipment (SE) - continued
Description
Type
Oil-water separator - API type.
OIL WATER
Material:
Liquid flow rate:
Maximum flow (see Configuration) less Specific
Gravity increase. For example, for BOX 135 GPM [8.5
L/S] at 0.965. Min: 25 GPM [16 L/S]
Diameter or width:
Range: 4 - 8 FEET [1.22 - 2.40 M]
Length:
Range: 20 - 40 FEET [6.1 - 12.0 M]
Configuration:
Default: *BOX*
RND- Round- max flow 545 GPM [34 L/S] at 0.85 SG
BOX- Box - max flow 700 GPM [44 L/S] at 0.85 SG
Oil specific gravity: Range” 0.85 - 0.97; Default:
*0.92*
14-28
Thickeners (T)
Description
Type
Thickeners are used in many solid/liquid separation
THICKENER
processes and consist of a slow-moving rake
mechanism rotating in a tank. The unit includes feed
well, bridge, drive head (with optional overload alarm
system), and a drive consisting of worm, gear and
motor. An optional flocculator mechanism with
flocculation chamber, paddles and flocculator drive
with reduction gear and motor can be included.
Additional storage capacity for the tank can be
specified for special applications such as green liquor
clarification, white liquor clarification or lime mud
washing; as used in paper mill operations. If only a
thickener mechanism is needed, the tank can be
excluded.
Application:
Default: *STANDARD*
STANDARD- Standard thickener/clarifier
PRM-ETP- Primary clarifier usually for effluent
SEC-ETP- Secondary clarifier usually for effluent
GRN-LQ- Green liquor clarifier for pulp/paper
WHITE-LQ- White liquor clarifier for pulp/paper
LIMMUD- Lime mud washer for pulp and paper mills
Rake and mechanism material:
Default: *CS*
CS- Carbon steel
SS304- SS304
SS316- SS316
MONEL- Monel
RUBCV- Rubber covered CS
Tank or vat material:
Tank material required to obtain tank cost, leave blank
for thickener mechanism only.
CS- Carbon steel
SS304- SS304
SS316- SS316
MONEL- Monel
RUBCV- Rubber covered CS
Vessel diameter:
Enter tank capacity or tank dimensions.
Range: 9.5 - 400 FEET [3.0 - 12.0 M]
Vessel height:
Liquid volume:
14-29
Thickeners (T) - continued
Description
Type
THICKENER - continued
Additional capacity:
Extra storage in addition to basic tank capability.
Default: *0.0* GALLONS [*0.0 M3].
Flocculator required: Default: *NO*
NO- No flocculation required
YES- Flocculator mechanism required
Bridge type:
Default: *FULL*
FULL- Full length bridge 100 FEET [30 M] maximum
SEMI- Semi-bridge for 100 FEET [30 M] diameter
TRCTN- Traction type clarifier on semi-bridge
Drive heat type:
Default: *DH-STD*
DH-STD- Standard drive head to 30 FEET [9 M]
diameter DH-HD- Heavy duty drive - large diameter,
thick sludge DH-HDA- Heavy duty, overload alarm,
lifting device
Design temperature:
Default: 190 DEG F [88 DEG C] for green liquor; else
68 DEG F [20 DEG C].
mechanism weight. Default: *0.0*
Number of manholes:
Default: *1*
Manhole diameter:
14-30
Screens (VS)
Rectangular, circular.
Description
Type
Rectangular single deck, open or enclosed.
Rectangular double deck, open or enclosed.
Rectangular triple deck, open or enclosed.
ONE DECK
TWO DECK
THREE DECK
Material:
Length:
Range: 6 - 24 FEET [2.0 - 7.25 M]
Width:
Range: 3 - 8 FEET [1.0 - 2.25 M]
Configuration:
Default: *OPEN*
OPEN- No duct enclosure
Circular single deck.
Circular double deck.
Circular triple deck.
SIFTER 1
SIFTER 2
SIFTER 3
Material:
Default: *CS*
CS- Carbon steel
SS304- SS304
SS316- SS316
Screen diameter:
Range: 18 - 60 INCHES [450 - 1,5000 MM]
Surface area:
Range: 1.5 - 18 SF [0.2 - 1.7 M2]
Rectangular hummer-type for fine separation; 1, 2 or
3 decks.
HUMMER
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Surface area:
Range: 10 - 80 SF [1.0 - 7.4 M2]
Number of decks:
Range: 1 - 3
14-31
Screens (VS) - continued
Description
Type
LD STOCK
Low consistency bow screen is used for fiber
collection in a paper mill.
The unit consists of a screen surface mounted on
a frame curvilinear in shape, with inlet nozzle,
discharge nozzle(s) and a collection chamber.
The automatic feature includes solenoids, timers
and an air cylinder for back-flushing and
cleaning.
Screen material:
Default: *SS*
CS- Carbon steel
SS- Stainless steel
Liquid flow rate:
Enter capacity or screen surface area.
Surface area:
Frame material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
0.60 - 2.00; Default: *0.80*
Mechanical bar screens are the first stage of screening BAR
used in an effluent treatment system. These are wide
mesh screens made from metal rods/flats welded onto
a frame.
Screen material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Liquid flow rate:
Surface area:
Pressure screen used for fine screening of
contaminants in a paper mill.
PRESSURE
Includes shell for screen basket housing, rotor, foil
blades, water lubricated packing box with packing
seals, V-belt drive with belts, metal guard and motor.
14-32
Description
Type
PRESSURE - continued
Basket material:
Default: *SS316*
CS- Carbon steel
SS304- SS304
SS316- SS316
Shell material:
Default: *SS316*
CS- Carbon steel
SS304- SS304
SS316- SS316
Hydraulic capacity:
Enter capacity or diameter and length.
Basket diameter:
Min: 60 INCHES [150 MM]
Basket height:
Min: 60 INCHES [150 MM]
Driver power:
Design gauge power:
Default: *15* PSIG [*150* MM]
Seal type:
Default: *MECH*
PACK- Packing
MECH- Mechanical seal
Sanitary fluming dewatering shaker
SHAKER
Vibratory conveyor with screen for dewatering fruits
and vegetables that have been carried by watertransport up to this point in the food pumping system.
The spreader (which is included by default, but can be
excluded by selecting NONE in the “Spreader option”
field) reduces the velocity of the water by spreading
the water and product onto the dewatering shaker.
added.
14-33
Description
Type
SHAKER - continued
Screen size:
24X60- 2x24 INCHES [609 MM] x 30 INCHES [762
MM] screens
36X60- 2x36 INCHES [914 MM] x 30 INCHES [762
MM] screens
Required to enter at least one of the following: size,
fluming rate or solids capacity.
Fluming rate:
MAX: 500 GPM [31 L/S]
Solids capacity:
MAX: 30,000 LB/H [13,500 KG/H]
Spreader option:
NONE- Not included
*INCL*- included
14-34
14-35
14-36
15 Utility Service Systems
(G6)
Steam Boilers (STB)
Heating Units (HU)
15 Utility Service Systems (G6)
15-1
Description
Type
Cooling tower includes fans, drivers, concrete basin
COOLING
and field erection; does not include pumps and piping.
Water flow rate:
Min: 1,000 GPM [65 L/S]
Temperature range:
10 - 50 DEG F [6 - 27 DEG C];
Approach gradient:
Range: 5 - 22 DEG F [3 - 12 DEG C];
Wet bulb temperature:
Range: 60 - 82 DEG F [16 - 28 DEG C];
Length each header:
15-2
Cooling Towers (CTW) - continued
Description
Type
Cooling tower includes fans, drivers, concrete basin,
two cooling water pumps, motor drivers,
instrumentation for tower and inhibition system (less
tanks and inhibition pumps), and field erection of
cooling tower.
COOLING WP
Water flow rate:
Min: 1,000 GPM [65 L/S]
Temperature range:
Range: 10 - 50 DEG F [6 - 27 DEG C];
Approach gradient:
Range: 5 - 22 DEG F [3 - 12 DEG C];
Range: 60 - 82 DEG F [16 - 28 DEG C];
Length each header:
Factory assembled cooling tower including fans,
drivers and basins.
PACKAGED
Water flow rate:
Range: 150 - 6,000 GPM [9.5 - 375 L/S]
Temperature range:
Range: 5 - 50 DEG F [3 - 27 DEG C];
Default: *15* DEC F [*8* DEG C]
Approach gradient:
Range: 5 - 22 DEG F [3 - 12 DEC C];
Range: 60 - 82 DEG F [16 - 28 DEG C];
Number of cells:
Default: *1*
15-3
Steam Boilers (STB)
Description
Type
Packaged boiler unit includes forced draft fans,
BOILER
instruments, controls, burners, soot-blowers,
feedwater deaerator, chemical injection system, steam
drum, mud drum and stack. Steam capacity to
800,000 LB/H [362,000 KG/H]. Shop assembled.
Material:
Boiler flow rate:
Range: 10,000 - 800,000 LB/H
[4,540 - 362,000 KG/H]
Range: 250 - 600 PSIG
[1,725 - 4130 KPA]; Default: *250* PSIG [*1,725*
KPA]
Superheat:
For saturated steam enter 0.0 degrees, else, minimum
superheat 100 DEG F [55 DEG C]. Max: 300 DEG F
[165 DEG C]; Default: *100* DEG F [*55* DEG C]
Heating medium:
GAS- Gas fuel
OIL- Oil fuel
Field erected boiler unit includes forced draft fans,
STM BOILER
instruments, controls, burners, soot-blowers,
feedwater deaerator, chemical injection system,
structural steel platforms, steam drum, mud drum and
stack with steam capacity to 2,220,000 LB/H [997,000
KG/H]. Oil fired. Economizer for large capacities.
Material:
Boiler flow rate:
Range: 40,000 - 2,200,000 LB/H
[18,2000 - 997,000 KG/H]
Max: 1,000 PSIG [6,890 KPA];
Superheat:
15-4
Heating Units (HU)
Description
Type
Process heater type dowtherm unit to 40 MMBTU/H
[11.5 MEGAW].
CYLINDER
Material:
Default: *CS*
Duty:
Max: 40 MMBTU/H [11.5 MEGAW]
Max: 6,000 PSIG [40,000 KPA];
Design temperature:
Max: 1,500 DEG F [815 DEG C];
15-5
Description
Type
Centrifugal compression refrigeration unit produces
CENT COMPR
chilled water cooling medium for circulation. Includes
centrifugal compressor, driver, condenser, controls,
interconnecting piping, refrigeration capacity to 3,000
TONS [10,500 KW] and field erection.
Material:
Refrigeration capacity:
Range: 50 - 3,000 TONS-REF
[180 - 10,500 KW]
Evaporator temperature:
Range: -40 - 40 DEG F [-40 - 5 DEG C]
Mechanical compression refrigeration unit produces
liquified refrigerant for circulation. Includes
reciprocating compressor, driver, water cooled
condenser, controls, interconnecting piping,
refrigeration capacity to 500 TONS [1,750 KW] and
field erection.
MECHANICAL
Material:
Refrigeration capacity:
Range: 4 - 500 TONS-REF [15 - 1,750 KW]
Evaporator temperature:
Range: -80 - 40 DEG F [-60 - 5 DEG C]
15-6
Description
Type
Portable stand-by diesel generator, skid-mounted to
800 KW.
PORTABLE
Used primarily as a stand-by unit to supply electrical
power in the event of an interruption of the main
power supply. Diesel generator sets can also be
operated continuously.
Includes a voltage regulator—3 phase sensing with
volts-per-hertz; auto start-stop module; electric
hourmeter; and voltmeter.
Also used as a standby for continual electrical service
during the interruption of normal power.
Fuel stop power in accordance with ISO 3046/1, DIN
6271, BS 5514, and ISO 8528. Ratings are based on
SAE J1349 standard conditions. These ratings also
apply at ISO 3046/1, DIN 6271 and BS 5514 standard
conditions. No generator set duration required below
55 DEG C (131 DEG F).
Material:
Output KW:
Range: 10 - 800 KW
Turbo-generator includes condensing steam turbine
and cooled electric generator. Steam at 850 PSIG
[5,860 KPA] and 900 DEG F [482 DEG C], exhaust at
2.5 in HG [8.4 KPA] and capacity to 100,000 KVA.
TURBO GEN
Used for the continuous generation of electrical
power.
Material:
Output KVA:
Range: for steam, 800 - 100,000 KVA; for gas,
800 - 260,000 KVA.
Driver type:
*Steam*, Gas.
15-7
Water Treatment Systems
(WTS)
Description
Type
Demineralizing system. Two-stage ion exchange unit.
First stage converts metal salts to acid and second
stage anion exchange removes acids. Optional
automatic degasification of oxygen and carbon
dioxide.
DEMINERAL
Material:
Water flow rate:
Range: 150 - 15,000 GPH [0.6 - 56.5 M3/H]
Mode of operation:
Default: *NONE*
NONE- No auto operation
AUTO- Auto degas CO2 + O2
Softening treatment system for boiler feedwater
consists of hot lime process softener, filters, Zeolite
softeners, associated piping and instruments.
SOFTENING
Material:
Water flow rate:
10,000 - 50,000 GPH [38 - 189 M3/H]
Aerators are used in aeration of effluent. The unit
AERATOR
consists of a drive motor, coupling, guard, rotor shaft
and impeller. Other features vary depending upon the
type as given below:
High Speed Floating — general aerator with pontoons.
Low Speed Floating — in addition to the gear box for
speed reduction, pontoons are included for floating.
Low Speed Fixed — speed reduction by means of gear
box.
Material:
*CS*- Carbon steel316L- 316L
SS304- SS304NI- Nickel
SS316- SS316INCNL- Inconel
SS321- SS321MONEL- Monel
SS347- SS347HAST- Hastelloy
304L- 304LTI- Titanium
15-8
Water Treatment Systems (WTS) - continued
Description
Type
AERATOR - continued
Aerator type:
Default: *LSFIELD*
LSFIXED- Low speed fixed aerator
LSFLOT- Low speed floating type aerator
HSFLOT- High speed floating type aerator
Aeration capacity:
Capacity is mass of O2 per hour. Enter capacity or
impeller diameter and power.
Impeller diameter:
Enter capacity or impeller diameter and driver power.
Driver power:
Enter capacity or impeller and driver power;
Range: 1.0 - 150.0 HP [0.75 - 112 KW]
Driver speed:
Number of pontoons:
Default: 3 for LSFLOT, 1 for HSFLOT, and none for
LSFIXED.
15-9
15-10
16 Flares and Stacks
(G6)
Flares (FLR)
Stacks (STK)
16 Flares and Stacks (G6)
16-1
Flares (FLR)
A flare system is composed of several parts: a flare tip, a seal, an ignition
system, a knock-out drum and a riser stack.
The flare tip may be either smokeless or non-smokeless. Smokeless flare tips
have nozzles for injecting steam at the exit of the tip. The high velocity steam
inspirates air into the flame resulting in more complete combustion and
therefore no smoke. Non-smokeless flare tips do not have these steam
injection nozzles.
Flares are also classified as continuous and emergency. Continuous flares
handle a continuous and steady flow of flare gas. Emergency flares are
designed to safely burn a sudden large release of combustible gases that are
not normally vented. Continuous flares are normally smokeless and
emergency flares non-smokeless.
The flare seal is a device for preventing air from diffusing down the stack and
creating a combustible mixture with the flare gas inside the stack. Flare gas is
ignited at the exit of the flare tip by one or more pilots. Should any of these
pilots go out, the ignition system would reignite them.
The flare vendor would supply all of the above components for a new
installation. The vendor may also be requested to supply a knock-out drum.
This device disengages entrained liquid from the flare gas. If this liquid is not
removed, it travels up the stack, is ignited and falls flaming to the ground
creating a fire hazard. If the flare is elevated, the final component of the flare
system is the riser stack. The stack is characterized by its method. A ground
flare requires no stack.
The diameter of the flare tip and the height of the stack that supports it (if it is
an elevated flare) is calculated using formulas that take into account process
conditions and safety considerations. The diameter of the flare tip is calculated
using the following formula:
D = sqrt(w/adfv)
where sqrt indicates the square root and:
D = tip diameter of the flare: INCHES [MM]
w = mass flowrate of the flare gas: LB/H [KG/H]
f = exit velocity / sonic velocity of the flare gas
d = density of the flare gas: PFC [KG/M3]
v = sonic velocity of the flare gas, calculated using sqrt(cT/M): FPS [M/S]
M = molecular weight of the flare gas
T = absolute temperature of the flare gas: DEG R [DEG K]
P = absolute pressure of the flare gas: (14.7 + PSIG) [101.3 + KPA]
a = 19.6 in I-P units = 0.0027123 in METRIC units.
R = 10.73 in I-P units = 8.3145 in METRIC units
c = 59682 in I-P units = 107427 in METRIC units
The total height of the stack is calculated using the following formula:
H = Y - 40D
16-2
where:
H = stack height, including flare type: FEET [M]
D = flare tip diameter: FEET [M]
and:
Y = sqrt [(EQwk/4 q)-x2]
where:
E = emissivity of the flame (see formula on page 16-4)
Q = heat content of the flare gas: BTU/LB [KG/KG]
w = mass flowrate of the flare gas: LB/H [KG/H]
k = 1.0 in I-P units, 0.8306 in METRIC units
q = allowable radiation intensity: BTU/SF/ H [W/M2]
x = radius of allowable radiation intensity (see formula on page 16-4):
FEET [M]
For flare types GUYED and DERRICK, and for self-supported stacks (SELFSUPP) 40 FEET [12 M] or less in height, the length of the bottom section (L) is
the total stack height. For self-supported stacks greater than 40 FEET [12 M]
in height, the length of the bottom section is determined from a consideration
of the load requirements.
Emissivity of the flame:
E = (0.048)sqrt (M)
where:
sqrt = square root
E = emmissivity of the flame
M = molecular weight of the flare gas
Radius of allowable radiation intensity:
X = (c)sqrt(QW/105)
where:
X = radius of allowable radiation intensity: FEET [M]
Q = heat content of flare gas: BTU/LB [KJ/KG]
W = mass flowrate of flare gas: LB/H [KG/H]
c = 0.58 in I-P units, 0.5647 in METRIC units
16-3
The diameter and thickness of the flare stack is determined by structural considerations
such as loadings and method of support.
Description
Type
Derrick-supported flare stack includes stack, support DERRICK
structure, flare tip, molecular seal and ignition system.
Design based upon process conditions or given sizes.
Derricks are used to support tall stacks. Generally,
derrick supported flare stacks are cheaper than selfsupporting stacks at heights above 200 FEET [60 M].
Derricks are used instead of guyed stacks when land is
limited.
Shell material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Gas mass flow rate:
Enter either mass flow rate or diameter and length
(height) of flare.
Diameter Bottom section:
For single diameter stacks, enter dimensions in bottom
section data.
Height Bottom section:
section data.
Diameter Middle section:
section data.
Height Middle section:
section data.
Diameter Top section:
section data.
16-4
Flares (FLR) - continued
Description
Type
DERRICK - continued
Height Top section:
For single diameter stacks, enter
dimensions in bottom section data.
Gas temperature:
Molecular weight:
Default: *40*
For single diameter stacks, enter
dimensions in bottom section data.
Thickness Middle section:
section data.
section data.
Percent sonic velocity at exit:
Enter the gas exit velocity as a percent of sonic
velocity. Default: *20*
Flare type:
Default: *SMOKELESS*
SMOKELESS- Standard smokeless flare
AIR ASSIST- Air assisted smokeless flare
NONSMOKE- Non-smokeless flare
Radius radiation intensity:
Minimum radius at which a person would be exposed
to the allowable radiation.
Allowable radiation intensity:
Allowable radiation intensity at the specified minimum
radius. Default: *1,500* BTU/H/SF [4,500 W/M2]
Gas heat content:
Default: *20,000* BTU/LB [*46,500* KJ/KG]
Guyed flare stack includes stack, supports, flare tip,
GUYED
molecular seal and ignition system. Design based upon
process conditions or given sizes.
This is generally the least expensive support system
for flare stacks over 50 FEET tall. However, a large
unobstructed area around the stack must be provided
so that there will be no interference with the guy wire.
Shell material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
16-5
Description
Type
GUYED - continued
Gas mass flow rate:
(height) of flare.
section data. Max: 96 INCHES [2,400 MM]
section data.
section data.
Height Top section:
section data.
Gas temperature:
Molecular weight:
Default: *40*
Thickness Bottom section: For single diameter stacks,
enter dimensions in bottom section data.
Thickness Middle section: For single diameter stacks,
Thickness Top section: For single diameter stacks,
Percent sonic velocity at exit: Enter gas exit velocity as
a percent of sonic velocity. Default: *20*.
Flare type:
Allowable radiation intensity: Allowable radiation
intensity at the specified minimum radius. Default:
*1,500* BTU/H/SF [*4,500* W/M2]
Gas heat content:
16-6
Description
Type
Self-supported flare stack includes stack, flare tip,
molecular seal and ignition system; one, two or three
segments of different length and diameter.
SELF SUPP
This flare is generally used for stack heights up to 50
FEET and when the availability of land does not permit
guyed stacks, self-supporting stacks are cheaper than
derrick supported stacks for stack heights up to 200
FEET [60 M].
Shell material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Gas mass flow rate:
(height) of flare.
section data.
section data.
Height Top section:
section data.
Gas temperature:
Molecular weight:
Default: *40*
Thickness Bottom section: For single diameter stacks,
Thickness Middle section: For single diameter stacks,
Thickness Top section: For single diameter stacks,
Enter gas exit velocity as a percent of sonic velocity.
Default: *20*.
16-7
Description
Type
SELF SUPP - continued
Flare type:
radius. Default: *1,500* BTU/H/SF [*4,500* W/M2]
Gas heat content:
Horizontal ground flare includes flare tip and horizontal HORIZONTAL
stack (30 FEET [10 M]) only; burn pit not included.
Design based upon process conditions or sizes.
This is an inexpensive flaring arrangement if land is
plentiful and cheap.
Shell material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Gas mass flow rate:
(height) of flare.
Length Bottom section:
section data.
Length Middle section:
section data.
16-8
Description
Type
HORIZONTAL - continued
Length Top section:
section data.
Gas temperature:
Molecular weight: Default: *40*
section data.
Thickness Middle section:
section data.
section data.
Enter gas exit velocity as a percent of sonic velocity.
Default: *20*.
Flare type: Default: *SMOKELESS*
radius. Default: *1,500* BTU/H/SF [*4,500* W/M2]
Gas heat content:
Recuperative thermal oxidizer for low concentration
non-chlorinated waste gas.
THRM OX LC
Material:
Standard gas load rate:
Low concentration non-chlorinated waste gas; burner,
box, stack, exchanger blower. Max: 20,000 CFM
Gas heat content:
Default: *13.00* BTU/CF [*484* KJ/M3]
Gas oxygen content:
Min: 0.0; Default: *14.00*
16-9
Description
Type
Vapor control flare for storage and loading. Includes
stack, burners, seal drum, flare, sensors, etc.
STORAGE
Material:
Default: *CS*
Standard gas load rate:
Max: 12,000 GPM [775 L/S]
Gas heat content:
Min: 50 BTU/CF [1,860 KJ/M3];
Default: *50* BTU/CF [1860 KJ/M3]
Stacks (STK)
Description
Type
Stack height to 200 FEET [60 M] and diameter to 60
INCHES [1500 MM].
STACK
Material:
Default: *CS*
CS- Carbon steel
SS- Stainless steel
Height:
Range: 30 - 200 FEET [10 - 60 M]
Diameter:
Range: 24 - 96 INCHES [600 - 2,400 MM]
16-10
17 Introduction to Plant
Bulks
(G6)
Introduction to Plant Bulks
List of Plant Bulks
17 Introduction to Plant Bulks (G6)
17-1
Introduction to Plant Bulks
Plant bulk items are those materials or non-process equipment items that
provide support or services to process equipment within a unit area, such as
yard pipe and duct, concrete tanks, pipe rack, instrument panels, electrical
cable trays, insulation and paint.
List of Plant Bulks
The following is a list of plant bulks by chapter. The plant bulk descriptions in
Chapters 18 through 24 include some of the entry fields for defining plant
bulks. The descriptions include the minimum and maximum values and the
defaults. Default values appear between asterisks (*).
17-2
Chapter 18: Piping
-
YARD PIPE
PIPE
UTIL PIPE
RCON PIPE
DUCT RD
DUCT SQ
EQPT TRACE
PIPE TRACE
LAUNDER SQ
LAUNDER RD
COAT WRAP
HOT TAP
SCRAPER LR
WELL HEAD
HDPE
SPRNK
FOAM
SPHOS
WSHWR
FLO PANEL
Above grade or buried yard piping
Above grade or buried piping
Utility pipe and utility stations
Buried concrete pipe
Round duct with hangers
Square duct with hangers
Fluid heat tracing for equipment
Fluid heat tracing for pipe
Square or rectangular launders
Half round launders
Coating and wrapping of buried pipe
Hot tap of production pipe for branch
Permanent scraper launcher and receiver
Pipe, valve and fittings at a well head
High density polyethylene pipe, fusion bonded
Sprinkler system (water / water+foam)
Foam fire systems
Standpipe and hose fire systems
Emergency eyewash and shower units
Sanitary flow diversion panel
Chapter 19: Civil
-
ABVGR TANK
BELGR TANK
CONCRETE
SCAFFOLD
TRENCH
CONTAINMNT
DIKE MEMBR
YARD PIPE
PIPE
HDPE
RCON PIPE
BUILDING
LINING
PIPE RACK
PIPE SUPPT
Above grade concrete tank
Below grade concrete tank
Foundations, slabs, other concrete items
Scaffold erection and dismantling
Drainage trench for paved areas
Tank containment - concrete paving, wall
Tank containment - dike and geomembrane
Building
Organic, metallic, abrasion resist. lining
Pipe rack
Tee or bent type pipe sleepers
17-3
Chapter 20: Steel
-
OPN STL ST
PIPE RACK
PIPE SUPPT
MILL BLDG
PLATFORM
GALLERY
TRNS TOWER
GRATE
LADDER
STAIR
MISC STEEL
FABR PLATE
SIDING
SAN PLATFM
Open steel structure
Pipe rack
Multiple-bay mill building
Elevated access platform - complete
Gallery for pipe, conveyor, personnel
Conveyor transfer tower
Steel grate - less support structure
Steel ladders
Stairs with grate, treads and handrail
Miscellaneous steel items
Fabricated steel plate items
Siding and roofing for steel structures
Sanitary platform
Chapter 21: Instrumentation
-
17-4
INST PANEL
INST TRAY
INST WIRE
PNU TUBING
THCPL WIRE
JUNC BOX
MULTI CONT
HL PIU
LL PIU
DATA HIWAY
OPER CENT
Instrument panel - analog
Instrument cable tray
Instrument electronic transmission wire
Instrument pneumatic tubing runs
Thermocouple wire runs
Instrument junction box
Multifunction controllers
High energy level process interface unit
Low energy level process interface unit
Data highway cable
Operator center
Chapter 22: Electrical
General
-
ELEC CABLE
CONDUIT
ELEC TRAY
EQPT TRACE
PIPE TRACE
GRND GRID
AREA LIGHT
CTRL CABLE
DEEP ANODE
GALV ANODE
SURF ANODE
POT TEST
RECTIFIER
SOLAR PANL
EMER LIGHT
CABLE DUCT
Electrical power cable run (3 or 4 wire)
Electrical conduit
Electrical cable tray
Electrical tracing for equipment
Electrical tracing for pipe
Ground grid
Area lighting on poles
Electrical control cable runs (600 v)
Group of anodes in deep well
Individual galvanic anode
Group of anodes in shallow surface bed
Potential measurement test station
Transformer/rectifier
Solar panel with storage batteries
Emergency light with battery
Underground cable duct
Substation
-
BUS DUCT
TRANSFORM
OIL C BRKR
DISCNCT SW
POLE LINE
SUBSTN STL
BREAKER
MCC
SWITCH BRD
AC DC TRAN
PKG TRANSF
EM PWR SET
UPS
PF CORRECT
Bus duct
Electrical transformer: 1 or 2 tap
Oil circuit breakers
Disconnect switch
Power pole lines
Steel for substation structure
Current breaker: main, feeder, tie
Motor control center
Switch board
AC/DC Transformer
Package transformer with panel
Emergency diesel generator
Uninterrupted power supply
Power factor connection capacitor
17-5
Chapter 23: Insulation and Firepoofing
-
INSUL AREA
INSUL PIPE
FIREP AREA
FIREP SSTL
General area insulation
Pipe insulation
General area fireproofing
Structural steel fireproofing
Chapter 24: Paint
- PAINT AREA
- PAINT PIPE
- PAINT SSTL
17-6
General area painting
Pipe painting
Structural steel painting
18 Piping
(G10)
Piping Plant Bulks
How Icarus Calculates Insulation Length on Piping
Trapping Distances (Steam)
Pipe Temperature Procedure
Pipe Insulation Material Procedure
Pipe Insulation Thickness Procedure
Pipe Paint Procedure
No. of Paint Coats Procedure
Pipe Diameters
Pipe Schedule
Standard Equations for Pipe Diameter (Old)
Standard Equations for Pipe Diameter (New)
Utility Piping Services
Utility Station Diagram
Default Piping Materials
Pipe Materials - Ferrous Materials
Carbon Steel
API Pipe
High Alloy Steel
Pipe Materials - Non-Ferrous Materials
Non - Ferrous Materials
Plastic and Resin Materials
Lined Steel Pipe
Spool Types
Remote & Field Shop Piping Procedures for Various Materials
Remote Shop Piping Procedures
Small Bore Piping Procedures
Icarus’ Pipe Fabrication, Erection and Testing Procedures
18 Piping (G10)
1
Valve and Fitting Options for Installation Bulk Piping
Valve Trim Specifications
2
18 Piping (G10)
Piping Plant Bulks
Piping plant bulks include transfer lines, utility piping, duct and tubed tracing.
Description
Type
Transfer lines, yard pipe runs, above/below grade
Insulated and traced pipe runs.
YARD PIPE
For above-grade piping, hangers are supplied, but
support steel, pipe racks, etc. must be specified
elsewhere.
If buried pipe is specified, trenching, coating,
wrapping, sand bed and backfilling is provided.
Custom pipe spec:
Enter either Custom Pipe Spec (see Design Basis) or
Material, not both.
Pipe material:
Material, not both. See piping materials listed later in
this chapter. Default: *CS*.
Length:
Min: 1.0 FEET [0.35 M]
Pipe diameter:
Range: 0.5 - 72 INCHES DIAM [15 - 1,800 MM DIAM]
Default: determined from Custom Pipe Spec or 150
PSIG [1,000 KPA].
Design temperature:
Default: determined from Custom Pipe Spec or 68 DEG
F [20 DEG C].
Pipe thickness:
Leave blank if schedule is specified.
Pipe schedule or gauge:
Leave blank if thickness is specified.
STD - Standard wall pipe
XS - Extra-strong pipe
XXS - Double extra-strong
5 - Pipe schedule
100 - Pipe schedule
120 - Pipe schedule
140 - Pipe schedule
160 - Pipe schedule
18 Piping (G10)
3
Piping Plant Bulks - continued
Description
Type
YARD PIPE - continued
10 - Pipe schedule
7G - SS gauge pipe only
20 - Pipe schedule
10G- SS gauge pipe only
30- Pipe schedule
11G - SS gauge pipe only
40 - Pipe schedule
60 - Pipe schedule
80- Pipe schedule
Flange class:
Default: determined from custom spec or pipe
material, temperature and pressure.
150- Class 150
300- Class 300
600- Class 600
900- Class 900
1500- Class 1500
2500- Class 2500
125- Class 125 WOG
250- Class 250 WOG
Configuration:
Default: *ABOVE*
ABOVE- Above-grade
BURIED- Buried
Depth buried pipe:
Below grade depth to top of pipe for buried pipe only.
This is the distance from grade level to the top of the
buried pipe. The trench depth is determined by the
below grade depth, the pipe diameter and sand bed (6
INCHES [150 MM] in depth). Range: 24 - 120 INCHES
[600 - 3,000 MM]. The default value will be taken as
36 INCHES [1,000 MM] minimally, or the depth of
footings specified for general civil data.
Buried Depth:
Default: 36 INCHES [1,000 MM]
Special pipe description:
Insulation, tracing, jacketing options. Default:
*NONE*
PPROT- Personnel protection insulation. The system
will generate 1.00 INCH of personnel protection for
100 percent of the pipe. This option can be used in
conjunction with the Personnel protect field, which
allows the user to tell the system how much pipe to
insulate.
For instance, if the user only needs 25 FEET of a 100
FEET run of pipe to be personnel protected, the user
can input the percentage in the Personnel protect
field. The system would generate 25 FEET plus waste.
4
18 Piping (G10)
Description
Type
The thickness of the personnel protection insulation
generated will always be 1.00 INCH.
AC-T- Anti-condensation insulation/tube tracer
AC-E- Anti-condensation insulation/elec tracer
FP-T- Freeze protection insulation/tube tracer
FP-E- Freeze protection insulation/elec tracer
FULL- Fully jacketed pipe (see illustration)
EXPD- Exposed-weld jacketed pipe (see illustration)
T-SP- Spiral traced/tube conn./no cement
T-SPC- Spiral traced/tube conn./heat cement
P-SP- Spiral traced/pipe conn./no cement
P-SPC- Spiral traced/pipe conn./heat cement
T-LO- Longit. traced/tube conn./no cement
T-LOC- Longit. traced/tube conn./heat cement
P-LO- Longit. traced/pipe conn./no cement
P-LOC- Longit. traced/pipe conn./heat cement
E-AMB- Electrical traced/ambient temp control
E-PRO- Electrical traced/process temp control
STAND- Standard heat or cold insulation
Steam supply pressure for traced or jacketed pipe
only. Default: *25* PSIG [*175* KPA]
E-Trace maintenance temperature:
For electrical tracing - process maintenance
temperature; Max: 250 DEG F [120 DEG C] over
ambient. Default: 220 DEG F [105 DEG C]
Weld X-ray%:
Min: 100; Default: See Area Design Basis.
Number of elbows: Default: *0*
Number of reducers: Default: *0*
Number of tees: Default: *0*
Number of flanges:
Enter number of flanges in addition to those for valves.
Default: *0*
Number of blinds: Default: *0*
Number of spectacle blinds: Default: *0*
Number of threadless: Default: *0*
Number of gate valves: Default: *0*
Number of globe valves: Default: *0*
18 Piping (G10)
5
Description
Type
Number of ball valves: Default: *0*
Number of butterfly valves: Default: *0*
Number of check valves: Default: *0*
Number of control valves:
Size: same as pipe size to 4 INCHES [100 MM],
smaller than pipe otherwise. Default: *0*. See
“Control Valve Options” in Chapter 21 for default size
reductions.
Number of safety valves: Default: *0*
Number of regulating valves: Default: *0*
Number of angle valves: Default: *0*
Number of plug valves: Default: *0*
Number of orifice plates: Default: *0*
No. Knife Gate Valve: Default: *0*
Personnel protect:
Personnel protection percent coverage.
For example, if out of 50 FEET run of pipe, 12.5 FEET
needs personnel protection, enter “25” in this field.
The system will then generate 12.5 FEET of personnel
protection plus waste. The thickness of the personnel
protection insulation generated will always be 1.00
INCH. Default: *100*.
Note: You must select PPROT in the Special Pipe
Descr. field before the system will use the personnel
protection.
Control valve minimum class:
For fluid control valves only. Default: *3*.
3- Minimum 300 class fluid control valve
Control valve reduced size:
Fluid positioning CV only. Default: reduced 0 to 4 line
sizes based on size.
L- Line size control valves
R- Standard size control valves
PIPE
Pipe material:
Material, not both. Default: from custom spec,
connected equipment or CS.
Pipe length:
Min: 1.0 FEET [0.35 M]
Pipe diameter:
Range: 0.5 - 72 INCHES DIAM [15 - 1,800 MM DIAM]
6
18 Piping (G10)
Description
Type
PIPE - continued
PIPE
Fluid phase:
*G*- Gas
L- Liquid
S- Steam
(enter desired flow rate below)
Liquid flow rate:
Enter diameter or liquid flow rate or gas flow rate.
Gas flow rate:
Enter diameter or liquid flow rate or gas flow rate.
Fluid density:
Default based on fluid phase:
Gas Phase:0.0674 PCF [1.08 KCM]
Liquid Phase:62.4 PCF [1000 KCM)
Steam Phase:Calculated as the inverse of specific
volume, which is calculated from design pressure and
temperature as described under “Steam Lines” in the
Standard Equations for Pipe Diameter section.
Fluid viscosity:
Default based on fluid phase:
Gas phase:0.025 CPOISE (0.025 millipascal-second)
Liquid Phase:1.0 CPOISE (1.0 millipascal-second)
Steam Phase:Calculated using an internal function of
design pressure and design temperature in which, for
a design pressure of 150 PSIG (~1000 KPA) and a
design temperature of 250 DEG F (120 DEG C),
default value is calculated to be 0.013 CPOISE.
PSIG [1,000 KPA].
Design temperature:
DEG F [20 DEG C].
Default: same as design temperature.
- Continued on next page-
18 Piping (G10)
7
Description
Type
PIPE - continued
Pipe schedule or gauge:
Enter thickness or schedule/gauge, not both. Default:
calculated from material temperature, pressure.
STD- Standard wall pipe100- Pipe schedule
XS- Extra-strong pipe120- Pipe schedule
XXS- Double extra-strong140- Pipe schedule
5- Pipe schedule160- Pipe schedule
10- Pipe schedule7G- SS gauge pipe only
80- Pipe schedule
Valves and fittings:
Enter type and quantity of each valve and fitting
required for this line.
Pipe type:
CS and SS only. Default: custom/material spec if
entered, or else welded.
W- Welded pipe
S- Seamless pipe
Flange type:
Default: see project design basis
W- Weld-neck
S- Slip-on
B- Lap flanges and stub to 12 INCHES (300 MM), or
else weld-neck
Note: When Flange Type "Lap Flange + Stub" is used,
there is a line item called "FLG BU" in the item
description in the report, which includes the cost for
both the backup flange and the stub.
Flange class:
Default: determined from custom spec or pipe
material, temperature and pressure.
150- Class 150
300- Class 300
600- Class 600
900- Class 900
1500- Class 1500
2500- Class 2500
125- Class 125 WOG
250- Class 250 WOG
8
18 Piping (G10)
Description
Type
PIPE - continued
Bend for elbow:
Substitute pipe bends for any specified elbow (up to
12 INCH [300 MM] pipe only).
*E*- Elbow
B- Bend instead of elbowBranch for tee:
Substitute fabricated branch nozzles for any specified
tees.
*T*-Tee
B-Branch
Pipe connector type:
SW- Socket weld connections; max: 2 INCHES (50
MM)
SB- Screw and backweld; max: 2 INCHES (50 MM)
SC- Screw (no backweld); max: 2 INCHES (50 MM)
WF- Weld pipe / flange valves
WW- Weld pipe / weld valves; min: 2 INCHES (50 MM)
VC- DI Victaulic couplings
VS- SS Victaulic couplings
PF- Press fit swage couplings; max: 2 INCHES (50
MM)
TC- Tri-clover sanitary; max: 4 INCHES (100 MM)
CB- Cherry-Burrel sanitary; max: 4 INCHES (100 MM)
Number of welds:
Default: determined from pipe length and combination
of valves and fittings
Control valve reduced size:
Fluid control valve only; default: reduced 0-4 sizes
except BVO and sanitary valves
L- Line size control valves
R- Standard size control valves
Control valve minimum class:
For fluid control valves only. Default: *3*.
Weld X-ray:
Stress relief:
C- Piping stress relief if code requires
Y- Stress relieve all piping
N- No piping stress relief required
Special pipe description:
Default: *NONE*
18 Piping (G10)
9
Description
Type
PIPE - continued
STAND- Standard heat or cold insulation
PPROT- Personnel protection insulation. The system
will generate 1.00 INCH of personnel protection for
100 percent of the pipe. This option can be used in
conjunction with the Personnel protection field,
which allows the user to tell the system how much
pipe to insulate. For instance, if the user only needs 25
FEET of a 100 FEET run of pipe to be personnel
protected, the user can input the percentage in the
Personnel protection field. The system would
generate 25 FEET plus waste. The thickness of the
personnel protection insulation generated will always
be 1.00 INCH.
AC-T- Anti-condensation insulation/tube tracer
AC-E- Anti-condensation insulation/elec tracer
FP-T- Freeze protection insulation/tube tracer
FP-E- Freeze protection insulation/elec tracer
FULL- Fully jacketed pipe (see illustration)
EXPD- Exposed-weld jacketed pipe (see illustration)
T-SP- Spiral traced/tube conn./no cement
T-SPC- Spiral traced/tube conn./heat cement
P-SP- Spiral traced/pipe conn./no cement
P-SPC- Spiral traced/pipe conn./heat cement
T-LO- Longit. traced/tube conn./no cement
T-LOC- Longit. traced/tube conn./heat cement
P-LO- Longit. traced/pipe conn./no cement
P-LOC- Longit. traced/pipe conn./heat cement
E-AMB- Electrical traced/ambient temp control
E-PRO - Electrical traced/process temp control
E-Trace maintenance temperature:
For electrical tracing - process maintenance
temperature. Default: 392 DEG F [200 DEG C] for M
series cable and 220 DEG F [105 DEG C]
for self-regulating cable. Max: 250 DEG F [120 DEG C]
for self-regulating cable and 1049 DEG F [565 DEG C]
for MI cable over low ambient temperature.
10
18 Piping (G10)
Description
Type
PIPE - continued
E-trace cable type: Use A series to 120 DEG F[48
DEG C], P series to 250 DEG F[120 DEG C] and M
series to 1049 DEG F [565 DEG C] over low ambient
temperature.
3A 3 W/FT (10 W/M) Chemelex BTV2-CT cable
10A 10 W/FT(33 W/M) Chemelex BTV2-CT cable
5P 5 W/FT (16 W/M) Chemelex XTV2-CT cable
M2 - 600V, dual conductor MI cable, 9 OHM/FT [29.5
OHM/M]
M4 - 600V, dual conductor MI cable, 4.14 OHM/FT
[13.6 OHM/M]
[3.77 OHM/M]
[1.66 OHM/M]
[0.656 OHM/M]
[0.328 OHM/M]
[0.184 OHM/M]
[0.0922 OHM/M]
[0.042 OHM/M]
[0.016 OHM/M]
E-trace cable category:
Default: *S*, self-regulating cable
Select M for MI tracing cable or S for self-regulating
tracing cable.
Heat trace fluid:
STM- Steam trapped
OTHR- Other fluid / no traps
Valve packing or seal:
*S*- Standard valve packing
E- Environmental (double stem)
B- Bellows seal SV/GL/GA else environmental
packing
18 Piping (G10)
11
Description
Type
PIPE - continued
Pipe sandblast percent of area:
Default: 100%; see design basis
Pipe insulation thickness:
Default from insulation schedule and unit area specs
(see minimum insulation temperature)
Pipe insulation jacket type:
Default: see project design basis; AL, SS, CS.
Pipe insulation type:
CA- Calcium silicate
MW- Mineral wool
FG- Foam-glass
Personnel protection:
Personnel protection percent coverage.
For example, if out of 50 FEET run of pipe, 12.5 FEET
needs personnel protection, enter “25” in this field.
The system will then generate 12.5 FEET of personnel
protection plus waste. The thickness of the personnel
protection insulation generated will always be 1.00
INCH. Default: see unit area pipe specs.
Note: You must select PPROT in the Special Pipe
Descr. field before the system will use the personnel
protection.
Pipe installation option:
Default: above ground pipe or supports on rack
(specified elsewhere)
*A*- Above ground piping
B - Buried piping
Depth buried pipe:
Min: 24.0 INCHES [600.0 MM]; Max: 120 INCHES
[3000.0 MM]. Below grade depth to top of pipe for
buried pipe only. Default: system calculated.
Steam gauge press:
Max: 25 PSIG [175 KPA]. Steam supply pressure for
traced or jacketed pipe.
12
18 Piping (G10)
Description
Type
PIPE - continued
Pipe routing type:
Specify pipe routing type to be used from the external
fitting specs file specified at the design basis level (see
your software user’s guide for instructions on where to
specify the file name).
AGU- Above ground unit piping
AGR- Above ground rack piping
UGU- Under ground unit piping
MRP- Machine room piping
OTP- Miscellaneous piping
Once a pipe routing type is specified, the system uses
the data in the external fitting specs file for the valve
rules, fitting rules, horizontal allowance, vertical
allowance and the diameter size definition. Pipe
routing type is meant to refer to the location of the
piping. However, the above descriptions are for
reference only; using the fitting specs file, the user
controls the context of the rules and can assign
meaning at his discretion.
The available fitting specs files are listed in the
PIPEDATA.SET file that the user places in the main
PIDS folder: [Icarus software folder]\PIDS. The user
sets up this file by copying the PIPEDATA.SET provided
in the [Icarus software folder]\New Files\dat\pids
folder to the main PIDS folder. The user can edit the
PIPEDATA.SET file in a true text editor, such as
Notepad, adding fitting specs files simply by typing in
the file names.
If the user has not set up this file, then the system
will look for a file called FITSPC.DAT. If available, this
file will be used as the fitting specs file. If not, a set of
default rules will be used. A default FITSPC.DAT file is
available at [Icarus software folder]/New Files/dat/
pids. This file can be copied, edited, and used as a
basis for alternate fitting specs files. Fitting specs files
must be listed in the PIPEDATA.SET file and placed in
the main PIDS folder.
See Figure FITSPC.DAT for an illustration explaining
the data in the FITSPC.DAT file.
18 Piping (G10)
13
Description
Type
PIPE - continued
Fitting rules application:
Select whether to use the fitting rules.
Y- Use fitting rules for the type of piping
N - Do not use fitting rules
Fitting and valve rules are specified in the external
fitting specs file (see illustration on following page),
selected at the project design basis level. Fitting and
valve codes are available in Valve and Fitting Options
for Installation Bulk Piping in this chapter. You put in
the number of each valve and fitting type per 100 feet
(30 meters). The length used in these calculations is
after the horizontal and vertical adjustments have
been accounted for.
Valve rules application:
Select whether to use the fitting and/or valve rules.
Y- Use valve rules for the type of piping
N - Do not use valve rules
Fitting and valve rules are specified in the external
fitting specs file (see illustration on following page),
selected at the project design basis level. Fitting and
valve codes are available in Valve and Fitting Options
for Installation Bulk Piping in this chapter. Users put in
the number of each valve and fitting type per 100 feet
(30 meters). The length used in these calculations is
after the horizontal and vertical adjustments have
been accounted for.
14
18 Piping (G10)
Figure FITSPC.DAT
18 Piping (G10)
15
Note: The user specifies four sets of diameter sizes, and four sets of fitting/
valve rules for each routing type. The user specifies only one set of allowance
rules per routing type.
Note: THe user is not limited to the first eight columns for fittings or to the
last eight columns for valves; this is just the suggested use of the columns.
The total percentage distribution should equal 100, but does not need to be the system will not crash if the distribution is not 100%.
Always edit the FITSPC.DAT file using a true text editor such as Notepad or
EDITPLUS (shareware).
To use a specific fitting specs file, add it to PIPEDATA.SET and move it to the /
PIDS directory. Then, select it at the base level (see software’s user guide). To
use this file with piping, add the above/below grade pipe item (PIPE) and
select one of the piping routing types in the form. Once the routing type is
selected, the system will use the file for this piping item.
The user may select alternative fitting specification files by changing the fitting
specification file name at the design basis level.
16
18 Piping (G10)
Description
Type
PIPE - continued
Horizontal allowance:
Select whether to use horizontal allowance.
Y- Use horizontal allowance for the type of piping
N- Do not use horizontal allowance
Horizontal allowance is specified for each piping
routing type in the external fitting specification file. An
entry of “100” means the system will not adjust the
input length, whereas an entry of “150” will increase
the input length by 50 percent.
Vertical allowance:
Select whether to use vertical allowance.
Y- Use vertical allowance for the type of piping
N - Do not use vertical allowance
Vertical allowance is specified for each piping routing
type in the external fitting specification file. An entry of
“100” means the system will not adjust the input
length, whereas an entry of “150” will increase the
input length by 50 percent.
Primary equipment user tag:
User tag of the primary (i.e., upstream) equipment to
which this pipe is connected. Default: NONE.
Primary equipment connection:
Connection location of the pipe on the primary (i.e.,
upstream) equipment; Default: not connected
<Blank>.
<Blank>- not connected to any equipment
S- connected to shell of equipment
U- connected to tube side of equipment
J- connected to jacket of equipment
B- connected to bottom of double diameter tower
T- connected to top of double diameter tower
Secondary equipment user tag:
User tag of the secondary (i.e., downstream)
equipment to which this pipe is connected. Default:
NONE.
Secondary equipment connection:
Connection location of the pipe on the secondary (i.e.,
downstream) equipment; Default: not connected
<Blank>.
<Blank>- not connected to any equipment
S- connected to shell of equipment
U- connected to tube side of equipment
J- connected to jacket of equipment
B- connected to bottom of double diameter tower
T- connected to top of double diameter tower
18 Piping (G10)
17
Jacket Pipe Illustrations
You can select jacketing for PIPE and YARD PIPE under Special Pipe
Description.
18
18 Piping (G10)
Description
Type
Utility service lines, stations: standard configuration
Utility headers: runs of pipe providing up to 15
different services. Utility station: short runs of smallbore pipe providing local air, water, steam and
condensate drain services.
UTIL PIPE
Pipe material:
See piping materials listed later in this chapter.
Default: *CS* (Carbon steel).
Number utility stations:
A utility station consists of three 100 FEET [30 M] lines
of 1 INCHES [25 MM] diameter pipe for air, water and
steam service, and one 50 FEET [15 M] condensate
line of 0.75 INCHES [20 MM] diameter.
Default: *1*. Enter “0.0” to exclude all utility stations.
Length parameter:
Pipe lengths = 1 x length parameter, except firewater
loop/lat. = 2 x, hp steam = 0.5 x. Default: 100 FEET
[30 M].
Utility station drop length:
Applies to all utility stations described above.
Default: 100 FEET [30 M] for air, water, and steam
service and 50 FEET [15 M] for condensate return.
Header diameter symbol:
Diameter symbol defines size of any line not specified.
See Utility Piping Services later in this chapter.
L- Low/small diameter
M- Medium diameter
H- High/large diameter
V- Very large diameter
Firewater loop diameter:
Default: determined by diameter symbol, enter 0.0 to
delete if diameter symbol set.
Firewater lateral diameter:
Potable water header diameter:
delete if diameter symbol set. Line will be insulated
based on location:
US - uninsulated,
UK - insulated.
Cooling water supply diameter:
based on location: US - uninsulated, UK - insulated.
18 Piping (G10)
19
Description
Type
UTIL PIPE - continued
Cool water return diameter:
base on location: US - uninsulated, UK - insulated.
Low Pressure (LP) steam header diameter:
Medium Pressure (MP) steam header diameter:
High Pressure (HP) steam header diameter:
Condensate return diameter:
Plant air header diameter: Default: determined by
diameter symbol, enter 0.0 to delete if diameter
symbol set.
Instrument air header diameter:
Fuel gas header diameter: Default: determined by
diameter symbol, enter 0.0 to delete if diameter
symbol set.
Inert gas header diameter:
Chemical sewer diameter:
Flare header diameter:
Buried concrete pipe, manholes, elbows, tees: trench, RCON PIPE
backfill Includes trenching and backfilling.
Diameter:
Range: 12 - 98 INCHES [300 - 2,450 MM]
Number of manholes: Default: *0*
20
18 Piping (G10)
Description
Type
Process ductwork, round
DUCT RD
Stiffeners and support hangers are designed, but
support steel, racks, etc. must be specified elsewhere.
Duct material:
Default: *GALV*
GALV- Galvanized CS
CS- Carbon steel
SS- Stainless steel
AL- Aluminum
Duct diameter:
If the duct capacity is specified, the duct dimension is
determined from the capacity and the gas velocity. The
velocity may be specified, or the system uses a
variable velocity between 2000 and 4000 FPM [36600
- 72100 M/H] depending on the specified pressure.
The calculated duct dimension is rounded to a
standard size.
Duct design pressure:
Should be specified (indicate + or -) for design of duct
thickness and stiffeners; -60 - 60 INCHES H2O
[114,930 - 14,930 PA]. Default: *-20* INCHES H2O
[*-4,980* PA].
Duct gauge:
Leave blank if thickness is entered; enter thickness if
thicker than 8 gauge. Range: 8 - 30.
Duct wall thickness:
Default: determined by size and pressure, leave blank
if duct gauge number entered.
Duct class:
The duct class indicates the quantity and abrasiveness
of particulate material. Default: *1*.
1 - Non-abrasive applied.
2- Mod-abras./lo concern.
3- Hi-abras.lo concern.
4- Hi-abras./hi concern.
Configuration:
Seam configuration; applies to class 1 duct only.
Default: *LONG*
LONG- Longitudinal seam
SPIR- Spiral seam
Duct insulation thickness:
Default: 0.0 INCHES [0.0 MM].
Particle density:
Density of concentrated particulates for duct classes 2,
3 and 4. Default: *25* PCF [*400* KG/M3].
18 Piping (G10)
21
Description
Type
DUCT RD - continued
Stiffener size:
Default: size and spacing determined from duct
pressure, dimensions and thickness.
Stiffener spacing:
Support weight:
Hanger weight (each); support steel, racks, etc. must
be specified elsewhere. The system determines the
support weight based on standard spacing
of 12 FEET [3.5 M] and the duct loads. The calculated
weight and spacing may be replaced with an input
weight and spacing.
Support spacing: Default: *12* FEET [*3.5* M].
Number of dampers: Default: *0*
Number of access doors: Default: *0*
Number Flexible connection: Default: *0*
Process ductwork, square
DUCT SQ
Stiffeners and support hangers are designed,
but support steel, racks, etc. must be specified
elsewhere.
Duct material:
Default: *GALV*
GALV- Galvanized CS
CS- Carbon steel
SS- Stainless steel
AL- Aluminum
Duct width:
If the duct capacity is specified, the duct dimension is
determined from the capacity and the gas velocity.
The velocity may be specified, the system uses a
variable velocity between 2000 and 4000 FPM [36600
- 73100 M/H] depending on the specified pressure.
The calculated duct dimension is rounded to a
standard size.
22
18 Piping (G10)
Description
Type
DUCT SQ - continued
Duct design pressure:
Should be specified (indicate + or -) for design of duct
thickness and stiffeners. -60 - 60 INCHES H2O [14,930 - 14,930 PA].
Default: *-20* INCHES H2O [*-4,980* PA].
Duct gauge:
Leave blank if thickness is entered; enter thickness if
thicker than 8 gauge. Range: 8 - 30.
Duct wall thickness:
Default: determined by size and pressure, leave blank
if duct gauge number entered.
Duct class:
The duct class indicates the quantity and abrasiveness
of particulate material. Default: *1*.
1 - Non-abrasive applied.
2- Mod-abras./lo concern.
3- Hi-abras.lo concern.
4- Hi-abras./hi concern.
Duct insulation thickness: Default: 0.0 INCHES [0.0
MM].
Partical density: Density of concentrated particulates
for duct classes 2, 3 and 4. Default: *25* PCF [*400*
KG/M3].
Stiffener size:
Stiffener spacing:
Support weight:
Hanger weight (each); support steel, racks, etc. must
be specified elsewhere. The system determines the
support weight based on standard spacing of 12 FEET
[3.5 M] and the duct loads. The calculated weight and
spacing may be replaced with an input weight and
spacing.
Support spacing: Default: *12* FEET [*3.5* M].
Number of dampers: Default: *0*
Number of access doors: Default: *0*
Number Flexible connection: Default: *0*
18 Piping (G10)
23
Description
Fluid heat tracing existing equipment
Type
EQPT TRACE
The item of equipment and its insulation are not
included; these are assumed to be specified elsewhere
in the project.
Material:
Default: *CU*
CU- Copper
SS- Stainless steel
Tracer tube length:
This is the total length of 0.5 INCHES O.D. tubing
required to heat trace an item specified elsewhere in
the estimate. This length does not include the run to
and from supply and return headers, as these lengths
are specified in the Dist./Supply Header and the Dist./
Return Header fields.
Tracing symbol:
T-SP- Traced: tube conn. - spiral tracer - no cement
T-SPC- Traced: tube conn. - spiral tracer - with cement
P-SP- Traced: pipe conn. - spiral tracer - no cement
P-SPC- Traced: pipe conn. - spiral tracer - with cement
Distance to supply header:
Distance specified is from traced equipment item to
supply and return headers. The headers are not
included in this item, but are specified by the user
elsewhere in the estimate for Area Pipe Specifications
or as a separate bulk item description. Min: 5.0 FEET
[1.6 M]; Default: *25* FEET [*7.5* M].
Distance to return header:
Distance specified is from traced equipment item to
supply and return headers. The headers are not
included in this item, but are specified by the user
elsewhere in the estimate for Area Pipe Specifications
or as a separate bulk item description. Min: 5.0 FEET
[1.6 M]; Default: *25* FEET [*7.5* M].
Heating medium:
Default: *STM*
STM- Steam heating medium
OTHR- Other heating medium
24
18 Piping (G10)
Description
Type
Fluid heat tracing for existing pipe runs
PIPE TRACE
0.5 INCHES O.D. tubing applied to existing pipe. The
traced pipe and its insulation are not included; these
are assumed to be specified elsewhere in the project.
An insulation adjustment is included to account for
tracers and tracer connections to headers.
Material:
Default: *CU*
CU- Copper
SS- Stainless steel
Traced pipe length:
The pipe being traced is not included, but must be
specified elsewhere.
Traced pipe diameter:
The pipe being traced is not included, but must be
Tracing symbol:
T-SP- Traced: tube conn. - spiral tracer - no cement
T-SPC- Traced: tube conn. - spiral tracer - with cement
P-SP- Traced: pipe conn. - spiral tracer - no cement
P-SPC- Traced: pipe conn. - spiral tracer - with cement
T-LO- Traced: tube conn. - longit. tracer - no cement
T-LOC- Traced: tube conn. - longit tracer - with cement
P-LO- Traced: pipe conn. - longit tracer - no cement
P-LOC- Traced pipe conn. - longit tracer - with cement
Distance to supply header:
Distance specified is from traced pipe to supply or
return header. Min: 5 FEET [1.6 MM]; Default: *25*
FEET [*7.5* M].
Distance to return header:
Distance specified is from traced pipe to supply or
return header. Min: 5 FEET [1.6 MM]; Default: *25*
FEET [*7.5* M].
Heating medium:
Default: *STM*
STM - Steam heating medium
OTHR - Other heating medium
Default *25* PSIG [*175* KPA]. (See “Trapping
Distances” tables.)
18 Piping (G10)
25
Trapping Distance (Steam)
Traced Process Line
Size
25 PSIG
150 PSIG
200 PSIG
[175 KPA]
[1050 KPA]
[1400
KPA]
No. of 0.5 INCH
[12.7 MM] O.D.
Tracers per Line
0.50 INCHES
[12.7 - 25.4 MM]
150 FEET
[45.72 M]
250 FEET
[76.20 M]
300 FEET
[91.44]
1 OR 2
1.25 -1.50 INCHES
[31.75-38.10 MM]
130 FEET
[39.62 M]
200 FEET
[60.96 M]
230 FEET
[70.10 M]
1 OR 2
2.00 INCHES
50.80 MM]
120 FEET
[36.57 M]
180 FEET
[54.86 M]
200 FEET
[60.96 M]
1
2.50 - 3.00 INCHES
[63.50 - 76.20 MM]
100 FEET
[30.48]
150 FEET
[45.72 M]
190 FEET
[57.91 M]
1
3.50 - 4.00 INCHES
[88.90 - 101.60 MM]
150 FEET
[45.72 M]
240 FEET
[73.15 M]
240 FEET
[73.15 M]
350 FEET
[106.68 M]
270 FEET
[82.29 M]
400 FEET
[121.92 M]
1
120 FEET
[36.57 M]
200 FEET
[60.96 M]
250 FEET
[76.20 M]
200 FEET
[60.96 M]
300 FEET
[91.44 M]
360 FEET
[109.72 M]
210 FEET
[64.00 M]
340 FEET
[103.63 M]
420 FEET
[128.01 M]
1
over 4.00 INCHES
[over 101.60 MM]
2
2
3
STEAM Tracing - Number of Tracers Per Line
Traced Process Line
Size (INCHES)
<3
No. of 0.5 INCH [12.7 MM]
O.D. Tracers per Line
1
> to < 8
2
>8
3
26
18 Piping (G10)
Trapping Distance (Steam) - continued
How Icarus Calculates Insulation Length on
Piping
All pipe insulation is calculated and reported as straight run equivalent length.
The final length is calculated by adding the specified length of straight run
pipe, plus straight run equivalent lengths for fittings (4 FEET [1.22 M]/fitting)
and valves (7 FEET [2.13 M]/valve), plus an overall 5% allowance for wastage.
The final equation in l-P is:
[pipe length + (fitting count * 4) + (valve count *7)] * 105%
Example calculations:
Specified
100 FEET [30.5 M] 4 INCH pipe +
18 Piping (G10)
Reported Length
FEET
M
0 fittings, 0 valves
105
32
1 FL, 0 valves
109
33
0 fittings, 1 GA (this creates 2 matching FL)
121
37
1 FL, 1 GA
125
38
1 FL, 3 EL, 1 GA
138
42
27
28
18 Piping (G10)
18 Piping (G10)
29
30
18 Piping (G10)
18 Piping (G10)
31
32
18 Piping (G10)
18 Piping (G10)
33
Description
Type
Launders, half-round, rubber lined
LAUNDER RD
Steel launder lined with 0.25 INCHES [6.0 MM] natural
rubber.
Material is RBLCS (Rubber-lined carbon steel)
Cover Type:
Default: *NONE*
COVRD- Plate cover
NONE- No cover
Launders, square/rectangular, rubber lined
Steel launder lined with 0.25 INCHES [6.0 MM]
natural rubber.
Material is RBLCS (Rubber-lined carbon steel)
LAUNDER SQ
Cover Type:
Default: *NONE*
COVRD- Plate cover
NONE- No cover
Coat and wrap pipe for burial: manual or machine
COAT WRAP
Application may be by hand or machine.
Application Symbol:
HAND- Manual
MACH- Machine
Hot tap: production line to branch line
Split tee or nipple, flange and valve provided; branch
must be specified elsewhere.
Available only in Aspen Capital Cost Estimator and
Icarus Process Evaluator.
HOT TAP
Material:
Default: *GRBW*
GRBW- API5L and 5LS Gr. B304LP- 304L
X42W- API5LX Grade X42316P- SS316
X52W- API5LX Grade X52316LP- 316L
X60W- API5LX Grade X60321P- SS321
X65W- API5LX Grade X65AL- Aluminum
A 53- A 53CU- Copper
A 106- A 106NI- Nickel
A333C- 3.5 NiMONEL- Monel
A335C- 1.25Cr -.5Mo - SiINCNL- Inconel
304P- SS304
34
18 Piping (G10)
Description
Type
HOT TAP - continued
Flange Class:
Default: *600*
150- Class 150
300- Class 300
600- Class 600
900- Class 900
1500- Class 1500
2500- Class 2500
125- Class 125 WOG
250- Class 250 WOG
Permanent scraper launcher and receiver
A pair (launcher and receiver) is provided for each
item.
Icarus Process Evaluator.
SCRAPER LR
Material:
Default: *X52W*
X52W- API5LLX-X52 welded
X42W- API5LX-X42 welded
GRBW- API5L - gr B/5LS welded
X52S- API5LX-X52 seamless
X42S- APIFLX-X42 seamless
GRBS- API5L - gr B seamless
Flange Class:
Default: *600*
150- Class 150
300- Class 300
600- Class 600
900- Class 900
1500- Class 1500
2500- Class 2500
125- Class 125 WOG
250- Class 250 WOG
18 Piping (G10)
35
Description
Type
Pipe, valve, and fittings at well head
Standard valve and fitting configuration plus 70 FEET
[20 M] of pipe.
Aspen Process Economic Evaluator.
WELL HEAD
Material:
Default: *X52W*
X52W- API5LLX-X52 welded
GRBW- API5L - gr B/5LS welded
X42S- APIFLX-X42 seamless
GRBS- API5L - gr B seamless
Pipe diameter:
Default: *8* INCHES DIAM [*200* MM DIAM]
Type of well:
Default: *PROD*
PROD- Production well
INJEC- Injection well
Sprinkler fire system (water / water+foam)
SPRNK
Pipe material:
*A 53*, 304P, 316P
Outlet arrangement:
*PLANE*- Outlet devices arranged over planar area
ARRAY- Outlet devices arranged over equipment area
Diameter or length: If outlet arrangement is PLANE,
with devices arranged over planar area, enter the
plane area; if outlet arrangement is ARRAY, with
devices arranged over equipment area, enter the
component length or diameter.
Width: If outlet arrangement is PLANE, with devices
arranged over planar area, enter the width of the
plane area; if outlet arrangement is ARRAY, with
devices arranged over equipment area, enter the
component width. Default: same as Diameter or
length.
Height:
For ARRAY outlet arrangement only, enter height of
outlet configuration. Default: *20* FEET [*6* M].
36
18 Piping (G10)
Description
Type
SPRNK - continued
Number of levels:
for PLANE outlet arrangement only, enter number of
levels or floors having the indicated dimensions.
Default: *1*.
Number of sprinklers:
Default based on hazard type and area dimensions.
Sprinkler location:
*OUT*- outdoor installation
IN- indoor installation
Hazard type:
*EFLH*- Extinguished fire - light hazard occupancy
EFOH1- Extinguished fire - ordinary hazard grp 1
EFOH2- Extinguished fire - ordinary hazard grp 2
EFXH1- Extinguished fire - extra hazard grp 1 occup
EFXH2- Extinguished fire - extra hazard grp 2 occup
EPXH2- Exposure prot. - extra hazard grp 2 occup
CBXH2- Control burning - extra hazard grp 2 occup
PFXH2- Fire prevention - extra hazard grp 2 occup
System type:
*WSPNK*- Water sprinkler
WSPRY- Water spray
FSPNK- Foam sprinkler
FSPRY- Foam spray
Pipe system type:
*DRSYS*- Dry pipe system
WTSYS- Wet pipe system
DPPNU- Deluge sys/pilot head/pneumatic actuator
DPHYD- Deluge sys/pilot head/hydraulic actuator
DELEC- Deluge sys/electric actuator
Detector type:
*SPRKR*- Automatic sprinkler detector
FXTMP- Fixed temperature detector
R-O-R- Rate of rise temperature detector
SMKAL- Smoke alarm detector
NONE- No detectors installed
18 Piping (G10)
37
Description
Type
SPRNK - continued
Application density:
Max: 1.00 GPM/SF [0.650 L/S/M2]
Volume of water/foam required per unit area. Default
based on hazard/class.
Coverage area per sprinkler:
Max: 400 SF [37.0 M2]
Number of hose stations: Default: 0
Number of hydrants: Default: 0
Foam concentration: Default: 3%; Max: 100%; for
foam System type only
Foam tank option:
*NONE*- No foam storage tank required
BALPR- Tank with balanced pressure proportioning
PRTNK- Tank with pressure proportioning
ARPMP- Tank with around the pump proportioning
Tank design gauge pressure:
Default: *15* PSIG [*100* KPA]; for foam systems
only
Tank temperature:
Default: *68* DEG F [*20* DEG C]; for foam systems
only
Pipe sizing method:
*HYDLC*- Hydraulic pressure drop calculations
PSCHD- Schedule of pipe sizes vs. number of
sprinklers
FOAM
Foam fire systems
Pipe material:
*A 53*, 304P, 316P.
Outlet arrangement:
*PLANE*- Outlet devices arranged over planar area
ARRAY- Outlet devices arranged over equipment area
Diameter or length:
If outlet arrangement is PLANE, with devices arranged
over planar area, enter the plane area; if outlet
arrangement is ARRAY, with devices arranged over
equipment area, enter the component length or
diameter.
Width:
If outlet arrangement is PLANE, with devices arranged
over planar area, enter the width of the plane area; if
outlet arrangement is ARRAY, with devices arranged
over equipment area, enter the component width.
Default: same as Diameter or length.
38
18 Piping (G10)
Description
Type
FOAM - continued
Height: For ARRAY outlet arrangement only, enter
height of outlet configuration. Default: *20* FEET
[*6* M].
Number of levels:
Default: 1.00; for PLANE outlet arrangement only,
number of levels or floors having the indicated
dimensions.
Number of foam outlets:
Default based on area size.
System type:
*LOEXP*- Low expansion foam system
MDEXP- Medium expansion foam system
HIEXP- High expansion foam system
Pipe system type:
*DRFXP*- Dry pipe system
WTFXP- Wet pipe system
DLFXP- Deluge system
PORT- Portable system with nozzle
Foam delivery option:
FCHMB- Foam chambers
MONTR- Monitors
*NOZLE*Nozzles
HNDLN- Hand lines
SPRKR- Sprinklers
Application density:
Volume of water/foam required per unit of area.
Default based on hazard/class.
Number of hose stations: Default: 0
Number of hydrants: Default: 0
Foam concentration:
Default: 3.00%; Max: 100%
Foam tank option:
*NONE*- No foam storage tank required
BALPR- Tank with balanced pressure proportioning
PRTNK- Tank with pressure proportioning
ARPMP- Tank with around the pump proportioning
Tank design gauge pressure:
Tank temperature:
18 Piping (G10)
39
Description
Type
Standpipe and hose fire systems
SPHOS
Pipe material:
*A 53*, 304P, 316P
Length:
Area length for determining number of hoses
Width:
Area width for determining number of hoses; default:
same as length
Number of levels:
Default: 1.00; number of levels or floors having the
indicated dimensions.
System type:
*C-I*- Class I stand pipe and hose system
C-II- Class II stand pipe and hose system
C-III- Class III stand pipe and hose system
Number of hoses:
Default based on class and area dimensions
Pipe system type:
*DRAUT*- Automatic dry system; Class I only
DRSMA- Semi-automatic dry system; Class I only
DRMNL- Manual dry system; Class I only
WTAUT- Automatic wet system
WTMNL- Manual wet system
Minimum flow per hose:
Max: 1,250.0 GPM [78.0 L/S];
Default: for C-I, C-III, 500 GPM [31 L/S]; for C-II,
100 GPM [6.3 L/S]
Number of hydrants:
Default: 0
Emergency eyewash and shower units
WSHWR
Pipe material:
*A 53*, 304P, 316P
Number of wash units:
Default: 0
Enter the number of wash units (type specified below
in Wash unit type field) to be included at the
eyewash station.
Number of shower units:
Default: 0
Enter the number of full-body showers.
Number of combined units:
Default: 0
40
18 Piping (G10)
Description
Type
WSHWR - continued
When a quantity is specified, this combination unit
provides a combination full-body shower and wash unit
(type specified below in Wash unit type field).
Number of nozzles per shower:
Default: 1; Max: 12
Enter the number of nozzles per shower unit.
Length supply pipe:
Default: *50.0* FEET [*50.0* M]
Wash unit type:
EYE1- single outlet eyewash unit
*EYE2*- double outlet eyewash unit
FACE- face wash unit
COMB- combination eye and face wash unit
Drain requirement:
*YES*, NO
HDPE PIPE
Pipe length:
Min: 1.0 FEET [0.35 M]
Pipe diameter:
2-54 INCHES DIAM [50-1350 MM DIAM]
Default: based on SDR and temperature
Temperature: Default: 73 DEG F [23 DEG C]
Configuration: *BURIED*, ABOVE
Depth of buried pipe:
24-120 INCHES [600-3000 MM]
Number of Elbows: Default: *0*
Number of Reducers: Default: *0*
Number of Wyes: Default: *0*
Number of Yes: Default: *0*
Number of Blinds: Default: *0*
Sanitary flow diversion panel
FLO PANEL
Panel consists of pipe with swivelling elbow (must be
positioned manually) used to divert flow to one of four
pipes. If included, proximity sensor identifies position of
elbow. Quick disconnects are used to connect elbow with
downstream pipe. Used in the sanitary industry.
Panel enclosures are stainless steel for sanitation.
Custom Pipe Spec: enter either Custom Pipe Spec (see
Design Basis) or material, not both. Default: 304 PS
18 Piping (G10)
41
Description
Type
FLO PANEL - continued
Material:
*304PS*- SS304, sanitary grade pipe material
316PS- SS316, sanitary grade pipe material
Material selection is for piping (wetted part) only;
enclosure material is SS316.
Pipe diameter:
Standard pipe diameters between1.50 INCHES [40.0
MM] and 4.00 INCHES [100 MM]
Panel type:
*DWALL*- Double wall type panel
SWALL- Single wall type panel
No. stations/panel:
MIN: *2*; MAX: 8
Proximity sensors:
NO- No proximity sensors will be provided
*YES*- Proximity sensors will be provided
Clamp connections:
select clamp connection type for front (U-bend) side
*CB*- Cherry-Burrel couplings
TC- Tri-Clover couplings
No. of extra U-bends:
Default: *0*
Ferrules on outlet:
*NO*- No ferrule will be provided
YES- Ferrules will be provided
Clamp type for back side is the same as front side
when ferrules are provided.
42
18 Piping (G10)
Pipe Diameters
(Inch - Pound diameters are for ANSI B36.19)
INCHES
MM
0.51
151
.75
20
1
25
1.251
32
1.51
401
2
50
2.51
651
3
80
3.51
901
4
100
51
1251
6
150
8
200
10
250
12
300
14
350
16
400
18
450
20
500
24
600
30
750
36
900
42
1050
48
1200
542
13502
602
15002
722
18002
842
21002
962
24002
1082
27002
1202
30002
1
Non-standard pipe sizes are not created by models unless specified.
2
Elbows and tees are fabricated from like-diameter pipe. Estimate includes more
welds to fabricate fittings.
Note: Pipe diameters greater than 722 (1800 mm) are only available for Plant Bulk
Pipe Items. These larger diameters cannot be specified in pipe item details or yard
pipe forms.
18 Piping (G10)
43
Pipe Schedule
Use ANSI B36.10 for all materials, all country locations.
Exceptions:
Japan - does have schedule 20SS 0.5 - 12 INCHES diameter.
Japan - schedule 40, 60, 80, and 100SS > 20 INCHES diameter is
much thinner.
Standard Equations for Pipe
Diameter (Old)
Liquid Lines
Slurry Lines
GPM Range
Velocity
GPM Range
Velocity
0 - 90
7
0 - 3000
3
91 - 250
8
3001 - 5000
5
251 - 500
9
5001 - 7000
7
501 - 1000
10
> 7000
8
1001 - 2000
11
2001 - 3000
12
3001 - 4000
13
> 4000
14
Diameter = 0.6384*(GPM/Velocity)**0.5
IF (Diameter > 4.0) THEN
Diameter = Diameter - 1.00
ELSE
Diameter = Diameter - 0.25
Gas Lines
Minimum Flowrate = 100000.0
Maximum Flowrate = 1.0E07
Velocity=Log-Log
Flowrate
LBS/HR
X1 = 1.0E05
X2 = 1.0E07
for velocity calculations
for velocity calculations
Velocity
FPS
Y1 = 30.0
Y2 = 100.0
Specific Volume = 10.73*(Fahrenheit+460.0)/(Molewt*(Pressure+15.0))
Diameter = 0.226*((Flowrate*Specific Volume)/Velocity)**0.50
IF (Diameter > 18.0) Use one pipe size smaller
44
18 Piping (G10)
Steam Lines
Minimum Flowrate = 10000.0
Maximum Flowrate = 1.0E06
Flowrate
LBS/HR
X1 = 1.0E04
X2 = 1.0E06
Velocity = Log-Log
for velocity equations
for velocity equations
Velocity
FPS
Y1=20.0
Y2=100.0
TempSteam = 100.0*(Pressure+30.0)**0.25
SpecificVolume = 0.596*(TempSteam+460.0)/(Pressure+15.0)
Diameter = 0.226*(Flowrate*SpecificVolume/Velocity)**0.50
IF (Diameter > 18.0) Use one pipe size smaller
Standard Equations for Pipe Diameter (Old) - continued
Relief Lines
18 Piping (G10)
SQ INCHES
DIAM INCHES
0.196
1.287
2.853
6.38
16.0
26.0
1.0
2.0
3.0
4.0
6.0
8.0
45
Standard Equations for Pipe
Diameter (New)
The “new” line sizing models are characterized by a maximum pipe velocity
criterion and a maximum pressure drop criterion, as listed below:
46
Parameter
Equation
Remarks
Pipe Velocity
V ≤ V max
V = flow Velocity;
Vmax = maximum velocity given below;
Pressure Drop (psi
per 100 ft.)
ΔP ⁄ 100 ≤ ΔP max
ΔP max is the allowable maximum pressure
Application
Maximum
Velocity
drop per 100ft, given below
Maximum Pressure Drop Per 100 ft.
18 Piping (G10)
Liquid Lines
V max = 100 ⁄ p 10.5
ΔP max = 1 psi
Where:
Vmax = Maximum
allowable velocity liquid (FT/S)
A = Maximum
velocity multiplier liquid( FT/S)
Default = 100
B = Maximum
velocity exponent liquid
Default = 0.5
Pl = Pressure liquid(Psia)
B
Vmax = A/Pl
Gas Lines
V max = 100 ⁄ p v0.5
ΔP max = 0.224 + 0.00172 P + 0.0000034 P2
where P is the operating pressure in psia.
18 Piping (G10)
Steam Lines
V max = 100 ⁄ p s0.5
ΔP max = 1 psi
Centrifugal Pump
Suction
V max = 5 ft/s
ΔP max = 1 psi
PD & Gear Pump
Suction
V max = 1.5 ft/s
ΔP max = 1 psi
All Pump Discharge
Table as a function
of Pipe Diameter
ΔP max = 3 psi
Tower Reboiler
V max = 3 ft/s
47
Standard Equations for Pipe Diameter (NEW) - continued
Name
Equation
Flare Stack inlet header V
max = 0.75* Sonic Velocity
Pipe Diameter Liquid
Vapor**
d=12*(4*gpm/(X*7.481*60*Vmax))0.5
d=0.226*(flowrate*specificvolume/Vmax)0.5
Where:
Vmax = Maximum allowable velocity - liquid (FT/S)
A = Maximum velocity multiplier - liquid( FT/S)
Default = 100
B = Maximum velocity exponent - liquid Default = 0.5
Pl = Pressure - liquid(Psia)
B
Vmax = A/Pl
Friction Factor
Vapor/Liquid
f=2*[(8/NRE)12 + 1/(C1+C2)1.5]0.0833
where:
C1={2.457*ln[1/((7NRE)0.9+(0.27*( ε /(d/12))))]}16
C2=(37530/NRE)16
( d ⁄ 12 ) v ρ
N RE = -------------------------μ
ε (abs. roughness) = 0.00015ft (Commercial steel/wrought
iron)
v (liquid velocity) = 0.4085*gpm/d2
v (vapor velocity) = 0.051076* flowrate*specificvolume/d2
ρ (liquid density) = lb/ft3
μ (liquid viscosity) = cP*6.7197*10-4
d = pipe ID, inches
Frictional pressure drop ΔP
100 ( 2fρv 2 )
------- = -----------------------(psi per 100 ft)
100
d
g c  ----- 144
Vapor/Liquid
 12
Vapor Density
ρ =((Pi+14.696)*MW)/(10.73*(Ti+460))
where:
Pi=Operating Pressure, psig
Ti= Operating Temperature, oF
MW=Molecular Weight
48
18 Piping (G10)
Standard Equations for Pipe Diameter (NEW) - continued
Name
Equation
Vapor Viscosity
μ g =K*10-4*EXP(X* ρ s y)
where:
1.5
( 9.4 + 0.02MW ) ( T i + 460 )
K = -----------------------------------------------------------------------209 + 19MW + ( T i + 460 )
X=3.5+(986/Ti+460)+0.01*MW
y=2.4 – 0.2*X
ρ s , Standard density=(MW/28.97)*0.0764*
(520/14.696)*(Pi+14.696)/Ti+460)*1/62.428
Pressure Drop
–6
2
Steam
ΔP
( 3.36 ×10 )f ( flowrate ) ------------------------------------------------------------------------------------ = 100
5
100
(ρd )
Friction Factor, Steam

2


1
f =  --------------------------------------------------------------------------------------------------
– 2 Log ( ε ⁄ ( d ⁄ 12 ) )  Log
( ε ⁄ ( d ⁄ 12 ) )- 
  -----------------------------------------------------------------------------------  3.7 – ( 5.02 ⁄ N RE )   3.7 + ( 13 ⁄ N RE )  
where:
( d ⁄ 12 ) v ρ
N RE = -------------------------μ
18 Piping (G10)
49
Maximum Flow Velocity as a function of
Pipe Diameter for Pump Discharge (Fluid
Specific Gravity = 1)
50
Pipe Diameter (inches)
Maximum Velocity (fps)
1
10.5
1.5
11.0
2
11.1
3
11.3
4
11.6
6
12.0
8
12.2
10
12.4
12
12.5
14
12.6
16
12.7
18
13.0
20
13.1
18 Piping (G10)
Utility Piping Services
Utility headers are sized based upon the following:
•
The Utility Header Diameter Symbol (L,M,H,V) as specified for Plant Bulk Utility
Piping will give diameters for each service as tabulated in the following table.
•
By specifying the desired diameter for that service. If the Utility Header Symbol is
designated, then a run of each service line is provided by the system in default of a
non-specified diameter. The default diameter corresponding to the service type is
listed in the table below.
A user-specified diameter for a service header overrides the diameter
associated with the Utility Header Diameter Symbol. Service headers may be
omitted by:
•
Specifying “0.0” diameter for the undesired service.
•
Omitting the Utility Diameter Symbol, whereby only diameter-specified headers are
provided.
•
These items are cost accounted to the same COA’s as process piping.
Service
Symbol Type
Nominal Pipe Diameter: INCHES [MM]
Diameter Symbol
L
M
H
V
excluded
excluded
excluded
excluded
Water
F (b)
F (b)
P
C
Firewater - loop
Firewater - lateral
Potable water
Cooling water and return line
6[150]
4[100]
2 [50]
6[150]
8[200]
6[150]
2 [50]
8[200]
12[300]
6 [150]
4 [100]
12[300]
16[400]
6 [150]
6 [150]
14[350]
3 [80]
3 [80]
3 [80]
4[100]
4[100]
4[100]
8[200]
8[200]
6[150]
12[300] excluded
12[300] excluded
8 [200] excluded
2 [50]
2 [50]
3 [80]
2 [50]
4[100]
3 [80]
6[150]
[100]
excluded
excluded
2 [50]
2 [50]
2 [50]
2 [50]
4[100]
4[100]
6[150]
6[150]
excluded
excluded
Steam*
L (i)
M (i)
H (i)
Low pressure steam
Medium pressure steam
High pressure steam
Air
P
I
Plant air
Instrument air
Gas
F
I
Fuel gas
Inert gas
Other
CS (b)
FL
US
Chemical sewer
Flare line
Utility station (see diagram)
8[200] 10[250] 12[300] 14[350] excluded
10[250] 14[350] 16[400] 24[600] excluded
1 [25] 1 [25]
1 [25] 1 [25]
*One condensate return line is provided upon selection of any combination of steam
services.
(b) Buried
(i) Insulated
18 Piping (G10)
51
Utility Station Diagram
Note: The drop lines are 1 INCH [25 MM] in diameter for air/water/steam and
0.75 INCH [20 MM] for condensate line. The lengths are 100 FEET [30 M] for
air, water, and steam service and and 50 FEET [15 M] for condensate line by
default. Length can be changed by specifying utility station drop length.
52
18 Piping (G10)
Default Piping Materials
Equipment Fabrication
Materials
Temperature Range*
F
Piping Material Symbol
C
Aspen In-Plant Cost Estimator
All Materials
all
all
A 106 (up to 2 INCHES [50 MM]
A 53 (2 INCHES [50mm] and larger)
-253 to -46
-45 to -29
-28 to 343
-28 to 343
344 to 537
538 to 648
649 to 815
304P
A333A
A 106 (up to 2 INCHES [50 MM]
A 53 (2 INCHES [50 MM] and larger)
A335C
A335F
304P
Aspen Project Economic Evaluator
All carbon and Low Alloy
Steel
-425 to 051
-50 to -21
-20 to 650
-20 to 650
651 to 1000
1000 to 1200
1201 to 1500
Clad Vessels
Material corresponding to processside cladding material.
Lined Vessels: Brick or
monolithic lined
all
all
Carbon steel - see above
Lined Vessels: rubber lined
all
all
RBLCS
all
Lined Vessels: organic
(except rubber), glass, lead
zinc lines
all
TFELS
High Alloy Steel (Stainless)
-425 to 650
651 to 1500
-252 to 343
344 to 815
304P
316P
Aluminum
-425 to 650
651 to 1500
-253 to 148
-28 to 204
AL
Copper and Copper Alloys;
Except for HE and RB HE
and RB only
-20 to 400
-28 to 204
HASTELLOY
all
all
INCONEL
all
all
INCNL
KARBATE (graphite)
all
all
TFELS
MONEL
all
all
MONEL
Nickel
all
all
N
Titanium
all
all
TI
Epoxy/Polypropylene (PPL)
all
all
TFELS
Wood
all
all
316P
CU
Carbon Steel - see above
HAST
The maximum temperature for any pipe material will not exceed the maximum temperature for
the corresponding plate material listed in Chapter 28.
18 Piping (G10)
53
Pipe Materials - Ferrous
Materials
Carbon Steel
(COA 310 - 319)
System
Material
Symbol
ASTM
BS
JIS
DIN
Composition Recommended Length
Type**
Maximum
Temperature
Degrees*
F
C
A 53 or CS
A-53
(B)
3601
G3454
ERW410 STPG
G3452
SGP
17172
StE240.7
1100
593
1
GALV
(B)
ERW410 STPG
G3452
SGP
StE240.7
Galvanized CS 1100
593
1
1100
593
1
1100
593
1
A 106 or CS A - 106 3602
(B)
HFS410
A333A
A-333
(6)
G3456
STPT
17175
St45.8
3603
G3460
SEQW-680
410LT50 STPL380 TTSt35N
* The maximum temperature for any pipe material will not exceed the maximum temperature for
** See Length Types.
API Pipe
(COA 310-319)
System
Material
Symbol
ASTM
BS
JIS
DIN
Composition Recommended Length
Type**
Maximum
Temperature
Degrees*
F
GRBW***
5L/5LS 3601
G3454
ERW410 STPG
17172
StE240.7
C
1100
593
1
X42W
1100
593
1
X52W
1100
593
1
X60W
1100
593
1
X65W
1100
593
1
X70W
1100
593
1
*** For GRBS (GR.B seamless), select GRBW (GR.B welded) as the system material symbol and
then select “Seamless” in the Pipe Type Field.
54
18 Piping (G10)
Low and Intermediate Alloy Steel
(All COA 320-329, except A##C COA 310-319)
System
Material
Symbol
ASTM
BS
JIS
DIN
Composition
Recommended Length
Type**
Maximum
Temperature
Degrees*
F
A-335 3604
C
G3458 17175
A335B
(12)
620-440
STPA22
13CrMo44
1Cr - .5Mo
1200
648
1
A335C
(11)
621
STPA23
13CrMo44
I.25CR-.5Mo-Si 1200
648
1
A335D
(22)
622
STPA24
10CrMo910
2.25Cr-1Mo
1200
648
1
A335F
(5)
625
STPA25
12CrMo195G
1200
648
1
Low Temperature Service
A-333 3603
A333C
(3)
G3460
Min. Temp
SEW680
503LT100 STPL450 10Ni14
3.5Ni
F
C
-150
-101
1
18 Piping (G10)
55
High Alloy Steel
(COA 320-329)
DIN
Composition
Recommended Length
Type**
Maximum
Temperature
Degrees*
2462
X5CrNi1810
18Cr-8Ni
1500
815
1
A312
3605
G3459
TP 304L 304S14 SUS304LTP
2462
X2CrNi1911
18Cr-8Ni
1500
815
1
316P
A-312
TP 316
2462
16Cr-12Ni-2Mo 1500
X5CrNiMo17122
815
1
316LP
A-312
3605
G3459
TP 316L 316S14 SUS316LTP
2462
16Cr-12Ni-2Mo 1500
X2CrNiMo17132
c
1
317LP
A-312
TP 317L
18Cr-13Ni-3Mo
1500
1500
1
321P
A-312
TP 321
1500
815
1
6MOP
A-312
3605
G3459
2463
20Cr-18Ni-6Mo 1382
TP 317L 316S22 SUS317LTP-A X2CrNiMo18143
750
1
304PG
A-312
TP 304
3605
G3459
304S18 SUS304TP
2462
X5CrNi1810
1500
815
2
316PG
A-312
TP 316
3605
G3459
316S18 SUS316TP
2462
16Cr-12Ni-2Mo 1500
X5CrNiMo17122
815
2
1500
815
3
1500
815
3
System
Material
Symbol
ASTM
BS
JIS
304P
A-312
TP 304
3605
G3459
304S18 SUS304TP
304LP
F
3606
G3459
316S18 SUS316TP
SUS317LTP
3605
G3459
321S18 SUS321TP
2462
X6CrNiTi1810
18Cr-10Ni-Ti
C
Gauge Pipe (Very Light Wall)
18Cr-8Ni
Sanitary Pipe (Polished, Quick Disconnects)
304PS*** A-312
TP 304
3605
G3459
304S18 SUS304TP
2462
X5CrNi1810
18Cr-8Ni
316PS*** A-312
TP 316
3605
G3459
316S18 SUS316TP
2462
16Cr-12Ni-Mo
X5CrNiMo17122
***Maximum 200 PSIG (1,379 KPAG)
56
18 Piping (G10)
Pipe Materials - Non-Ferrous
Materials
Non-Ferrous Materials
(COA 330-339)
System ASTM
Material
Symbol
BS
JIS
DIN
Composition
Recommended Length
Type*
Maximum
*
Temperature
Degrees*
F
C
AL
B-241 1474 H4080
1746
Aluminum
U.S to 10 INCHES [250 MM]
A96961 6061 A6061T
U.S above 10 INCHES [250 MM] and all others
350
176
1
CU
B-42
2871
C10200 C103
H3300
C1020T
1754
OF-Cu
Copper
400
204
3
Ni
B-161
3074
N02200 NA11
H4552
NNCT
17740
Ni99.2
Nickel
99Ni
600
315
3
MONEL
B-165
3074
N04400 NA13
H4552
NCuT
17751
NiCu30Fe
Monel
67Ni-30Cu
800
426
3
INCNL
B-167
N06600
Inconel
72Ni-15Cr-8Fe
1200
648
3
TI
B-337
R50400
H4630
TTP35
17850
Titanium
600
315
3
HAST
B-619
N10276
H4552
NMCr
17751
Hastelloy
NiMo16Cr15 54Ni-16Mo-15Cr
1250
676
3
A 20
B-464
N08020
Alloy 20
800
35Ni-35Fe-20Cr-Cb
426
3
ZR
B-658
R60702
Zirconium
99.2Zr
371
3
700
18 Piping (G10)
57
Plastic and Resin Materials
(COA 350-359)
Recommended
Maximum
Temperature
Material Class
Pipe Material
System
Material DEG F
Symbol
F
DEG C Length
C Type*
FRP
260
125
Polyvinyl Chloride,
Maximum 8 INCHES [200
MM}diameter
PVC
140
60
4
Chlorinated Polyvinyl
Chloride, Maximum 8
INCHES [200 MM] diameter
CPVC
200
93
4
Plastics and Resins Fiberglass Reinforced **
Epoxy Resin
* See below for Length Types
** Thickness/schedule not adjustable
Type
Length
10 FEET
15 FEET
20 FEET
30 FEET
[3 M]
[4.6 M]
[6.1 M]
[9.1 M]
< = 1.5 INCHE
> 1.5 INCHE
1
2
All D
3
All D
4
5
58
All D
All D
18 Piping (G10)
Lined Steel Pipe
(COA 340-349)
Lined piping of the materials in the following table are developed irrespective
of the equipment or pipe temperature. The user must give consideration to
temperature-material selections for these materials, as the system does not
produce a warning or error condition if the recommended maximum
temperature is exceeded.
Recommended
Maximum
Temperature
Lined Steel
System
Material Degrees
Symbol
F
Remote shop fabricated carbon steel pipe and
fittings, lined with:
Epoxy
Glass
Natural rubber, (1/4 INCHES [6 MM] thick
Nitrile rubber (1/4 INCHES [6 MM] thick
Hypalon rubber (1/4 INCHES [6 MM] thick
EPLCS
GSLCS
RBLCS
NITRL
HYPLN
260
450
175
175
175
125
230
80
80
80
Butyl rubber (1/4 INCHES [6 MM] thick)
Neoprene rubber (1/4 INCHES [6 MM] thick
Ebonite (1/4 INCHES [6 MM] thick
Cement
Polypropylene
BUTYL
NEPNE
EBONT
CMLCS
PPLCS*
175
175
175
80
80
80
225
110
1
Polyvinylidene Fluoride (KYNAR)
Polyvinylidene Chloride (SARAN)
Fluorinated Ethylene Propylene (FEP TEFLON)
Polytetrafluoroethylene (TFE TEFLON)
PVDF*
PVDC
FEP
TFELS*
275
175
400
450
135
80
200
230
1
3
4
1
Remote shop fabricated stainless steel pipe
and fittings, lined with:
TFESS*
450
230
1
Degrees Spool
C
Type*
4
2
4
Polytetrafluoroethylene (TFE TEFLON)
* Can use bends up to 4 INCHES instead of elbows.
Spool Types
18 Piping (G10)
Spool
Type
Spool Diameter
Default Spool
Length
Maximum Spool
Length
1
All
20 FEET [6.1 M]
40 FEET [12 M]
2
< = 1 INCH
> 1 and < 2 INCH
> 2 INCH
2 FEET [0.6 M]
6 FEET [1.9M]
10 FEET [3.1M]
2 FEET [0.6 M]
6 FEET [1.9M]
10 FEET [3.1M]
3
All
10 FEET [3.1M]
10 FEET [3.1M]
4
All
20 FEET [6.1 M]
20 FEET [6.1 M]
59
Icarus systems automatically include two flanges per spool.
For yard pipe (Plant bulks - YARD PIPE), specifying the number of flanges
overrides the default. An error message appears if the number of flanges you
specified causes the spool piece to exceed the maximum length for that
particular spool piece type and diameter.
For installation bulk piping (Component - Pipe Item Details), specifying the
number of flanges overrides the default. If the number of flanges specified
causes the spool piece to exceed the maximum length for that particular spool
piece type and diameter, the default spool length is used. However, the system
will not generate a message that there are too few flanges.
The spool pieces are shipped pre-flanged and ready for bolt-up to valves and
flanged fittings in the field.
The following is a yard pipe example:
Yard Pipe Example:
20 FEET [61 M] Yard Pipe
10 INCHES diameter
System generates:
10 sections
Spool length = 20 FEET [6.1 M]
TFELS (material)
20 flanges
200 FEET [61 M] Yard Pipe 10 INCHES diameter
User enters:
System generates:
5 Sections
Spool lengths = 40 FEET [12 M}
TFELS (Material)
10 flanges
10 flanges
200 FEET Yard Pipe
10 INCHES diameter
TFELS (Material)
User enters:
8 flanges
System generates:
“ERROR: Too few flanges on this run of pipe”
System cannot generate this run of year pipe. When the user enters ‘8 flanges,’ the
system tries to break the yard pipe into 4 sections (Spools):
The Spool Type Chart indicates that TFELS is a Type 1 spool and cannot exceed a
maximum length of 40 FEET [12 M] on a single spool piece; therefore, the system
generates an error message.
60
18 Piping (G10)
Yard Pipe Example - continued
To determine the minimum number of flanges on a spool piece of yard pipe:
1) Determine the length of the pipe.
2) Determine the Spool Type.
3) Look at the maximum length of spool for the spool type.
Calculate:
Minimum Number of flanges = (Length of Pipe / Maximum Length) x2
Example:
Material = TFELS Spool Type = 1
Length = 200 FEET [61 M] Maximum spool length = 40 FEET [12.2 M]
The minimum number of flanges a user could enter for this run of pipe is:
(200 FEET / 40 FEET) x 2 = (5 ) x 2 = 10 flanges
[61.96 M/ 12.2 M] x 2 = [5.000] x 2 = 10 flanges
Entering fewer than 10 flanges will generate an error in your estimate.
Note: Odd sizes will round up to the next integer.
Material = TFELS Spool Type = 1
Length = 208 FEET [63.4 M] Maximum spool length = 40 FEET [12.2 M]
(208 FEET / 40 FEET) x 2 = (5.2 ) x 2 = 11 flanges
(rounds up to the next integer)
[63.4 M / 12.2 M] x 2 = (6 ) x 2 = 12 flanges
Entering fewer than 12 flanges will generate an error in the estimate.
GB 150 Pipe Materials
Icarus
GB Material
GB Material
Material
Standard
Designation
Symbol
Internal
Pressure
Internal
Pressure
Max Temp
(Deg F)
Max Temp
(Deg C)
A 53
GB/T 13793
20
662
350
A 106
GB/T 8163-2008
20
842
450
A333A
GB 6479
16Mn
887
475
A335B
GB 5310-2008
15CrMo
1022
550
A335C
GB 5310-2008
12Cr1MoVG
1067
575
A335D
GB 5310-2008
12Cr2Mo
1067
575
A335F
GB 6479
1Cr5Mo
1112
600
304P
GB/T 12771-2008
06Cr19Ni10
1292
700
304PS
GB/T 12771-2008
06Cr19Ni10
1292
700
304LP
GB/T 12771-2008
022Cr19Ni10
797
425
304PG
GB/T 12771-2008
06Cr19Ni10
1292
700
316P
GB/T 12771-2008
06Cr17Ni12Mo2
1292
700
316PS
GB/T 12771-2008
06Cr17Ni12Mo2
1292
700
316LP
GB/T 12771-2008
022Cr17Ni12Mo2
842
450
316PG
GB/T 12771-2008
06Cr17Ni12Mo2
1292
700
317LP
GB/T 14976-2008
06Cr19Ni13Mo3
842
450
321P
GB/T 12771-2008
O6Cr18Ni11Ti
1292
700
18 Piping (G10)
61
62
18 Piping (G10)
18 Piping (G10)
63
64
18 Piping (G10)
Icarus’ Pipe Fabrication,
Erection and Testing
Procedures
Code of Account
Icarus Operation
3X2 FIELD SHOP FAB
(312-CS, 322-SS, etc.)
HANDLE AND WELD PREP OPER.
Shop handling for fabrication
Weld prep
Pre-heating
CUTTING PIPE
Flame cutting
Machine cutting
BEVELING PIPE
Flame beveling
Machine beveling
WELDING (shop)
Butt weld
Repair bad x-ray welds
3X4 REMOTE SHOP FAB
(3140CS, 324-SS, etc.)
18 Piping (G10)
What is Included
Unload from train/truck
into shop storage’ procure
material for fabrication;
place completed spools in
temporary storage.
Prepare for welding
(clean, pickle, etc.);
smooth weld (deburr/
grind), and clean-up
For temperatures up to
400F [204C]
Flame cut pipe- plain end
Machine cut pipe - plain
end
Flame bevel pipe for
welding
Machine bevel pipe for
welding
Manual butt weld
Dig out & re-weld bad Xray welds
FIELD SHOP X-RAY
Radiographic inspection
FIELD SHOP STRESS RELIEF
Local stress, relieving
TESTING, MISC. CLEANING
Clean & polish
Other testing
User specified
User specified
[Operations same as Field Shop] [Cost accounted as
material cost]
65
Icarus’ Pipe Fabrication, Erection and Testing Procedures - continued
Code of Account
Icarus Operation
3X7 PIPE ERECTION
ERECT SHOP FAB PIPE
(317-CS, 327-SS, etc.)
66
What is Included
Handle and erect fabricated
spool pieces; includes handle
and haul from storage yard,
unload and rig in place and
align.
ERECT VALVE
Field handle valves, orifice
unions, etc.
BOLT UP CONNECTIONS
Field attach flanges and do
bolt-ups
ERECT STRAIGHT RUN PIPE
Same item as Erect Shop Fab
Pipe
WELDING (field)
Flame cutting
Machine cutting
Flame beveling
Machine beveling
Butt weld
Repair bad X-ray welds
Same
Same
Same
Same
Same
Same
FIELD X-RAY
Same items as Field Shop Fab
FIELD STRESS RELIEF
Same items as Field Shop Fab
307 PREFAB PIPE
REWORK
REPAIR & ADJ PREFAB PIPE
10% of all shop man-hours
(12.5% in UK)
306 PIPING SYSTEM
TESTING
PIPE TESTING (field only)
Hydrostatic testing
items
items
items
items
items
items
as
as
as
as
as
as
Field
Field
Field
Field
Field
Field
Shop
Shop
Shop
Shop
Shop
Shop
Fab
Fab
Fab
Fab
Fab
Fab
Prepare for test (place blinds &
blanks, open valves, support
items, air purge, etc.); test
(fill, pressurize and monitor
lines, soap test joints); clean
up after test (drain lines,
remove temporary items,
close valves, etc.)
18 Piping (G10)
Valve and Fitting Options for
Installation Bulk Piping
Selections of available valves and fittings on installation bulk piping are listed
alphabetically below, with those available for standard piping materials listed
separately from those available only for sanitary piping materials. These
choices are available only on installation bulk piping (Piping - Line Item Detail)
or when adding installation bulk piping through the use of the P&ID editor on
Aspen Capital Cost Estimator systems.
Description
Symbol
For Standard Piping Materials (all available piping materials
except 304PS and 316PS)
Angle valve
AN
Ball valve
BA
Blind
BL
Butterfly valve
BU
Check valve
CH
DI or SS Victaulic coupling (Vict. Pipe only
VS
Elbow
EL
Expansion joint
ST
Extra drains*
DR
Flange (exclude valve flanges, set by system)** FL
Gate valve
GA
Globe valve
GL
Knife gate valve
KN
None
18 Piping (G10)
Orifice plate and union
OP
Plug valve
PL
Reducer
RE
Regulating valve
RV
Rupture disk
RD
Safety/relief valve
SV
Spectacle blind
SB
Strainer
ST
Steam trap
TP
Tee
TE
Temperature valve
TV
Threadolet
TL
67
Description
Symbol
Transition joint at material change
TR
**Drain is defined as a fitting assembly composed of three elbows, one
gate valve, and 10 FEET (3 M) of 0.75 INCH (20 mm) pipe. However,
the user can select the diameter, length, number of fittings, and
type of fittings (a maximum of four different types) at the project
level.
*Flange costs include cost of gaskets and bolts.
Note: Pipe Fittings for sizes greater than 48” OD:
1. The fabricated fitting is assumed to require a length of pipe
equivalent to 2 times the nominal diameter of the pipe. For example,
for a 54 inch diameter pipe, to fabricate 1 elbow (or 1 tee) would
require 2*54 inch = 108 inch or 9 ft of pipe.
2. The material cost of the fabricated elbow would equal that of 9 feet
of straight length pipe.
3. The material cost reported in the line item is multiplied by the
number of elbows (or tees) specified by you. For example, for 2
elbows (54 inch diameter), the material cost = 2*9 ft = 18 feet of
straight length pipe.
4. The weight of each fabricated elbow (or tee) is similarly the weight
of straight pipe of (2 times nominal diameter) length.
Description
Symbol
For Sanitary Piping Materials (304PS and 316PS) Only
Butterfly valve - sanitary, max 8 IN[200 MM]
BU
Check valve - sanitary, max 4 IN[100 MM]
CH
Cross - sanitary, max 8 IN[200 MM]
CR
Elbow (45 degree)-sanitary, max 8 IN[200 MM]
45
Elbow (90 degree)-sanitary, max 8 IN[200 MM]
EL
Flange - sanitary (exclude valve flanges)
FL
Hose adapter -sanitary, max 4 IN[100 MM]
HA
Pipe adapter-sanitary, max 4 IN[100 MM]
PA
Quick-joint conn. -sanitary, max 4 IN[100 MM]
QJ
Reducer (concen.)-sanitary, max 8 IN[200 MM]
RE
Reducer (eccen.)-sanitary, max 8 IN[200 MM]
ER
Safety valve - sanitary, max 4 IN[100 MM]
SV
Swivel-joint conn. -sanitary, max 4 IN[100 MM]
SJ
Tee - sanitary, max 8 IN[200 MM]
TE
Threadolet - sanitary
TL
**Drain is defined as a fitting assembly composed of three elbows, one gate
valve, and 10 FEET (3 M) of 0.75 INCH (20 mm) pipe. However, the user can
select the diameter, length, number of fittings, and type of fittings (a
maximum of four different types) at the project level.
*Flange costs include cost of gaskets and bolts.
68
18 Piping (G10)
Valve Trim Specifications
The valve trim specifications in Aspen Icarus custom pipe specifications are
based on the API-600 specification. The API-600 specifications pertain to steel
gate valves only, but Aspen Icarus extends these valve trim specifications to
apply to gate, globe and check valves. Aspen Icarus has implemented a subset
of the specification based on the data available. The table below provides a
summary of the differences between the trim choices. Please refer to the
specification for further information.
Definition of Aspen Icarus Valve Trim Specifications
API-600 Trim Number Trim Definition
Comments
TRIM 01
F6 Nominal Trim
Default trim for all Carbon Steel
Gate, Globe and Check valves
TRIM 02
SS 304 Trim
Default Trim for all SS Gate,
Globe and Check Valves
TRIM 05
Hard Faced Trim
Cobalt-chromium alloy seats
TRIM 08
F6 and Hard Faced
TRIM 09
Monel Trim
Default for Monel valves
TRIM 10
SS 316 Trim
Default for SS 316 Valves
TRIM 12
SS316 Trim + Hard faced
Note that selecting a trim that has a lower number than the default trim for
that valve body material will be ignored (e.g., selecting TRIM 01 for a Monel
valve is not valid, you must select TRIM 09,10,12). Also, these specs do not
apply to control valves.
Please contact Aspen Icarus if you are interested in working with us to extend
the list of choices to address your requirements.
18 Piping (G10)
69
70
18 Piping (G10)
18 Piping (G10)
71
72
18 Piping (G10)
19 Civil
(G8)
Civil Plant Bulks
Foundation Types
Typical Structure Live Loads
Soil Types
Specifying Seismic Data
Specifying Wind Loads
How Icarus Calculates Wind Load and Seismic Shear
Example of Equipment Foundation Design
Example of Pile Foundation for an Equipment
19 Civil (G8)
19-1
Civil Plant Bulks
Civil plant bulk items include concrete tanks, foundations and structures.
Description
Concrete tanks: above grade, circular/rectangular
Type
ABVGR TANK
Shape symbol:
Inside length or diameter:
Enter length for rectangular tanks or diameter for
cylindrical tanks.
Inside width:
Enter length for rectangular tanks, leave blank for
cylindrical tanks.
Fluid density: Default: *62.4* PCF [*1,000* KG/M3]
Foundation thickness: Min: 4.0 INCHES [100 MM]
Wall thickness top: Min: 4.0 INCHES [100 MM]
Wall thickness bottom: Min: 4.0 INCHES [100 MM]
Soil type: See “Soil Types” later in this chapter.
19-2
19 Civil (G8)
Civil Plant Bulks - continued
Description
Type
Concrete tanks: below grade, circular/rectangular
BELGR TANK
Shape symbol:
Inside length or diameter:
Enter length for rectangular tanks or diameter for
cylindrical tanks.
Inside width:
Enter length for rectangular tanks, leave blank for
cylindrical tanks.
Fluid density:
Default: *62.4* PCF [*1,000* KG/M3]
Foundation thickness: Min: 4.0 INCHES [100 MM]
Wall thickness top: Min: 4.0 INCHES [100 MM]
Wall thickness bottom: Min: 4.0 INCHES [100 MM]
Height above ground:
Enter height that wall projects above grade. Default:
Top flush with grade *0.0*.
Soil type:
See “Soil Types” later in this chapter. Include
allowance (material and labor) for shoring if soil type
is SAND or poorer; full exposed surface and depth is
shored. No equipment rental included.
Concrete foundations, structures: 18 types (see
Foundation Types later in this chapter)
CONCRETE
Various types of concrete items. Material quantities
are per item.
If using Aspen Capital Cost Estimator, see Aspen
Capital Cost Estimator User’s Guide, Chapter 4,
“Defining Report Groups, Areas, and Project
Components,” for information on customizing
foundation data by using an external file to define
foundation quantities, man-hours, and costs.
Concrete quantity:
Enter design quantity, overpour will be added based
on item type.
Foundation type:
See “Foundation Types” later in this chapter.
Excavation quantity: ‘Default: Excavation, formwork
and rebar based on concrete quantity and type.
Rebar quantity:
Default: Excavation, formwork and rebar based on
concrete quantity and type.
Formwork quantity:
Default: Excavation, formwork and rebar based on
concrete quantity and type.
19 Civil (G8)
19-3
Description
Type
CONCRETE - continued
Grout quantity:
Default: *0.0* CY [*0.0* M3]. Non-shrink grout.
Anchors and embedments:
Default: = 0 if grout = 0; determined from concrete
quantity if external civil file exists, or else determined
from grout quantity.
Sealcoat or liner type:
SC- Sealcoat
GM- Standard geosynthetic membrane
C1- Bentonite clay liner - 1 membrane
C2- Bentonite clay liner - 2 membranes
*NO*- No sealcoat or membrane liner
Sealcoat or liner area:
Default 0.0 SY
Membrane thickness:
Default 0.060 INCHES [1.50 MM]; Min: 0.020 INCHES
[0.500 MM]; Max: 0.120 [3.0 MM]
How Icarus Calculates the foundation footprint surface area.
Convert to a square of equivalent size.
•
Excavated footprint = equivalent square + allowance [Width] for formwork.
•
Depth of footing [to the frostline] in your Project Civil Design Basis = 1
FOOT
•
Blinding slab covers the footprint of the equivalent-sized square.
Note: You can specify the excavation slope in the project and area level civil
specs. By default, Icarus calculates excavation slope based on soil type.
19-4
19 Civil (G8)
Description
Type
Scaffold labor: erect, dismantle
SCAFFOLD
Temporary tubular steel scaffold, rental excluded.
Default plank area = L x W.
Concrete drainage trench, grate cover
TRENCH
Average invert depth:
Trench width:
Tank containment with concrete paving and
surrounding wall with coating
CONTAINMNT
Depth of paving:
Wall height:
Default: *3* FEET [*0.900* M]
Wall thickness:
Number of stairways:
Access stairway over wall. Default: *2*.
Sealcoat option:
Default: *YES*
YES- Concrete sealer coating required
NO- No sealer coating
Tank containment with diked area and geomembrane DIKE MEMBR
Contained length:
Length, width and depth of diked area.
Contained width:
Length, width and depth of diked area.
19 Civil (G8)
19-5
Description
Type
DIKE MEMBR - continued
Contained depth:
Length, width and depth of diked area. Default: *6*
FEET [*1.80* M]
Imported fill depth:
Imported fill for membrane bedding and/or protective
cover. Default: *12* INCHES [*300* MM]
Unit cost of fill:
Imported fill for membrane bedding and/or protective
cover. Default: *0.0* currency/CY [*0.0* currency/
M3]
Membrane thickness:
Range: 0.020 - 0.120 INCHES [0.500 - 300 MM];
Membrane liner type:
*GM*- Standard geosynthetic membrane liner
C1- Bentonite clay liner - 1 membrane
C2- Bentonite clay liner - 2 membrane sandwich
NO- No geosynthetic membrane liner
Width at top of dike:
Default: 6 FT [1.8 M]
Width at bottom of dike:
Default: 18 FT [5.5 M]
19-6
19 Civil (G8)
Description
Type
YARD PIPE
See Chapter 18, “Piping”
PIPE
HDPE
RCON PIPE
Building
BUILDING
See Chapter 26, “Buildings”
Organic, metallic, abrasion resist. lining
LINING
Material:
*EPLCS*- Epoxt resin lining
ASRSN- Asphalt resin lining
PHRSN- Phenolic resin lining
PVDF- Kynar sheet lining
TFELS- Teflon sheet lining
BUTYL - Butyle rubber sheet 1/4 INCH [6 MM]
NATRB- Natural rubber sheet 1/4 INCH [6 MM]
NITRL- Nitrile rubber sheet 1/4 INCH [6 MM]
HYPLN- Hypalon rubber sheet 1/4 INCH [6 MM]
NEPNE- Neoprene sheet 1/4 INCH [6 MM]
CLEAD- Chemical lead 16 PSF [80 KG/M2]
I-ZN- Inorganic zinc coat 3 MIL [0.08 MM]
ZNMZL- Flame sprayed zinc 8 MIL [0.20 MM]
CERML- Ceramic liner, light abrasion and impact
CERMM- Ceramic liner, med. abrasion, light impact
CERMH- Ceramic liner, hvy. abrasion, light impact
CERMV- Ceramic liner, hvy. abrasion, heavy impact
ABRPL- Abrasion resistant plate 1 INCH [25 MM]
REPRB- Replaceable rubber lining 1 INCH [25 MM]
LS304- Replaceable SS304 plate 1 INCH [25 MM]
LS316- Replaceable SS316 plate 1 INCH [25 MM]
Lining adjustment: *4.00*; MIN: 1.00; MAX: 10.0;
Adjustment: 1=large flat area, 4=typical; 10=small
obstructed area, congested space
19 Civil (G8)
19-7
Description
Type
Pipe rack
PIPE RACK
See Chapter 20, “Steel”
PIPE SUPPT
See Chapter 20, “Steel”
Open Concrete Structure
OPN CON ST
Precast or Cast-in-place concrete open structure. The
default structure type is Precast. Structure can have
combination of grating and concrete floor slab. In
Aspen Capital Cost Estimator, you can load equipment
into an open structure by assigning the structure and
the equipment the same Structure Tag Number. See
chapter 20, "Open Steel Structure".
Concrete structure to support equipments with the
option of cast-in-place or precast structure.
Includes columns, beams, floor slab, grating, siding,
handrail and toeplates, stairways, lighting, electrical
panelboard and supply wiring/conduit.
The number of levels, if not specified is determined
from the total height and a level-to-level spacing of 15
FEET [4.5 M].
The bay span and bay width represent the typical
column spacing and is used to determine the number
of columns and column load.
You can load equipment into an open structure by
assigning the structure and the equipment, the
same User Tage Number (Refer Open steel structure)
Number of Floors:
Default: based on structure height and approximate
floor height of 15 FEET [4.5M]
Distributed Load per Level:
Default: 300 PSF [14 KN/M2]
19-8
19 Civil (G8)
Description
Type
OPN CON ST - continued
Structure Type:
* PREC * - Precast concrete structure
CONC - Cast-in-place concrete structure
Concrete Type:
Default: as specified in unit area civil specs.
Bay span: Default: 20-25 FEET [6-7.6 M]
Bay width: Default: 20-25 FEET [6-7.6 M]
Default: 1 + 1 per 5000 SF [500 M2] of area per
floor
Floor slab percent of area: Default: 75
Floor slab thickness: Concrete slab thickness.
Default: If not specified, system calculates
based on span and loading.
Floor grate - percent of area: Default: 0
Grating type:
Default: grating type from area steel specs
Siding per wall area: Default: 0
Siding type:
* CORR * - Corrugated siding
NSUL - insulated siding
Wind Force Adjustment:
project civil design specs. Default: 1
Seismic Force Adjustment:
Additional adjustment for seismic force specified
in project civil design specs. Default: 1
19 Civil (G8)
19-9
Foundation Types
Type
Symbol Type
Description
1
OCT+PROJ
Octagon Slabs and Piers with Projection.
Foundation
2
OCTAGONL
Octagon Slabs and Piers without Projection.
Foundation
3
PAVING
MASSPOUR
Typical Application
Mass Pours - Large Mats, Pile Caps, and Other
Shapes - 25 CY [19 M3] minimum.
Foundation
19-10
Typical Application
Area Paving.
Foundation
4
Typical Application
Typical Application
19 Civil (G8)
Foundation Types - continued
Type
Symbol Type
Description
5
SM BLOCK
Small Blocks - Pumps, Compressors, 3 CY [2.3 M3]
or less.
Foundation
6
LG BLOCK
7
PILE CAPS
Large Blocks - Large Compressors, Turbines 3-25
CY [2.3-1.9 M3].
Foundation
CONDUIT
RING
Typical Application
Circular Ring Foundation - For Large Tanks.
Foundation
19 Civil (G8)
Typical Application
Conduit Envelope.
Foundation
9
Typical Application
Pile Caps - 5 CY [3.8 M3] or less.
Foundation
8
Typical Application
Typical Application
19-11
Type
Symbol Type
Description
10
BASIN
Basins.
11
EL SLAB
Foundation
Foundation
12
COLM/BM
WALL
GRIND BM
Typical Application
Grade Beam.
Foundation
19-12
Typical Application
Wall and Wall Footings.
Foundation
14
Typical Application
Columns and Beams.
Foundation
13
Typical Application
Elevated Slab.
Typical Application
19 Civil (G8)
Type
Symbol Type
Description
15
PIER
Piers.
Foundation
16
FOOTING
Column Footings, Sleepers.
Foundation
17
BOX
SLAB GRB
Typical Application
Slab on grade.
Foundation
19 Civil (G8)
Typical Application
Valve Boxes, Manholes etc.
Foundation
18
Typical Application
Typical Application
19-13
Typical Structure Live Loads
Typical Distributed
Structure Loads
Remarks
PSF
[KB/M2]
50.0
2.5
Minimum possible design loading.
150.0
7.0
Mostly access and platform areas, minor equipment
support and stairways
300.0
14.0
Designed for average elevated equipment supports,
platform areas, and stairways; open construction used for
most of the structure.
450.0
21.0
Designed for heavy equipment supports, crane or catalyst
loading structures, some covered construction (metal
siding for potential wind loads), and outside freight.
600.0
28.0
Elevators (lifts); equipment, cranes, elevators (lifts) not
included.
Soil Types
Soil Type
Soil Type
Symbol
Soil Loading
PSF
19-14
Soil Density
KN/M2 PCF
KG/M3
Soft dry clay in thick beds
SOFT CLAY
2000
100
60
960
Firm dry clay
FIRM CLAY
4000
200
70
1120
Wet Sand
WET SAND
4000
200
120
1920
Sand mixed with dry clay
SAND+CLAY 4000
200
85
1360
Dry compact sand
DRY SAND
6000
300
100
1600
Coarse compact sand
SAND
8000
400
90
1440
Compact gravel
GRAVEL
12000 600
95
1520
Soft friable rock or shale formation
SOFT ROCK
16000 800
105
1680
Hardpan or compact sandstone beds
HARDPAN
20000 1000
106
1700
Medium rock or granite formation
MED-ROCK
30000 1400
108
1730
Hard rock formation
HARD ROCK
80000 3800
110
1760
19 Civil (G8)
Specifying Seismic Data
There are four different ways to specify seismic data. Because the system actually uses
horizontal acceleration (measured in g: 0.17 means 17% of "g") to get the seismic
load, the most accurate way of specifying your seismic design requirements is to
specify the acceleration value to be designed for in the Horizontal acceleration field.
Entering Mercalli Number or UBC Zone is less accurate because it forces the system to
estimate acceleration using the following table.
UBC Zone
Mercalli number
Acceleration (g)
0
1,2,3,4
0.017
1
5,6
0.075
2A (A)
0.15
2B (2)
7
0.20
3
8
0.30
4
9,10,11,12
0.40
Using the Ss and S1 parameters provides very accurate seismic data as well, which you
can then tweak if you want using the Horizontal acceleration field.
Important: Because Icarus provides four methods of specifying seismic data,
it is important to note the hierarchy of the methods.
1
Horizontal acceleration (g)
2
UBC zone
3
Mercalli number
4
Ss
5
S1
Thus, for example, the SS and SS1 parameters is used only if the Horizontal
acceleration (g), UBC number and Mercalli zone fields are blank.
Using the Ss and S1 parameters to specify
seismic data
Ss parameter:
•
definition: the Mapped Maximum Considered Earthquake (MCE) ground
motion of 0.2 sec Spectral Response Acceleration (5% of Critical Damping)
•
the Ss parameter is location specific and is determined from a seismic
ground motion map including in the ASCE 7 Standards
•
see http://earthquake.usgs.gov/hazards/designmaps for online resources
that will provide the value for the Ss parameter based on the version of
ASCE 7 and the location’s lattitude/longitude.
The Ss parameter’s default is based on the project’s country base as shown
below:
19 Civil (G8)
•
US Country Base, S_s = 0.09
•
UK Country Base, S_s = 0.29
•
JP Country Base, S_s = 1.87
19-15
•
EU Country Base, S_s = 0.14
•
ME Country Base, S_s = 0.11
S1 parameter:
•
definition: the Mapped Maximum Considered Earthquake (MCE) ground
motion of 1.0 sec Spectral Response Acceleration (5% of Critical Damping)
•
the S1 parameter is location specific and is determined from a seismic
ground motion map including in the ASCE 7 Standards
•
see http://earthquake.usgs.gov/hazards/designmaps for online resources
that will provide the value for the S1 parameter based on the version of
ASCE 7 and the location’s lattitude/longitude.
The S1 parameter’s default is based on the project’s country base as shown
below:
•
US Country Base, S_1 = 0.04
•
UK Country Base, S_1 = 0.11
•
JP Country Base, S_1 = 0.75
•
EU Country Base, S_1 = 0.06
•
ME Country Base, S_1 = 0.04
In order to determine the seismic ground acceleration for a given location, the
ASCE 7 standards require the following parameters:
•
Occupancy/Risk Category
•
Soil Type
•
Ss
•
S1
Icarus provides country-based defaults for the Soil Type, Ss and S1
parameters. The Occupancy/Risk Category default is III. But these seismic
parameters can vary significantly with in a given country. Therefore, once the
site location is known, it is very important to update the seismic parameters
for accurate estimation purposes.
To obtain accurate location-specific parameters:
1
Browse to the internet site: http://earthquake.usgs.gov/hazards/
designmaps/.
2
Use one of the following three tools provided at the site:
•
Java Ground Motion Parameter Calculator
Use this application to look up Ss and S1 in accordance with ASCE 7-05.
This application is applicable only to U.S. states and territories.
•
U.S. Seismic DesignMaps Web Application
Use this application to look up Ss and S1 in accordance with ASCE 7-10.
This application is applicable only to U.S. states and territories.
•
19-16
Worldwide Seismic DesignMaps Web Application
19 Civil (G8)
Use this application to look up Ss and S1 in areas outside the U.S. states
and territories. This data is obtained from the Global Seismic Hazard
Assessment Program (GSHAP). You can use this data with ASCE 7-05 or
ASCE 7-10.
Specifying Wind Loads
The current wind load design complies with ASCE 7-05. It assumes an
importance factor of 1.15, which corresponds with Occupancy Category III,
the default value.
You can choose the Occupancy category at the project and area levels by using
the ASCE 7 Occupancy/Risk Category drop-down list. The Icarus wind
design calculations determine the importance factor based on the selected
category.
Once you have selected the appropriate version of ASCE 7 and the Occupancy/
Risk Category that is suitable for the project, you should specify the wind data
input fields as well, unless you deem the default values are appropriate for
your project.
The Japan location index, the Wind force adjustment, and the Wind exposure
category are not dependent on the version of ASCE 7 selected. However, it is
very important to specify either the Wind velocity or the Wind load according
to either ASCE 7-05 or ASCE 7-10. Both versions of ASCE 7 include wind speed
maps, but the wind velocity and selection criteria vary.
ASCE 7-05 uses wind speed maps that are based on nominal 3-second guest
speeds in miles per hour at 33 feet above ground for Exposure C category. If
you specify an alternative exposure category, Icarus adjusts the wind load
calculations as necessary.
ASCE 7-10 uses wind speed maps tat are also based on nominal 3-second gust
wind speeds in miles per hour at 33 feet above ground for Exposure C
category. However, the appropriate map must be chosen based on the
Occupancy Category. Also, the wind velocities are higher than those found in
the ASCE 7-05 standard. Icarus does NOT adjust the wind velocity based on
the drop-down selection of the ASCE 7 Occupancy/Risk Category. If you
specify an alternative exposure category, Icarus adjusts the wind load
calculations as necessary.
The Applied Technology Council provides a Wind Speed Web Site that
provides site-specific wind speeds based on the site’s latitude and longitude at
http://atcouncil.org/windspeed/. However, wind speeds are available
only for U.S. states and territories.
How Icarus Calculates Wind
Load and Seismic Shear
1) Wind Velocity
The Wind Velocity to be entered is the Basic Wind Speed which is the 3-second
gust speed at 33 ft (10m) above ground. Icarus calculates the Wind Load
19 Civil (G8)
19-17
profile along the height based on the ASCE Standard: Minimum Design Loads
for Buildings and Other Structures. Icarus uses a default Wind Exposure C and
a Wind Velocity of 100 MPH [160 KMPH] at 33', which corresponds to a Wind
load (velocity pressure qz) of 30 PSF.
Note: You can enter the Wind load directly in the Wind load field.
qz = 0.00256 Kz Kzt V * V * I (lb/sq ft)
You can select Wind exposure [B, C, D] and Default Wind Exposure is C.
Default Kzt=1.0 and Importance factor I=1.15.
For Exposure "C", Kz=1.0 at 33'
For V = 100 MPH and Exposure "C"
qz=0.00256*1.0*1.0*100*100*1.15 = 29.5 PSF at 33': this is the default
pressure (30 PSF)
Icarus develops the Wind profile along the height as in the code and then
calculate the wind load along the height.
2) Use of Wind Force Adjustment (default=1.0)
If you want to make adjustments to the wind load or Kzt*I, it could be entered
in Wind Force adjustment as a factor.
Icarus also uses:
Gust effect factor (Gf) = 1.0 for exposure C (not 0.85)
Cf = 0.7 for Vertical Vessels and 1.4 for structures
Additional Icarus factor: 1.10
Adjusted Pressure at 33' = qz* Cf* windadj*1.10
3) Seismic acceleration (g) and Seismic Force Adjustment
(default=1.0)
Icarus use the input value of the Horizontal acceleration field (measured in
g: 0.17 means 17% of "g") directly to get the Seismic Shear. In the case of
equipments, Icarus uses an additional factor of 1.1, Icarus does not make any
other adjustments.
Seismic Shear = Operating weight of Equipment * 1.10 * Seismic acceleration
* SeismicForceAdjustment.
Note: When the Japan location index field is specified with a Japanese
country base, a Japanese wind design is performed that is independent of the
ASCE 7 wind design.
Example of Equipment
Foundation Design
Vessel Dia. = 8' Height = 20' Allowable soil pressure = 4000 psf, Wind speed
=100 MPH
System Calculations:
Wt of Vessel = 9300 lbs
Moment due to wind = 124031 lb-ft
19-18
19 Civil (G8)
Top Area reqd. = 0.828*(Dia + 2.0)**2 = 0.828*10*10 = 82.8 sf
frost ht = 4.0 ft
self wt of footing = top area * (frost+1) * 150.0 = 82.8*5.0*150.0 = 62100
lbs
Total Weight = 9300 + 62100 = 71400 lbs
eccentricity = 124031/71400 = 1.737'
For the example above, and soil pressure, we have Type 2 footing, c.s. area =
82.8 is sufficient.
This can be verified if we use the formula for square footing:
71400/(B**2) + 124031/(B**3 /6) = 4000
Area = B*B
Concrete = 82.8* (frost+1)/27 = 15.33 CY
For Type 2 Foundation:
Contact Surface formwork = 15.0 sf/cy * 15.33 cy = 230 sf
Back-up-lumber = 30.0 BF/cy * 15.33 cy = 460 BF
Rebar quantity = 70 #/cy * 15.33 cy /2000 = 0.56 Tons
Manhours:
(need some adjustment based on the quantity unless external file is used)
Formwork Fabrication = 0.08 mh /sf * 230 sf = 18*adj. = 22
Formwork Installation = (0.30*0.83)*230 = 57*adj. = 35
Formwork Strip & Clean = (0.30*0.17)*230 = 12*adj. = 12
Rebar Installation = 16.0/Ton * 0.56 = 9*adj.= 14
Pour & Finish Concrete = 2.0/CY * 15.33 = 30.66*adj = 30
Example of Pile Foundation for
an Equipment
This is a sample calculation:
Process equipment: VT CYLINDER
Vessel Diameter = 12 feet
Height = 20 feet
Wind Speed = 100 MPH
From Area Civil Specs for pile design:
Footing depth (frost height) = 4 feet
Pile Design Requirement = PILE; Pile Type = HP; Compressive Capacity=90
tons; Tensile capacity = 45 tons;
Driven Depth = 60 feet; Pile Spacing = 4 feet; shear capacity = 2 tons
19 Civil (G8)
19-19
Equipment Loading from System:
Wt of Vessel = 20800 lbs
Wind Force
= 12695 lbs
Moment due to wind = 260237 lb-ft
base Area = 0.828*(Dia + 2.0)**2 = 0.828*14*14 = 162.288 sf
Weight of Concrete = 133888 lbs
D.L. with vessel empty = Weight of Vessel+Weight of Concrete +
Weight of Soil (if there is projection) = 20800+133888+0 = 154688 lbs
Weight of water (we assume 50% full for pile design) = 70573 lbs
Maximum Weight = Empty weight + weight of Water = 154688+70573 =
225261 lbs
Radius of Pile Group = (diameter - 1)/2.0 = 5.5 ft
Minimum number of Piles = 4 (For individual foundations like piperack, open
steel the minimum is 2 per column)
Number of piles based on shear = (12695/2000) tons / 2tons= 4
Max. Number of piles possible based on spacing = 8
Start with 4 piles and then calculate the maximum load per pile based on the
Vertical Load and Moment (for
compression we use the Maximum weight, and for Tension we use the weight
without water, the base moment
here is the moment due to wind).
Checks whether load per pile is less than allowable load. If it requires more
than 8 piles, we try to provide a
inner circle of piles.
Number of piles required in this case = 4
19-20
19 Civil (G8)
20 Steel
(G6)
Steel Plant Bulks
How ICARUS Generates the Number of Column Struts
20 Steel (G6)
20-1
Steel Plant Bulks
Steel plant bulks include structures, assemblies and components.
Description
Type
Open structure: columns/girders/beams/X-brace,
grate, stairs
Includes columns, girders, beams, cross-bracing,
grating and column footings, handrail and toeplates,
and stairways. Stairways are “through-going,”
meaning each one extends from the top-most floor
level down to the grate.
OPN STL ST
The default design is bolted frame, for which bolted
connections are provided. The design is changed to
rigid frame if the user chooses FEM or F as the
Analysis Type, in which case a rigid connection is
provided.
The number of levels, if not specified, is determined
from the total height and a level-to-level spacing of 15
FEET [4.5 M], rounded to the nearest whole number;
minimum of one level.
The bay span and width represent the typical column
spacing and is used to determine the number of
columns and column load. The bay span is used to size
the support beams, and bay width is used to size the
main girders connecting to the columns.
20-2
20 Steel (G6)
Steel Plant Bulks - continued
Description
Type
OPN STL ST - continued
The maximum number of open steel structures in an
area is 10.
In Aspen Capital Cost Estimator, you can load
equipment into an open steel structure by assigning
the structure and the equipment the same Structure
Tag Number. The structure must be added to the area
before the equipment, or else the system will generate
an error. However, when the structures are evaluated,
they appear at the end of the area's detailed design
datasheet, equipment list, and detailed bulks. The
system evaluates them last because the equipment
that goes in the structures must be evaluated first
before their calculated weights are added to the
structure's loading.
The flow chart on the following page shows the logic
for hanging equipment in steel structures.
Number of floors:
Default: based on structure height and approximate
floor height of 15 FEET [4.5 M].
Distributed load per level:
Default: *300* PSF [*14.0* KN/M2]
Bay span:
Bay dimensions determine column spacing.
Default: 20-25 FEET [6-7.6 M] each way.
Bay width:
Bay dimensions determine column spacing.
Default: 20-25 FEET [6-7.6 M] each way.
Default: 1 + 1 per 5,000 SF [500 M2] of area per floor.
Structural steel analysis:
S- Simplified stress analysis
F- 2D finite element rigid frame analysis (required if a
rigid frame analysis with deflection check is desired)
Column base option:
FIXED- Rigid connection at column base.
*PINNED*- Pinned connection at column base.
Floor grates per area:
Default: *75*
Grating type:
See “Grating Types” later in this chapter.
Siding per wall area:
Default: 0%; Min.: 0%; Max:100%
20 Steel (G6)
20-3
Description
Type
OPN STL ST - continued
Siding type:
*CORR*- corrugated siding
INSUL- insulated siding
Slab thickness: Default: *4* INCHES [*100 MM];
Min: 2 INCHES [50 MM]; Max: 8 INCHES. Concrete
slab thickness over formed shell deck, applicable if
slab% area > 0.
Floor slab percent of area: Default: 0%; Min:0%;
Max: 100%. Total of floor slab% area and floor grate%
area must not be more than 100%.
20-4
20 Steel (G6)
20 Steel (G6)
20-5
Description
Type
Steel pipe rack: columns, beams, X-brace, catwalk,
PIPE RACK
stairs, ladders
Includes columns, lateral and longitudinal members,
cross-bracing, column footings, catwalks, handrail and
toeplates, stairs, and ladders (caged if over 10 FEET [3
M]).
Main bents have rigid connections between beams and
columns at odd numbered levels. Otherwise all joints
are pinned connections. Column base may be rigid or
pinned connection. Piping loads are defined as
distributed load per level. An air cooler load can be
defined above top level if required. Wide racks may
require a third column at the midpoint of the beams in
each bent. The height to the first level is defined
separately since it is usually bigger than the height
between levels which is assumed to be uniform. (A
sketch of a typical pipe rack is located on the following
page.)
Width: *20* FEET [*6.0* M] Max 120 FEET[36M]
Height: *20* FEET [*6.0* M] Max 60 FEET[18M]
Number of levels: *1*
Height to 1st level:
*12.0* FEET; MIN: 8.00 FEET; MAX: 40 FEET[12M]
Pipe rack type:
*STEEL*- All steel piperack
CONC-S- Concrete frame and steel sheets.
CONC-P- Concrete frame and precast conc. struts
PRECAST- All precast concrete piperack
Structural steel analysis:
S- Simplified stress analysis
F- 2D finite element rigid frame analysis
Main bent spacing:
Default: *20.0* FEET
Longitudinal column spacing along rack.
Third column option:
Option is for small racks. Racks wider than 40 FEET
[12 M] get three column rows.
YES- Third column now required (2 bay rack)
NO- No third column (1 bay rack)
Column base option:
FIXED- Rigid connection at column base.
*PINNED*- Pinned connection at column base.
- Continued on next page
-
20-6
20 Steel (G6)
Description
Type
PIPE RACK - continued
Distributed load per level:
*50* PSF [*2.5* KN/M2]
Air cooler loading: *0.0*
Air cool distributed load above top rack level, if any.
Catwalk width: *4.0* FEET [*1.2* M]
Number of catwalks: *1* per level
Number of ladders:
*1* per 80 FEET [25 M] of length; MIN: 2
Number of stairways: Default: *0*
No. of braced bays: Number of braced bays along rack
length. *2* per 120 FEET [36M]; MIN: 0.
Beam struts per column line:
Number of longitudinal struts per column.
*1* per each two beam levels. See figure on page 307 for explanation.
Beam struts per pipe level:
Number of longitudinal struts/beam per level/bay.
Default: *0* or, if beam length is greater than 24 FEET
[7 M], *1*
Exclude end bent:
Exclude end bents if this is a segment of a rack that is
part of a longer rack.
*NO*- Do not exclude end bents.
ONE- Exclude one end bent.
TWO- Exclude two end bents.
Minimum beam or column width:
*12.0* INCHES [*304* MM]
For concrete pipe rack only, default is calculated by the
system. If not, default is 12.0 INCHES.
Concrete type:
For concrete pipe rack only, default is area civil data
for concrete strength and cost.
2- Standard concrete (Type B)
3- Higher grade concrete (Type C)
4- Chemical resistant concrete (Type D)
Grating type:
See “Grating Types” later in this chapter
20 Steel (G6)
20-7
Sketch of a Typical Pipe Rack
20-8
20 Steel (G6)
How ICARUS Generates the Number of Column Struts
System Generated Sets:
User-Entered Sets:
Default Number of Column Struts
If a pipe rack has the default number of levels (1), the default number of
column struts is also 1. For each additional two levels, the default number of
column struts grows by 2; therefore, the default number of column struts may
best be understood as “1 per each 2 beam level”.
20 Steel (G6)
20-9
* User-entered values override system-generated values.
Description
Type
Pipe Truss Bridge
PIPE TRUSS
A truss structure with multiple levels which can span
longer areas. Wide Flange shapes are used for main
members.
Includes columns, lateral members, longitudinal chord
members, bracings and column footing.
(A sketch of a typical pipe bridge is located on the
following page)
Truss Width:
Default: 20 FEET [6.0 M]
Truss Height:
Levels between top and bottom chord: Default: 0
Height to bottom chord:
Distrib. Load/Level:
Default: 50 PSF [2.4 KN/M2]
Bay Length:
Truss length determine bay length
Default: Around 8 FEET [2.4 M]
Wind Force Adjustment:
Default: 1
Seismic Force Adjustment:
Default: 1
20-10
20 Steel (G6)
Description
Type
Pipe supports/sleepers: bent or tee, just above grade PIPE SUPPT
Series of individual steel pipe supports for long runs of
pipe just above grade. The TEE type has one post with
concrete footing; the BENT type has two posts with
concrete footings. CONS uses round concrete columns
with a steel wide flange on top connecting the
columns. Round form tubes are used as formwork for
the concrete columns.
Support type:
TEE- 1 steel post with beam
BENT- 2 steel posts with beam
CONT- Concrete tee
CONS - 2 concrete columns with steel beam
20 Steel (G6)
20-11
Description
Type
Multiple-bay steel mill building: structural steel, siding
MILL BLDG
Structural steel, crane beams and rails, elevated grate floors,
corrugated or insulated exterior if applicable, foundations, lighting and
electrical panelboard and supply wiring/conduit.
The mill building model designs a frame that is specifically suited for a
particular purpose — multiple bays where overhead cranes carry
materials along the length of the building. The term “Bay” in this case
refers to a portion of the building width.
The system assumes a cleared, level site; excavation is provided only
for grade slab and column footings. Other site work must be specified
using Site Development.
Main column spacing:
Column spacing along the length of the building.
Siding per wall area:
Default: 100% roofing and specified% siding provided, except “0.0”
input deletes both.
Siding type:
Default: *CORR*
CORR- Corrugated siding
INSUL- Insulated corrugated siding
Slab-on-grade thickness: Default: *12* INCHES [*300* MM]
Distributed load level: Default: *200* PSF [*10* KN/M2]
1st Section bay width: First bay type, describes one or more
identical, adjacent bays.
1st Section bay height: First bay type, describes one or more
Number of bays 1st Section: First bay type, describes one or more
identical, adjacent bays. Default: *1*
20-12
20 Steel (G6)
Description
Type
MILL BLDG - continued
Number of elevated floors 1st Section:
First bay type, describes one or more identical, adjacent bays. Default:
*0*
Crane capacity per bay 1st Section: Bay type 1: Load for struct.,
crane rail, etc.; crane must be specified elsewhere. Default: *0.0*
TONS [*0.0* TON]
Floor grate per area 1st Section: First bay type, describes one or
more identical, adjacent bays. Default: *100*
2nd Section bay width: Second bay type, describes one or more
2nd Section bay height: Second bay type, describes one or more
Number of bays 2nd Section: Second bay type, describes one or
Number elevated floors 2nd Section: Second bay type, describes
one or more identical, adjacent bays. Default: *0*
Crane capacity per bay 2nd Section: Bay type 2: Load for struct.,
crane rail, etc.; crane must be specified elsewhere. Default: *0.0*
TONS [*0.0* TON]
Floor per area 2nd Section: Second bay type, describes one or more
3rd Section bay width: Third bay type, describes one or more
3rd Section bay height: Third bay type, describes one or more
Number of bays 3rd Section: Third bay type, describes one or more
Number of elevated floors 3rd Section: Third bay type, describes
one or more identical, adjacent bays. Default: *0*
Crane capacity per bay 3rd Section: Bay type 3: Load for struct., crane
rail, etc.; crane must be specified elsewhere. Default: *0.0* TONS
[*0.0* TON]
Floor grate per area 3rd Section: Third bay type, describes one or
Elevated access platforms: columns/beams, rail, grate, ladder
PLATFORM
Elevated access platform, with handrail, toeplate, grating, columns,
civil foundations, lighting and electrical.
Platform width: *6* FEET [*2* M]
Number of ladders: Default: *1*
Handrail percent: Default: *100*
Floor grate per area: Default: *100*
Grating: See “Grating Types” later in this chapter.
20 Steel (G6)
20-13
Description
Type
Steel gallery structure for pipe, conveyors, walkways
GALLERY
Gallery for piping, conveyors, elevated walkways, etc., footings,
lighting and electrical included. May be specified in combinations of
three section types or as a single section
type.
Gallery height:
Max: 15 FEET [4.5 M]; Default: *9.0* FEET [*2.75* M]
Distributed load:
Default: *100* PSF [*5.0* KN/M2]
Height grade section:
Grade section has this uniform, nominal height for entire length.
Default: *6.0* FEET [*2.0* M].
20-14
20 Steel (G6)
Description
Type
GALLERY - continued
Length grade section:
Total length is sum of grade, slope and above-grade lengths.
At least one is required.
Height slope section:
Slope section varies from grade section height to this designated
height.
Length slope section:
Total length is sum of grade, slope and above-grade lengths. At least
one is required.
Above grade height:
Above ground section varies from slope section height to this
designated height.
Above grade length:
Total length is sum of grade, slope and above-grade lengths. At least
one is required.
Gallery enclosure:
Default: *OPEN*
OPEN- No enclosure
ENCLOSED- Enclosed
Tower bent spacing:
Tower (bent) spacing applies to elevated sections only. Default: *80*
FEET [*25* M].
Cantilever length:
Cantilever length may be specified only for the end of an elevated
section. Default: *0* FEET [*0* M].
Number of walkways: Default: *2*
Walkway width: Default: *54* INCHES [*2,370* MM]
Conveyor transfer tower, square cross-section
TRNS
TOWER
Steel tower only; conveyors, hoppers and chutes must be specified
elsewhere.
Steel grate, less support steel
GRATE
Grating: Default: *CS*. See “Grating Types” later in this chapter.
Steel ladders
Ladders greater than 10 FEET [3 M] are automatically caged.
LADDER
Ladder Type:
Default: *CAGED*
CAGED- Caged ladder
NONE- Ladder without cage
Steel stairs, with grate treads, handrail
20 Steel (G6)
STAIR
20-15
Description
Type
Columns, beams, bracing, brackets
MISC STEEL
The steel member size is designated by its weight per foot of length.
Steel item types are columns, beams, bracing and brackets.
Connections are included; the system increases the cost by about 15%
to account for connections.
Steel type:
COLUM- Column
BEAM- Beam
BRACE- Bracing
BRAKT- Bracket
Fabricated, lined, stiffened plate items for chutes, boxes, etc.
FABR PLATE
Fabricated stiffened steel plate items (e.g., boxes, chutes, hoods,
skirts, etc.). One or more replaceable abrasion resistant lining types
may be specified over portions of the plate area.
Material:
Default: *CS*
CS- Carbon steel
SS304- SS304
SS316- SS316
Plate per area item:
Total area of plate excluding stiffeners.
Lining thickness Type 1:
Lining type 1: thickness may not be specified for ceramic linings;
Default: *1.0* INCHES [*25* MM].
Lining per plate area Type 1:
Lining type 1; Default: *100*
Lining material Type 1:
Lining type 1. See “Abrasion Resistant Linings; Replaceable” in Chapter
28.
Lining per plate area Type 2:
Lining type 2; Default: *0.0*
28.
Lining per plate area Type 3: Lining type 3; Default: *0.0*
28.
20-16
20 Steel (G6)
Description
Type
Siding and roofing for steel structures
SIDING
Siding girts and roof purlins are designated based on column spacing.
Corrugated steel siding (18 gauge) is provided with the option of 1
INCH [25 MM] insulation in sandwich panel.
Siding area:
Siding and/or roofing area is required. Default: *0.0* SF [*0.0* M2]
Roofing area:
Siding and/or roofing area is required. Default: *0.0 SF [*0.0* M2]
Main column spacing: Default: *20* FEET [*6* M]
Siding type:
Default: *CORR*
CORR- Corrugated siding
INSUL- Insulated corrugated siding
Sanitary platform for equipment access
SAN PLATFM
A polished, stainless steel platform built to sanitary standards, e.g.,
without weld crevices or surfaces that collect standing water.
Platform height:
MAX: 12.0 FEET [3.60 M]
Platform area:
Required to enter total platform or length and width for long
platforms. If area is given, the program calculates length and width as
being the square root of area, and bases its design on this information.
Platform length:
Required to enter total platform or length and width for long platforms.
If area is given, the program calculates length and width as being the
square root of area, and bases its design on this information.
Platform width:
Required to enter total platform or length and width for long platforms.
If area is given, the program calculates length and width as being the
square root of area, and bases its design on this information.
Platform design loading:
*100* PSF [*5.00* KN/M2]
General platform design load for access/walkway areas.
Equipment percent area:
Percent of platform area that supports equipment load.
Equipment weight:
Must be entered for the program to calculate equipment access-sides.
Number of equipment access sides: *2*, MAX: 4.
Number of sides from which equipment accessed on platform.
Grating percent of area: *80.0*
20 Steel (G6)
20-17
Description
Type
SAN PLATFM - continued
Grating type:
FIBER- Fibergrate 1.5 X 1.5 IN [40 X 40 MM]
SLIP 2- 1/8 INCH [3 MM] SS304 slipnot plate
SLIP 3- 3/16 INCH [5 MM] SS304 slipnot plate
*SLIP4*- 1/4 INCH [6 MM] SS304 slipnot plate
Number of stairways: *1.00*
Number of ladders: *0*
Number of columns
Length of handrail and toeplate: FEET [M]
Grating Types
20-18
FG
Fibergrate
S2
1/8 IN [3 MM] SS slipnot plate
S3
S4
CS
1 IN x 3/16 IN [25 MM x 5 MM] CS welded bar
CM
1 1/4 IN x 3/16 IN [32 MM x 5 MM] CS Welded Bar
CH
1 1/2 IN x 3/16 IN [38 MM x 5 MM] CS welded bar
CV
2.0 IN x 3/16 IN [50 MM x 5 MM] CS welded bar
C2
1/8 IN [3 MM] CS checker plate
C3
C4
AS
1 IN x 3/16 IN [25 MM x 5 MM] AL welded bar
AH
1.5 IN X 3/16 IN [38 MM X 5 MM] AL welded bar
AV
2.0 IN x 3/16 IN [50 MM x 5 MM] AL welded bar
20 Steel (G6)
21 Instrumentation
(G10)
Instrumentation Plant Bulks
Sensor Loop Descriptions
Pressure (P)
Differential Pressure (DP)
Temperature (T)
Flow (F)
Level (L)
Analyzers (A)
Speed (S)
Motion (X): Axial, Radial, Vibration
Position (PN)
Weight (W)
Electrical Conductivity (C)
Hand (Manual Activation) (H)
Field Mounted Solenoid (SL)
Typical Pressure Instrument Process Hookup
Panel Action Descriptions
Panel Option Descriptions
Fisher Control Valve Information
Control Valve Options
Control Valve Configurations
Air Supply Piping
Remote Control Type
Transmitter Type
Overview of Instrumentation Report Details
Report Details for Analog/Electrical Instrumentation
Report Details for Analog/Electrical Pneumatic Instrumentation
Report Details for Digital/Electrical Instrumentation
Report Details for Digital/Electrical Pneumatic Instrumentation
21 Instrumentation (G10)
21-1
Instrumentation Plant Bulks
Description
Type
Conduit material: Default: *GALV*
GALV- Galvanized rigid steel conduit
EMT- Electrical mechanical tubing
AL- Aluminum
PVC- PVC plastic conduit
PBON- PVC coated rigid steel (plasti-bond)
PVCA- PVC coated aluminum
FRE- Fiberglass
Cable Size:
*14*, 12, 10 AWG; *1.5*, 2.5, 4.0 MM2.
Rigid conduit, galvanized steel, couplings, fittings and seals
CONDUIT
Material:
Default: *GALV*
AL- Aluminum
FRE- Fiberglass
Conduit diameter:
Range: 0.5 - 6.0 INCHES [15 - 150 MM]
Number of fittings: Default: *0*
Number of conduit seals: Default: *0*
Instrument panel, electronic/pneumatic
INST PANEL
Panel type:
ELC- Electronic panel
PNU- Pneumatic panel
E/P- Combined electronic/pneumatic
21-2
Description
Type
Instrument cable tray
INST TRAY
Tray width:
Range: 6 - 36 INCHES [150 - 910 MM];
Default:
*18* INCHES [*450* MM]
Electronic signal wire: wire, armored wire, wire in conduit
INST WIRE
Material:
Default: *IM*
IM- Insul., standard wire
ARMOR- IM with interlock armor
RIGID- IM in rigid conduit (See Chapter 22, Electrical Plant Bulks,
CONDUIT, for a schematic of the conduit)
PPM- Pluggable Pre-Molded wire (fieldbus only)
Number of conductor sets per cable:
Optional twisted pair or triad in each wire set.
Range: 1 - 50.
Conductor set type:
Default: *PAIR*
PAIR- Pair
TRIAD- Triad
Instrument pneumatic multi-tube bundle runs
PNU TUBING
Number of tubes per bundle: Range: 7, 12, or 19
21-3
Instrumentation Plant Bulks - continued
Description
Type
Thermocouple wire: wire, armored wire, wire in conduit
THCPL WIRE
Material:
Default: *TM*
TM- Insul., solid wire
ARMOR- TM with interlock armor
RIGID- TM in rigid conduit
Number of conductor sets per cable:
Optional number of twisted pairs per cable.
Range: 1 - 36.
Conductor type:
Default: *JX*
JX- Iron constantan
KX- Chromel alumel
TX- Copper constantan
Instrument junction boxes: electronic, pneumatic,
thermocouple
JUNC BOX
Junction box type:
EL50- Electronic - 50 conductor
PL4 - 4 Drop pluggable brick (Fieldbus only)
PL4S - 4 Drop pluggable brick with short circuit
protection (Fieldbus only)
21-4
Description
Type
JUNC BOX - continued
PN19- Pneumatic - 19 tubes
TC50- Thermocouple - 50 conductor
SRSC- 3 Drop brick with spring clamp (fieldbus only)
SRST- 3 Drop brick with screw terminal (fieldbus only)
MB4- 4 Drop brick (fieldbus only)
MB4S- Hawke International 4 Drop brick with short-circuit protection
(fieldbus only)
MB8- 8 Drop brick (fieldbus only)
MB8S- Hawke International 8 Drop brick with short-circuit protection
(fieldbus only)
Enclosure type:
Default: *GP*
GP- General purpose
EXPR- Explosion proof
Operator center: Honeywell TDC3000
OPER CENT
Operator center type:
Universal operator center or local center for one data
hiway.
Default: *UNIV*
UNIV- Universal center
LOCAL- Local center
Number of operator display units:
Number of operator CRT (Cathode-Ray Tube
Terminals), includes keyboards
Number of Hiway Gateways:
Number of gateways for data hiways.
Number of Indicating CRT:
Number of indicating CRT, no keyboard included.
Number of disk drives:
Number of dual floppy disk drivers.
Number of engineering keyboards:
Engineer’s keyboard for display.
21-5
Description
Type
OPER CENT - continued
Number of LCN cables:
Number of local control network cables.
History module:
History module for trend analysis.
Default: *NONE*
HIST- Add history module
NONE- No history module
MULTI CONT
Multifunction controllers: analog/digital I, IC, S, A circuits
Multifunction controllers for indicating and control loops, and switch
and alarm circuits.
The Instrumentation Plant Bulk items referred to as Multifunction
controllers, High energy level process interface units, and Low energy
level process interface units are based on elements of a Honeywell
TDC 2000/3000 process control system.
A Multifunction controller consists of a metal cabinet (6 FEET tall [1.83
M] and 19 INCHES [0.48 M] wide, containing 1 or more electronic
controllers with a power supply, analog and digital I/O signal
processing cards mounted in electronic racks as depicted in the
following
drawing.
21-6
Description
Type
MULTI CONT - continued
The multifunction controller is programmed from the engineer’s station
in the Operator Center over a redundant, coaxial cable (Data-highway
cable). The controller polls the
analog and digital input cards which report to it to collect the signals
transmitted by the field sensors connected to those cards. The
controller either passes the signal up to the Operator Center for
permanent storage in a History Module (computer storage) and/or
compares the measured signal with the programmed set point and
generates a corrective command. This corrective command is sent to
output cards which, in turn, generate
either an analog (4-20mA for positioning control valves) or digital (for
solenoids, on/off valves) control signal which is sent to the appropriate
final control element in the field.
The signals from and to the field interface to the Multifunction
controller through a junction box on the back plane of the unit. Signals
are distributed within the unit over a data bus.
Electric power is required to support all the electronics and a cooling
fan on top of the unit. Battery backup may be specified if it is
important that the controller not lose its
ability to control the processing in the event of a power outage.
Redundant multifunction controllers may be specified to insure
continued control even in the event of a failure in the primary
controller.
High and low energy level PIUs look similar but have no controllers.
The High level PIUs are for analog inputs only (4-20mA) and provide
simple control; the Low level PIUs collect signals from thermocouple
and RTD loops.
There are 3 types of temperature transmitters available:
• RTD: resistance temperature detector.
• TC: thermocouple; the only time that you can specify a TC
transmitter type is when you specify Temperature (T) as the
Process Variable.
• Filled system: liquid-filled.
21-7
Description
Type
MULTI CONT - continued
The TDC2000/3000 controller handles 16 analog output per controller.
The I/O cards handle the following number of signals:
Signal Type
No. Input
No. Output
Signals per Card Signals per Card
Analog
8
4
Digital
16
8
Number of controllers:
One cabinet and power supply provided per two controllers.
Redundancy:
Redundancy provides 1 backup controller for up to eight primary
controllers.
Default:
*NONE*
RED- Redundancy required
NONE- No redundancy
Number of analog input cards:
Number of I/O cards for analog input (indicating).
Number of analog output cards:
Number of I/O cards for analog output (control).
Number of digital input cards:
Number of I/O cards for digital input (alarm).
Number of digital output cards:
Number of I/O cards for digital output (switch).
Number of battery backups:
Number of backup battery power supplies for multifunction
controllers. Default: *0*
21-8
Description
Type
High energy level process interface units: Indicator, switch, alarm
circuits
HL PIU
Number of digital input cards:
Enter number of input cards required.
Number of digital output cards:
Enter number of output cards required.
Low energy level process interface units:
Thermocouple and RTD circuits
LL PIU
Data-highway cable, redundant (fiber optic) Coaxial or
fiber optic cables connecting digital controllers to
operator centers.
DATA
HIWAY
Material selection:
Default: *COAX*
COAX- Coax cable
FIBER- Fiber optic cable
Number of terminations:
Min: 1; Default: *2*
Enclosure type:
Default: *NONE*
NONE- None
COND- Conduit
21-9
Sensor Loop Descriptions
Pressure (p)
Sensor Loop Description
Type
Symbol
Process Panel Instrument Signal
Variable Action Location
Type
(1)
(2)
(3)
1
P
I
LC
none
Pressure Gauge, field mounted:
Sensor element types
(default = ST):
pipe fittings to process (ST),
gauge valves to process (FT)
draft gauge (DG)
3
Pressure Controller: field mounted,
pipe and tubing.
P
IC
LC
P
2
Pressure Transmitter:
field mounted, via pipe and tubing.
Sensor element types:
transmitter without seal (TN)
transmitter with seal (TS)
standard or microprocessor
P
I
IC
RC
R1
R2R3
LP
or
CC
e
4
Pressure Switch:
field mounted, via pipe and tubing.
*NS*- No chemical seal
CS- With chemical seal
P
A
LP
or
CC
e
6
Additional Control Valve:
secondary control valve for adding
to another control loop.
P
IC
LP
or
CC
P
or
e
1
For panel action, panel option and control valve option, refer to the
applicable section later in this chapter.
2
Instrument Location:
LC= local, on equipment or piping
LP= local panel
CC= control center (analog or digital).
3
21-10
Signal Type: e = electronic, p = pneumatic.
Differential Pressure (DP)
Type
Symbol
Type
(1)
(2)
(3)
1
Differential Pressure Gauge:
connected to process via pipe and
tubing.
DP
l
LC
none
2
Differential Pressure Transmitter:
tubing.
transmitter without seal (TN)
transmitter with seal (TS)
standard or mircoprocessor
DP
A
LP
or
CC
p
or
e
4
Differential Pressure Switch:
tubing.
*NS*- No chemical seal
CS- With chemical seal
DP
A
LP
or
CC
e
6
to another control loop
DP
lC
LP
or
CC
p
or
e
1
2
LP= local panel
3
21-11
Temperature (T)
Type
Symbol
Type
(1)
(2)
(3)
1
Temperature indicator
TM- Dial thermometer with
thermowell
TC- Thermocouple thermowell
T
l
LC
none
3
Temperature Controller:
filled system, with thermowell
T
lC
LC
p
0
Testwell:
thermowell and cap only
T
none
LC
none
2
Temperature transmitter, with
thermowell
Sensor element types (default =
FS):
FS- Filled system
TC- Thermocouple
RT- Resistance temperature
WB- Wet bulb temperature
SM- Surface mounted
T
l
lIC
RC
R1
R2
R3
LP
or
CC
p
or
e
4
Temperature Switch: with
thermowell, field-mounted
T
A
LP
or
CC
e
6
Additional Control Valve
secondary control valve
for adding to another control loop
T
lC
LP
or
CC
p
or
e
1
2
LP= local panel
3
21-12
Flow (F)
Type
Symbol
Type
(1)
(2)
(3)
1
Flow Indicator
F
l
LC
none
2
Flow Transmitter:
F
l
lC
RC
R1
R2
R3
lP
or
CC
e
or
p
OP):
OP- Orifice plate and DP transmitter
OS- Orifice plate, DP transmitter
and chemical seals
VX- Vortex meter
MG- Magnetic meter (standard
or microprocessor)
MS- Mass flow meter
NS- No sensing element,
transmitter loop only (NS)
UM- Ultrasonic meter
TM- Turbine meter
MR - Meter run with orifice plate
RS- Meter run with orifice plate
and chemical seals
3
Flow Controller: orifice
plate, field-mounted, connected to
process via pipe, valves, tubing
F
lC
LC
p
4
Flow Switch with orifice plate:
F
Sensor element types (default FS):
FS- Flow switch (FS),
TS- Flow sensing and totalizing
switch
A
LP
or
CC
e
6
C
LP
or
CC
p
or
e
F
1
2
LP= local panel
3
21-13
Level (L)
Type
Symbol
Type
(1)
(2)
(3)
1
L
l
LC
none
Level Indicators:
Sensor element types (default LG):
LG- Level glass - reflex type
external standpipe
SP- Level gauge - reflex type with
external standpipe
BB- Level indicator - bubble type
3
Level Controller:
displacement type
L
lC
LC
p
2
Level Transmitter:
DS):
DS- Displacement type
DP- Differential pressure
(standard or micro-processor)
RS- DP with chemical seals
TF- Tape/float
UL- Single point Ultrasonic level
NL- Nuclear level
RD- Radar type
L
l
lC
RC
R1
R2
R3
LP
or
CC
e
or
p
4
Level Switch:
Sensor element types (default (DS):
DS- Displacement level switch-fluids
PD- Paddle type level switch-solids
VS- Vibrating (tuning fork) switch
CD- Conductivity (max/min)
detection switch
CS- Capacitive type switch
6
1
2
LP= local panel
3
21-14
Analyzers (A)
Type
Symbol
Type
(1)
(2)
(3)
2
Analyzers:
A
Sensor element types (default PH):
PH- pH indicating transmitter ORORP (Oxidation Reduction Potential)
(Redox) transmitter
O2- Oxygen analyzer (up to 4
samples)
BT- BTU transmitter
CS- Consistency analyzer
PL- Gas detection% LEL (incl.
electronics, rack)
HD- Gas detection H2S (incl.
electronics, rack
C2- C02 (without sample
conditioning system)
VS- Viscosity (w/o sample
CL- Color (without sample
FP- Flame point (w/o sample
CP- Cloud point
SD- Smoke density
FL- Flash point
SG- Specific gravity (liquid)
HV- Heating value (incl. sample
conditioning)
GC- Gas chromatograph (1 sample
point, 6 comp.)
HC- H2 and hydrocarbons (w/o
sample probe)
HS- H2S analyzer
H2- Hydrocarbon in water
HR- H2S/S02 ratio
SO- Sulphur in oil
l
lC
RC
R2
R3
LP
or
CC
e
6
to another control loop.
lC
LP
or
CC
p
or
e
1
A
applicable section later in this chapter. Instrument Location:
LP= local panel
2
21-15
Speed (S)
Type
Symbol
Type
(1)
(2)
(3)
2
Speed Indicating Transmitter:
electronic,
non-contact type
S
l
lC
RC
R1
R2
R3
LP
or
CC
e
4
Speed Switch:
S
A
LP
or
CC
e
1
2
LP= local panel
3
21-16
Motion (X): Axial, Radial, Vibration
Type
Symbol
Type
(1)
(2)
(3)
2
Motion Transmitter - non contact
type, (default AX):
Radial (RD)
X
l
lC
RC
R1
R2
R3
LP
or
CC
e
4
Vibration Switch;
vibrating read type
X
A
LP
or
CC
e
1
2
LP= local panel
3
21-17
Position (PN)
Type
Symbol
Type
(1)
(2)
(3)
2
Position Transmitter,
(default VP):
Variable position (VP):
On/Off positions (NF)
PN
l
lC
RC
R1
R2
R3
LP
or
CC
e
or
p
4
Position Switch
PN
A
LP
or
CC
e
1
2
LP= local panel
3
21-18
Weight (W)
Type
Symbol
Type
(1)
(2)
(3)
2
W
Load Cells;
Sensing element options
(Default = 4C):
3 cell configuration (3C)
l
lC
RC
R1
R2
R3
LP
or
CC
1
2
e
LP= local panel
3
Electrical Conductivity (C)
Type
Symbol
Type
(1)
(2)
(3)
2
C
Conductivity Transmitter:
l
lC
RC
R1
R2
R3
LP
or
CC
1
2
e
LP= local panel
3
21-19
Hand (Manual Activation) (H)
Type
Symbol
Type
(1)
(2)
(3)
3
Hand Regulator:
field-mounted (pneumatic)
H
lC
LC
p
6
Manual Controller:
panel-mounted, no input signal,
output signal only
H
lC
LP
or
CC
e
or
p
4
Manual switch: panel-mounted
(front of panel)
H
S
LP
or
CC
e
1
2
LP= local panel
3
Field Mounted Solenoid (SL)
Type
Symbol
Type
(1)
(2)
(3)
6
SL
Solenoid: Field-mounted
none
LP
or
CC
1
2
e
LP= local panel
3
21-20
Instrument Hookup
21-21
Panel Action Descriptions
Panel Action
Symbol
Definition
l
Indicator:
field-mounted indicator if local to equipment (LC), or,
panel-mounted indicator (receiver type) if on local panel (LP) or in
control center (CC)
lC
Indicating Controller:
field-mounted indicating controller if local to equipment (LC), or,
panel-mounted indicating controller (receiver type) if on local panel
(LP) or in
control center (CC)
RC
Recording Controller (LP or CC):
panel-mounted, one pen
R1
R2
R3
Recorder (LP or CC):
panel-mounted, one pen
panel-mounted, two pens
panel-mounted, three pens
A
Annunciator Point (LP or CC):
activated by a field-mounted switch
S
Switch: indicating, front-of-panel mounted (LP or CC)
Cl
Jl
JR
Thermocouple-based Temperature Indicator, panel mounted (LP or
CC):
complete with back-of-panel mounted EMF converter
multi-point
Thermocouple-based Temperature Recorder, multi-point, panel
mounted (LP or CC)
In Aspen Capital Cost Estimator, the system automatically generates panel
instrumentation (combined control/operator center) required for analog
systems. The system includes the control center by default for digital systems,
but not the operator center.
21-22
Panel Option Descriptions
Panel Action
Symbol
Definition
A1
Panel alarm: one back-of-panel switch
A2
Panel alarm: two back-of-panel switches
CR
Computation relay: +, -, X, /
SQ
Square root function
FX
Defined function of X
LR
Limit regulation: high/low
ES
Emergency shutdown (ESD)
BS
Bias relay
Fisher Control Valve Information
Control Valve
Type
Size Range
Globe
Actuator
Positioner
< = 4 INCHES CE
6 - 8 INCHES ED
585
657
3611JP
3582
Ball
all sizes
V100
1052
3610J
Butterfly
all sizes
8532
1052
3610J
Body Type
21-23
Control Valve Options
Type
Definition
STD
Standard positioning - type varies with size:
GLP
Type
Size
Globe
0.5 - 4 INCH
[12 - 100 MM]
Ball
6 - 12 INCH
[150 - 300 MM]
Butterfly
> 12 INCH
[>300 MM]
Globe type positioning, usually sizes up to 8 INCH [200 MM]
BAP
Ball type positioning, usually medium sizes up to 12 INCH [300 MM]
BUP
Butterfly type position, usually large sizes from 3 INCH [75 MM]
GLO
On/off globe valve, usually small sizes
BVO
On/off ball valve, usually medium sizes
BVU
On/off butterfly valve, usually larger sizes
SGO
On/off Slide gatte for bin discharge
SGP
Positioning slide gate for bin discharge
DIV
Diverter valve for solids handling
ANO
On/off angle valve, sanitary, max 4 INCH [100 MM]
ANP
Angle positioning, sanitary, max 4 INCH [100 MM]
DVS
Diverter, sanitary only, max 4 INCH [100 MM]
TKS
Tank outlet, sanitary only, max 4 INCH [100 MM]
BUP
Butterfly position, sanitary, max 8 INCH [200 MM]
Fluid positioning control valves may be specified as line size or reduced size.
The default size reductions are as follows:
Line size
21-24
Control valve
0.5 - 4INCH
[12 - 100MM]
Same as line.
6INCH
[150MM]
One size smaller than line.
8 - 12INCH
[200 - 300MM]
Two sizes smaller than line.
14 - 24INCH
[350 - 600MM]
Three sizes smaller than line.
> 24INCH
[>600MM]
Four sizes smaller than line.
Control Valve Configurations
21-25
Air Supply Piping
Feed
Drop
21-26
Remote Control Type
Symbol
Description
(blank)
No remote on/off control valves
H
Hydraulic operated remote on/off control valves
M
Motor operated remote on/off control valves
P
Pneumatic operated remote on/off control valves
Transmitter Type
Type
Definition
S
Standard
M
Microprocessor (Smart)
21-27
Overview of Instrumentation Report Details
21-28
Report Details for Analog/Electrical
Instrumentation
21-29
Report Details for Analog/Electrical
Pneumatic Instrumentation
21-30
Report Details for Digital/Electrical
Instrumentation
21-31
Report Details for Digital/Electricl
Pneumatic Instrumentation
21-32
22 Electrical
(G13)
Electrical Plant Bulks
General Electrical Plant Bulks
Substation Electrical Plant Bulks
Schematic of Transmission Line
Substation Schematics
Electrical & Control Hook-Ups for Electric Motors
Power Distribution Network
Wire Sizes
US and ME Country Bases
UK, JP, and EU Country Bases
Electrical Class/Division
National Electrical Code (NEC)
International Electrical Code (IEC)
22 Electrical (G13)
22-1
Electrical Plant Bulks
Electrical plant bulks are divided into two categories, general and substation
plant bulks. A description of each follows.
General Electrical Plant Bulks
General electrical plant bulks include cables, trays, grounding, lighting
and tracing.
Description
Type
Material:
ELEC CABLE
ARMOR- Armored multi-core cable
W-C- Single wires in conduit, includes conduit
W-NC - Single wires in conduit (less conduit)
W-TR- Single wires in tray (less tray)
M-C- Multi-core in conduit, includes conduit
M-NC- Multi-core in conduit (less conduit)
M-TR- Multi-core cable in tray (less tray)
LARM- Lead covered armored cable
Rated voltage:
600- 600 V at 60 HZ
5000- 5000 V at 60 HZ
15000- 15000 V at 60 HZ
600- 600 V at 50 HZ
3300- 3300 V at 50 HZ
1000- 11000 at 50 HZ
Cable size:
Default: US: single wires in conduit, else multi-core cable in tray
without tray. See “Wire Sizes” later in this chapter.
Cable placement:
Default: Project/Area Design Basis
ABOVE - Above ground cable/wire
BELOW - Buried cable/wire with trenching
NOTRN - Buried cable/wire without trenching
Conduit material:
Default: *GALV*
AL- Aluminum
1PVC- PVC plastic conduit
FRE- Fiberglass
22-2
22 Electrical (G13)
Electric Plant Bulks - General Electrical Plant Bulks - continued
Description
Type
Electrical control cable runs (LV)
CTRL CABLE
Material:
W-NC- Single wires in conduit (less conduit)
LARM - Lead covered armored cable
Length of cable run:
Default: US: multi-core cable in conduit, else multi-core cable in tray
w/o tray
Cable placement:
Number of conductors:
Range: 1 - 37
Conduit material: Default: *GALV*
AL- Aluminum
FRE- Fiberglass
Cable Size:
*14*, 12, 10 AWG; *1.5*, 2.5, 4.0 MM2.
Rigid conduit, galvanized steel, couplings, fittings and seals
CONDUIT
22 Electrical (G13)
22-3
Description
Type
CONDUIT - continued.
Material:
Default: *GALV*
AL- Aluminum
FRE- Fiberglass
Conduit diameter:
Range: 0.5 - 6.0 INCHES [15 - 150 MM]
Number of fittings: Default: *0*
Number of conduit seals: Default: *0*
Electrical cable tray
ELEC TRAY
Material:
*GALV*, FBRGL, SS, AL
Tray Width:
Range: 6 - 36 INCHES [150 - 910 MM];
Default:
*18* INCHES [*450* MM]
Number of 90 degree bends:
*0*
Tray type:
*L*, T, C, B
Electrical tracing of existing equipment
Electrical tracing of equipment; item of equipment and its insulation
are assumed specified elsewhere in the project.
EQPT TRACE
Heating cable type:
Use P, M series cable for process temperature maintenance, and A, P,
or M series cable for ambient temperature maintenance.
3A- 3 W/FT [10 W/M] Chemelex BTV2-CT cable
5P- 5 W/FT [16 W/M] Chemelex XTV2-CT cable
40M - 40 W/FT [131 W/M] 300 Volt MI cable
22-4
22 Electrical (G13)
Description
Type
EQPT TRACE - continued.
M2 - 600V, dual conductor MI cable, 9 OHM/FT [29.5 OHM/M]
M4 - 600V, dual conductor MI cable, 4.14 OHM/FT [13.6 OHM/M]
[0.0922 OHM/M]
[0.042 OHM/M]
[0.016 OHM/M]
Distance to panel:
If the distance to the panel board is not specified, the system
defaults to the value defined for Area Electrical Specifications.
Thermostat control:
Default: *E-AMB*
E-AMB -Electric tracing/ambient temperature control
Single thermostat, control of electrical tracer based upon low
ambient temperature specified for General Area Specifications.
E-PRO- Electric tracing/process temperature control
Multiple thermostated circuits, control of electrical tracer based upon
low ambient temperature specified for General Area Specifications.
Electrical tracing of existing piping run
PIPE TRACE
Electrical tracing of piping; piping is assumed specified elsewhere. This
item also provides insulation of the same size, or one size larger than
pipe diameter for pipe diameters of 8 INCHES [200 MM] or smaller.
E-trace cable category: Default: *S*, self-regulating cable. Select M
for MI tracing cable or S for self-regulating tracing cable.
Traced pipe length: The pipe being traced is not included, but must be
Traced pipe diameter: The pipe being traced is not included, but must
be specified elsewhere.
Length of tracer cable: Total length of tracer segments, default based
on pipe length and diameter.
22 Electrical (G13)
22-5
Description
Type
PIPE TRACE - continued
Heating cable type:
Use A series to 120 DEGF[48DEGC], P series to 250 DEGF[120DEGC]
and M series to 1049DEGF [565DEGC] over low ambient temperature.
10A- 10 W/FT [33 W/M] Chemelex BTV2-CT cable 5P- 5 W/FT [16 W/
M] Chemelex XTV2-CT cable
40P- 40M W/FT [131 W/M] 300 volt MI cable
M2 - 600V, dual conductor MI cable, 9 OHM/FT [29.5 OHM/M]
[0.0922 OHM/M]
[0.016 OHM/M]
Maintenance temperature:
Process temperature to be maintained.
Default: 392 DEG F [200 DEG C] for M series cable and 220 DEG F
[105 DEG C] for self-regulating and 40M cable.
Max: 250 DEG F [120 DEG C] for self-regulating cable and 1049 DEG F
[565 DEG C] for MI cable over low ambient temperature.
Thermostat control:
Default: *E-AMB*
E-AMB -Electric tracing/ambient temperature control Single
thermostat, control of electrical tracer based upon low
E-PRO- Electric tracing/process temperature control Multiple
thermostated circuits, control of electrical tracer based upon low
22-6
22 Electrical (G13)
Description
Type
PIPE TRACE - continued
Distance to panel:
Distance -pipe to local panel, feeder run to individual tracers
determined by system.
Number of thermostats:
Default: 1 for ambient control, based on number of watts for process
maintenance.
Ground grid
GRND GRID
A system of buried cable and rods provide a grid work for grounding
equipment, buildings and structures.
Ground cable length:
AWG (US only): 6, 2, 1/0, 2/0, 4/0; MM2: 16, 35, 50, 70, 95, 120.
Default:
*2* AWG [*35* MM2]
Ground rod types:
*STD*, EL-L, EL-S.
Includes direct-buried grid cable brazed to each ground rod. The
default rod type, STD, includes manually-driven ¾ INCH x 10 FEET
[3.05 METER] copper-clad ground rods with studs, clamps, etc. The
electrolytic rod types, EL-L (3 FEET vertical x 10 FEET horizontal [0.91
x 3.05 METER]) and EL-S (straight 10 FEET length [3.05 M]), include
pipe with weep holes, electrolytic filling material, special conductive
backfill material, and protective cover.
If the number of ground rods is not specified, 4 rods are generated for
the first 1-199 FEET [0.3-60.6 METER] of grid cable, then 1 rod for
each 200 FEET [61 METER] thereafter. For example, a 10 FEET [3.05
METER] length generates 4 rods, a 200 FEET [61 METER] length
generates 5, and 1,000 FEET [305 METER] generates 9.
Does not include trenching and backfill.
Ground Grid Diagram and Rod Types:
22 Electrical (G13)
22-7
Description
Type
Area lighting: includes poles, lights and cable
AREA LIGHT
Flood:
400 - 1000 W; Default: *400*
Other:
100 - 400 W; Default: *175*
Fixture type:
Default: Mercury vapor/explosion proof
FL1- Fluorescent - 1 bulb
FL2- Fluorescent - 2 bulbs
FL1E- Fluorescent - 1 bulb, explosion proof
FL2E- Fluorescent - 1 bulbs, explosion proofMVPE - Mercury vapor/
explosion proof
MVPV- Mercury vapor/vaportite
MVCE - Mercury vapor/ceiling/explosion proof
MVCV - Mercury vapor/ceiling vaportite
MVF- Mercury vapor/flood
SVPE-Sodium vapor/explosion proof
SVPV- Sodium vapor/vaportite
SVCE- Sodium vapor/ceiling/explosion proof
SVCV- Sodium vapor/ceiling/vaportite
SVF- Sodium vapor/flood
INPE- Incandescent/explosion proof
INPV- Incandescent/vaportite
INCE- Incandescent/ceiling/explosion proof
INCV- Incandescent/ceiling/vaportite
MHV- Mercury halide flood
Electrical cable length:
Cable run length from lighting panel.
Number of lights:
Default: *0*
Power per light:
Min (flood):
400 W; Max (fluorescent): 120 W;
Default: 175 W
Support type:
See illustrations on following page.
*PENDT*- Pendant support
BRAKT- Bracket support
STAND- Stand and support arm
POLE- Pole support (see height entry below)
22-8
22 Electrical (G13)
Description
Type
AREA LIGHT - continued
Number of poles:
Default: *0*.
Pole height:
Number of general receptacles:
Low voltage (30-50 A). Default: *0*.
Number of weld receptacles:
300 A. Default: *0*.
Wiring system:
Default: *3 wire system*
2- 2 conductor system
Cable size:
Default: US: *12 AWG*, else: 2.5 MM2.
14- 14 AWG - US only
1.5- 1.5 MM2 - other bases
2.5- 2.5 MM2 - other bases
4- 4 MM2 - other bases
Cable placement:
Electrical cable type:
W-NC- Single wires in conduit (less conduit)
22 Electrical (G13)
22-9
AREA LIGHT - continued
22-10
STAND Support Type
STAND Support Type with Mast
POLE Support Type
BRAKT and PENDT Support Types
22 Electrical (G13)
Description
Type
Group of anodes in deep well
DEEP
A group of anodes in a deep well with connecting leads to an adjacent ANODE
junction box.
Anode capacity:
Based on five amps per anode.
Anode depth:
Depth should be based on the local soil conditions. The depth is 100
FEET [30 M] plus 7 FEET [2 M] per anode (5 amps per anode).
Well casing symbol:
Default: *NONE*
NONE- No well casing
CASED- Cased well
Individual galvanic anode
GALV
ANODE
An individual galvanic anode for road crossings, etc.
Length per cable run: Default: *40* FEET [*12* M]
Group of anodes in shallow surface bed
SURF
ANODE
A shallow surface anode bed consisting of anodes with underground
leads to an adjacent junction box.
Type of anode:
A- Drilled hole, native backfill
B- Drilled hole, coke breeze backfill
C- Trench, coke breeze backfill
D- Trench, native backfill
Number of anodes per bed: *10*
Spacing:
Anode spacing is the center-to-center distance.
Default: *8* FEET [*2.5* M]
Potential measurement test station
POT TEST
Number of test stations:
Enter number of test stations per location.
Transformer/rectifier
RECTIFIER
480 V/60 HZ [415 V/50 HZ] 3 phase input
D.C. Output: 50 V/50 A or 100 V/100 A
Power pole line must be specified separately.
Anode capacity:
50:50A / 50V
150:150A / 100V
Length per cable run:
22 Electrical (G13)
22-11
Description
Type
Solar panel with storage batteries
Solar panels, adjacent storage batteries, control center, supporting
structure, fencing and cable to a junction box.
SOLAR PANL
Length per cable run: Default: *500* FEET [*150* M]
Emergency light with battery
EMER LIGHT
Provides short-term, local lighting for personnel in case of an electric
power failure. Indoor, general-purpose type includes selection of light
types, 6V battery, battery-recharger, power cable with plug for local
outlet, and mounting bracket.
Light type:
HEPS, HEPR, LEPS, LEPR, STDS, STDR
Number of light bulbs:
*1*, 2
Underground cable duct
CABLE DUCT
Buried depth:
Cable duct width:
Cable duct type:
*TILE*, ENVEL, CONC, PRCST
Lighting panelboard and distribution board
PANEL BRD
Local lighting panelboard or distribution board in substation.
Lighting panel/distr. board size: 8-36 for panelboard and 6-12 for
distribution board.
Transformer size:
transformer for panelboard, 15-75 KVA.
Default: *0*
Lighting panel/distr. board opt.:
P - Local lighting panelboard
D - Distribution board in substation
Default: D (distribution board) for UK and EU country bases and P
(panelboard) for all other country bases.
Panel/distr. board exp. proof opt.:
blank - Based on area/project electrical class and division or zone
EXPR - Explosion proof enclosure
NEXPR - Non-explosion proof enclosure
Default: based on area/project specification for electrical class and
division or zone.
Tracing panelboard for electrical heat tracing
TRACE PANL
Panelboard for electrical heat tracing circuits.
Panelboard size: 12-36
22-12
22 Electrical (G13)
Description
Type
Electrical heat tracing controller - single and multi-point
TRACE CNTR
Provides control and monitoring of electrical heating cable circuits.
Single-circuit, dual-circuit and multi-circuit controllers provide
temperature control and monitors temperature, ground fault level and
controller failure.
Packaged unit is modular-rack design and contains 10 controllers in
one panel
Single/Multi-point Controller
Tracing control points:
Default: *0*, Maximum 20
Relay type:
EMR - Electromechanical relay
SSR - Solid state relay
Default: *EMR*
Communication option:
communication module with 2-wire RS-485 communication.
blank -No RS-485 communication interface required (default)
X -RS-485 communication interface required.
Default: no RS-485 communication interface required.
Enclosure material:
blank - Fiberglass enclosure
SS - Stainless steel enclosure
Default: Fiberglass enclosure with window Packaged Controller and
Panelboard
Tracing control points:
Only 10 control points allowed
Panelboard size: *24*, 30 and 42
Relay type:
EMR - Electromechanical relay
SSR - Solid state relay
Default: *EMR*
22 Electrical (G13)
22-13
Description
Public Address and General Alarm
Equipment cabinets:
Default: 1 cabinet per 150 devices.
Raceway length
Default: 30% of the raceway length.
Raceway width:
Default:
°
IP - 4 inches
° Metric- 100 mm
Raceway type:
°
*L - Ladder tray
°
T - Trough tray
°
C - Trough tray with top cover
°
B - Trough tray with top and bottom cover
° Default: Ladder tray
Cable length per device:
Distance from the cabinet to the field device.
Default: Area level Electrical specifications.
Cable placement:
T - Cable in tray
C- Cable in conduit
B - Buried cable
Default: *T*
Junction boxes:
Default: 1 each per 10 speakers/strobes combined.
Outdoor speakers:
Default: None
Indoor speakers:
Default: None
Outdoor strobes:
Default: None
Indoor strobes:
Default: None
Outdoor handsets:
Default: None
Indoor handsets:
Default: None
Acoustic hoods:
Default: Equal to the number of outside handsets.
Poles:
Default: 1 pole per 2 outdoor speakers and 1 strobes.
22-14
22 Electrical (G13)
Description
Closed Circuit Television
Equipment cabinets:
Default: 1 cabinet per system.
Raceway length
°
IP - 4 inches
°
Metric- 100 mm
Raceway type:
°
*L - Ladder tray
°
T - Trough tray
°
°
°
Default: Ladder tray
Cable placement:
T - Cable in tray
C- Cable in conduit
B - Buried cable
Default: *T*
Junction boxes:
Default: 1 junction box per camera
Cameras:
Default: 0
Monitors:
Default: 1 monitor per 4 cameras.
Poles:
Default: 1 pole per camera
22 Electrical (G13)
22-15
Telephone System
Equipment cabinets:
Raceway length
Raceway width:
Default:
°
IP - 4 inches
° Metric- 100 mm
Raceway type:
°
*L - Ladder tray
°
T - Trough tray
°
°
Cable placement:
T - Cable in tray
C- Cable in conduit
B - Buried cable
Default: *T*
Junction boxes:
Default: 0
Outdoor phones:
Default: 0
Indoor phones:
Default: 0.
Video conference:
Default: 0
22-16
22 Electrical (G13)
Description
Area Network System
Equipment cabinets:
Raceway length
Default: 90% of the total cable length.
Raceway width:
Default:
°
IP - 4 inches
° Metric- 100 mm
Raceway type:
°
*L - Ladder tray
°
T - Trough tray
°
°
Cable placement:
T - Cable in tray
C- Cable in conduit
B - Buried cable
Default: *T*
Plant radios:
Default: 0
Marine radios:
Default: 0
Aviation radios:
Default: 0
Antenna/towers:
Default: 1 if any of the radios is specified.
22 Electrical (G13)
22-17
Description
Access Control System
Equipment cabinets:
Raceway length
Default: 90% of the total cable length.
Raceway width:
Default:
°
IP - 4 inches
° Metric- 100 mm
Raceway type:
°
*L - Ladder tray
°
T - Trough tray
°
°
Cable placement:
T - Cable in tray
C- Cable in conduit
B - Buried cable
Default: *T*
Junction boxes:
Default: 1 per card reader/door operator.
Workstations:
Default: 0
Card readers:
Default: 0
Controllers:
Default: 0
Door/Turnstile Operators:
Default: 0
22-18
22 Electrical (G13)
Description
Intrusion Detection System
Equipment cabinets:
Default: 1 cabinet per project.
Raceway length
Default: 0.
Raceway width:
Default:
°
IP - 4 inches
° Metric- 100 mm
Raceway type:
°
*L - Ladder tray
°
T - Trough tray
°
°
Cable placement:
T - Cable in tray
C- Cable in conduit
B - Buried cable
Default: *B*
Junction boxes:
Default: 1 per pole
Workstations:
Default: 1 per 45 cameras
Detectors:
Default: 0
Cameras:
Default: 0
Monitors:
Default: 4 per work station
Poles:
Default: 1 per camera
22 Electrical (G13)
22-19
Description
Meteorlogical Monitoring System
Equipment cabinets:
Default: 1 cabinet per project.
Raceway length
Default: 90% of the total cable length..
Raceway width:
Default:
°
IP - 4 inches
° Metric- 100 mm
Raceway type:
°
*L - Ladder tray
°
T - Trough tray
°
°
Cable placement:
T - Cable in tray
C- Cable in conduit
B - Buried cable
Default: *T*
Weather Station:
Default: 1 weather station per system.
Structured Cabling for Buildings
Fiber optic cable length:
Default: 0
Fiber optic cable terminations:
Default: 0
CAT5 cable length:
Default: 0
CAT5 cable terminations:
Default: 0
22-20
22 Electrical (G13)
Substation Electrical Plant Bulks
Substation electrical plant bulks include transformers, breakers, transmission
lines and bus.
Description
Type
Bus duct
BUS DUCT
Continuous Current:
Max: 3,000 A
Length default elbows:
1 per 20 FEET [6 M]
Rated voltage:
*600*- 600 V at 60 HZ.
5000- 5000 V at 60 HZ.
15000- 15000 V at 60 HZ.
600-600 V at 50 HZ.
3300- 3300 V at 50 HZ.
11000- 11000 V at 50 HZ.
Number of elbows:
Default: 1 per 20 FEET [6 M]
Termination type:
*NONE*
NONE- No terminations
TRANS- Transformer termination only
SWGR- Switchgear termination only
BOTH- Switchgear and transformer termination
Electrical transformer: 1 or 2 tap
TRANSFORM
Rated load:
Range: 10 - 100,000 KVA
Transformer type:
*DRY*, OIL
Oil circuit breakers
OIL C BRKR
Rated voltage:
Range: 11 - 400 KV
Continuous Current:
Max: 5 KA [5000 A]
Disconnect switches
DISCNCT
SW
Rated voltage:
Range: 4 - 230 KV
Overhead transmission line: cables, structures, guys, grounds
POLE LINE
See “Schematic of Project Site Transmission Line Hook-Up”
Wire size: See “Wire Sizes” later in this chapter.
Steel for substation structure
22 Electrical (G13)
SUBSTN STL
22-21
Electrical Plant Bulks - Substation Electrical Plant Bulks - continued
Description
Type
Circuit breakers: main, feeder, tie-breakers
BREAKER
Continuous current: Max: 3,000 A
Rated voltage: through the maximum HV.
Interrupt capacity:
LV: 25 - 70 MVA; MV: 250 - 350 MVA;
HV: 500 - 1000 MVA
Circuit breaker type:
*AIR*, SF6, VAC
Breaker location:
Default: *FEED*
FEED- Feeder breaker
MAIN- Main breaker
TIE- Tie breaker
Motor control center
MCC
Floor-mounted assemblies of one or more enclosed vertical sections
principally containing combination motor control/overload protection
units (starters).
Voltage range:
LV: 0.5 - 400 HP [0.33 - 300 KW]
MV: 200 - 1000 HP [150 - 3000 KW]
MCC type: *S*, I
The MCCs described are intended for inside use (i.e., are not for
outside use local to the motors). They are unaffected by the electrical
class/zone specifications covered later in this chapter. The “intelligent”
MCCs provide more sophisticated electronic control and communication
to a control center. The cost for upstream items are not included (e.g.,
supply bus duct/cable; switchgear [feeder breakers, metering,
substation disconnect switch, main breaker]; and substation
transformer).
22-22
22 Electrical (G13)
Electrical Plant Bulks - Substation Electrical Plant Bulks - continued
Description
Type
Switch board
SWITCH
BRD
Continuous current:
600-4000 A
Rated voltage:
3-13.8 KV
Switchboard type:
VCB- Vacuum circuit breaker
VCS1- Vacuum circuit breaker 1 unit stack
Short circuit current:
*25*-40 KA
AC/DC Transformer
AC DC TRAN
Rating:
30-300 ampere-hours
Package transformer with panel
PKG TRANSF
Rated load:
50-800 KVA
Transformer primary voltage:
3000-13800 V
Number of phases:
1 or *3*
Emergency diesel generator
EM PWR SET
Power output:
5 - 1500 KVA
Uninterrupted power supply
UPS
Rated load:
2-300 KVA.
UPS type:
*STD*, MULT.
Power factor connection capacitor
PF CORRECT
Capacity:
24-2500 KVAR.
Voltage:
LV (low voltage), MV (medium voltage).
22 Electrical (G13)
22-23
Schematic of Transmission Line
22-24
22 Electrical (G13)
Substation
Schematics
22 Electrical (G13)
22-25
Electrical & Control Hook-Ups
for Electric Motors
Motor Control Center
The MCCs described are intended for inside use (i.e., are not for outside use
local to the motors). They are unaffected by the electrical class/zone
specifications covered later in this chapter. The “intelligent” MCCs provide
more sophisticated electronic control and communication to a control center.
The cost for upstream items are not included (e.g., supply bus duct/cable;
switchgear [feeder breakers, metering, substation disconnect switch, main
breaker]; and substation transformer).
There are two types of MCC available in the system (see diagram below) —
those with electric motors driven at low voltage (MCC-LV: COA 733) and those
with electric motors driven at mid-voltage (MCC-MV: COA 744). Both types of
MCCs include starters.
22-26
22 Electrical (G13)
The MCC-LV is a 12-NEMA space cabinet; the MCC-MV is a 3-NEMA space
cabinet. This item is specified by the HP [KW] rating of the motor being
supplied- this permits the system to select an appropriately sized starter (see
table below). The resulting cost includes both the cost of the starter as well as
the cost for the fraction of the cabinet occupied by the starter.
For example, assume that you specify a 20 HP [15 KW] rating- the reported
cost for the MCC-LV is the cost of the 3-space starter plus three-twelfths of the
whole cost of the cabinet. Specifying four such items would, in effect,
completely account for the cost of one 12-space MCC-LV containing four 3space starters.
Motor Size
HP
Voltage
KW
Starter Size
(spaces)
< = 10 HP
< = 7.5 KW
LV
2
20 - 50 HP
15 - 37.4 KW
LV
3
60 - 100 HP
44.7 - 75 KW
LV
5
125 - 200 HP
95 - 150 KW
LV
6
250 - 400 HP
180 - 300 KW
LV
9
200 - 400 HP
150 - 300 KW
MV
3
450 - 4, 000 HP
335 - 3, 1150 KW
MV
3
22 Electrical (G13)
22-27
Medium Voltage (MV) and Low Voltage (LV) Motor Control Centers (MCC):
Note: When you select the high voltage as 34.5kV (US, ME) / 33kV (UK, EU,
JP) in the general electrical specifications, then all the high voltage motors in
the project should be powered at the corresponding medium voltage, because
all the motors in the system are at the most rated for 15kV (US, ME) / 11kV
(UK, EU, JP) only.
22-28
22 Electrical (G13)
Power Distribution Network
22 Electrical (G13)
22-29
Wire Sizes
Wires sizes must be chosen from one of the following tables.
US and ME Country Bases or AWG Wire Units
Wire Size Symbols (guage sizes)
-------------- LV ------------------------------------------------ MV --------------------------------------- HV -------------------------14
8
2
250
1000
12
6
1
350
1250
10
4
1/0
500
1500
2/0
750
1750
4/0
-------- (AWG) ---
2000
----- (KCMIL) -----
UK, EU, and JP Country Bases
UK, EU, and JP Country Base or MM2 Wire
Units
Wire Size Symbols (MM2 sizes)
-------------- LV ----------------------------------------------- MV --------------------------------------- HV -------------------------1.5
10
35
185
500
2.5
16
50
240
630
4
25
70
300
800
95
400
1000
6
120
150
---------------------- (MM2) -------------------------
22-30
22 Electrical (G13)
Electrical Class/Division
National Electrical Code (NEC)
Electrical Class and Division Symbol
Single Core
or MultiCore Wire
In Tray
Single Core Armoror Multied
Core Wire
Cable
In Conduit
Flammable Gasses or Vapors
11
Highly inflammable gasses and/or
vapors. Hazardous atmospheres exist
continuously or can occur during course
of normal operation for this area.
Explosion-proof.
-
+
-
*12*
Flammable liquids are handled and
processed in this area, but they are
normally confined (Default).
-
+
-
Combustible Dust
21
Dust is suspended in air continuously or
during course of normal operation for
this area.
-
+
-
22
Suspension of dust is not likely in this
area, but deposits of dust can occur and
be ignited by sparks.
-
+
-
Combustible Fibers or Particles
31
Locations exist in this area in which
ignitable fibers are handled or used.
-
+
-
32
Locations exist in this area in which
easily ignitable fibers are stored.
-
+
-
-
+
-
General Purpose
GP
Non-hazardous conditions.
+ Indicates cable type consistent with electrical class and division.
- Indicates cable type inconsistent with electrical class and division.
22 Electrical (G13)
22-31
International Electrical Code
(IEC)
Electrical Zone
Single Core
or MultiCore Wire
In Tray
Single Core Armore
or Multid Cable
Core Wire
In Conduit
Flammable Gasses or Vapors
0
Explosive gas/air mixture is constantly
present or is present for long periods.
_
+
+
1
Explosive gas/air mixture is likely to
occur under normal operating
conditions.
_
+
+
2
Explosive gas/air mixture is unlikely to
occur under normal operating
conditions. If it does occur, it will be of
short duration.
+
+
+
GP
Non-hazardous conditions
+
+
+
+ Indicates cable type consistent with electrical class and division.
- Indicates cable type inconsistent with electrical class and division.
22-32
22 Electrical (G13)
22 Electrical (G13)
22-33
22-34
22 Electrical (G13)
23 Insulation and
Fireproofing
(G8)
Insulation Plant Bulks
Insulation Materials
Fireproofing Materials
Insulation Schedules - System Default Tables
Hot Insulation - Light Schedule (L): I-P Units
Hot Insulation - Medium Schedule (M): I-P Units
Hot Insulation - Heavy Schedule (H): I-P Units
Cold Insulation - 1 to 5.5 INCH Thicknesses
Cold Insulation - 6 to 10 INCH Thicknesses
Hot Insulation - Light Schedule (L): Metric Units
Hot Insulation - Medium Schedule (M): Metric Units
Hot Insulation - Heavy Schedule (H): Metric Units
Cold Insulation - 25 to 165 MM Thicknesses
Customizing Insulation Specifications
23 Insulation and Fireproofing (G8)
23-1
Insulation Plant Bulks
Description
Type
Fireproofing for existing surface area
FIREP AREA
General fireproofing specified as a surface area to be covered.
Material:
*MAGN*- Magnesium oxychloride
CONC- Concrete
Fire resistance rating:
Range: 2 - 4
The thickness changes according to the Firepr. Rating-Hours:
For magnesium oxychlor fireproofing:
2 hours- 9/16 INCHES [14 MM]
4 hours- 1 3/16 INCHES [30 MM]
For concrete fireproofing:
< 3 hours- 2 1/2 INCHES [64 MM]
3 hours- 3 INCHES [76 MM]
Fireproofing for existing structural steel
FIREP SSTL
Material:
*MAGN*- Magnesium oxychloride
CONC- Concrete
Range: 2 - 4
The thickness changes according to the Firepr. Rating-Hours:
For magnesium oxychlor fireproofing:
For concrete fireproofing:
< 3 hours- 2 1/2 INCHES [64 MM]
3 hours- 3 INCHES [76 MM]
General area insulation.
INSUL AREA
Insulation for existing surface area: hot, cold insulation.
General insulation specified as surface area to be covered.
Material:
*CASIL*- Calcium silicate
MWOOL- Mineral wool
FOAM- Foam glass
23-2
Insulation Plant Bulks - continued
Description
Type
INSUL AREA - continued
Temperature:
Temperature for FOAM only, provides cold (default) or hot insulation.
Jacket type:
AL- Aluminum jacket
SS- Stainless steel jacket
CS- Painted carbon steel jacket
Insulation for existing piping: hot, cold
INSUL PIPE
Material:
*CASIL*- Calcium silicate
MWOOL- Mineral wool
FOAM- Foam glass
Temperature:
Temperature for FOAM only, provides cold (default) or hot
insulation.
Jacket type:
AL- Aluminum jacket
SS- Stainless steel jacket
CS- Painted carbon steel jacket
Packed bulk insulation
INSUL BULK
Material:
*PERL*- Perlite bulk insulation
VERM- Vermiculite bulk insulation
RWOOL- Rockwool bulk insulation
Cable Tray fireproofing
FIREP TRAY
Range: 2 - 4
23-3
Insulation Materials
Note that insulation is applied to equipment and piping as specified by the
user. The default, if no choice is specified, is foam glass insulation for
temperatures 50 DEG F [10 DEG C] or lower; calcium silicate insulation is
applied for higher temperatures.
Description
Maximum Thickness Temperature Range
DEG C
Insulation
Symbol
Calcium silicate
12.0
300.0
51 to 1500
11 to 815
CASIL
Mineral wool
12.0
300.0
51 to 1200
11 to 645
MWOOL
INCHES
MM
DEG F
Foam glass
12.0
300.0
-450 to 665
-265 to 350
FOAM
Ceramic wool
12.0
300.0
51 to 1500
11 to 815
CWOOL
Polyisocyanurate/
Plyurethane
12.0
300.0
-450 to 250
-265 to 120
PURF
Fireproofing Materials
Note that fireproofing is not applied to equipment (skirts/legs, support steel,
ladders) and various steel structures by default. The user must specify at least
the rating (thickness to use) in project level specifications and separately
specify the thickness of fireproofing on each component. The default material
is magnesium oxychloride.
Description
Rating
(hours)
Magnesium
oxychloride
0
0
0
2
9----16
14
3
4
1 -----16
22
4
3
1 -----16
30
0
0
0
2
1
1 --2
64
3
3
76
4
1
1 --2
89
1
3--4
19
2
1
25
3
1
1 --4
32
4
1
1 --2
38
Concrete
Pyrocrete
23-4
Thickness
INCHES
MM
Fireproofing
Symbol
MAGN
CONC
PYRO
Insulation Schedules - System
Default Tables
Hot Insulation - Light Schedule (L): I-P
Units
Nominal
Pipe
Diameter
Insulation Thickness - INCHES
1
1.5
2
2.5
Inches
3
3.5
4
4.5
5
5.5
6
Temperatures - Degrees F
0.75
268
460
790
1170
1774
2000
1
150
454
780
1161
1586
1989
2000
1.5
150
411
581
1049
1410
1801
2000
2
150
305
558
869
1181
1640
1836 2000
2.5
150
253
500
848
1148
1613
1778 2000
3
150
236
441
679
949
1232
1558 1887
2000
4
150
216
389
598
848
1142
1406 1737
2000
6
150
164
306
493
709
950
1237 1520
1810 2000
8
150
162
295
475
693
914
1133 1385
1700 2000
10
150
162
90
445
628
823
1008 1268
1556 1922 2000
12
150
162
275
414
585
776
960
1236
1492 1846 2000
14
150
256
392
557
748
952
1177
1419 1775 2000
16
150
250
383
542
725
928
1147
1384 1708 2000
18
150
244
373
529
706
911
1126
1364 1646 2000
20
150
238
365
517
696
894
1109
1361 1588 2000
22
150
238
365
517
696
894
1109
1346 1534 2000
24
150
226
349
501
676
874
1090
1329 1483 2000
26
150
226
349
501
676
874
1090
1329 1436 2000
28
150
225
340
501
622
850
1032
1250 1392 1546
30
150
225
340
501
622
850
1032
1250 1392 1546
36
150
225
340
501
622
850
1032
1250 1392 2000
Notes: Light insulation schedule is typical for average low ambient
temperatures above 40 degrees F. Insulation for hot service would be applied
to designated surfaces of 51 degrees F or hotter.
To use the table:
1
Locate pipe diameter in left column.
2
Read across line to locate the operating temperature (degrees F).
3
Read required insulation thickness at top of column. For intermediate
temperatures, use next larger insulation thickness.
4
For large diameter pipe, equipment, or other large flat surfaces, use
thicknesses in the last line in the table.
23-5
Hot Insulation - Medium Schedule (M): I-P
Units
Nominal
Pipe
Diameter
1
1.5
2
2.5
Inches
3
3.5
4
4.5
5
5.5
6
6.5
0.75
209 305 520
758
1185 1457
1659 1911 2000
1
150 302 498
732
1051 1399
1588 1825 2000
1.5
150 231 389
665
944
1279
1557 1786 2000
2
150 228 369
565
811
1173
1444 1747 2000
2.5
150 202 332
544
777
1137
1433 1710 1941 2000
3
150 193 296
450
660
925
1240 1617 1882 2000
4
150 183 270
392
579
838
1112 1475 1801 2000
6
150 157 228
322
479
705
977
1304 1630 1953 2000
8
150 156 223
313
444
648
881
1177 1505 1869 2000
10
150 156 220
298
389
571
774
1067 1366 1788 2000
12
150 156 213
282
368
517
710
1001 1277 1716 1922 2000
14
150 203
271
354
474
670
926
1184 1653 1846 2000
16
150 200
267
346
438
625
860
1115 1587 1775 2000
18
150 197
262
340
428
585
819
1056 1530 1708 2000
20
150 194
258
334
423
548
778
1013 1476 1646 2000
22
150 194
258
334
423
522
739
963
1427 1588 2000
24
150 188
250
326
413
512
701
916
1380 1534 1797
26
150 188
250
326
413
512
676
881
1337 1483 1707
28
150 188
245
326
386
500
613
809
1297 1436 1622
30
150 188
245
326
386
500
591
778
1251 1392 1546
36
150 188
245
326
386
500
591
778
1251 1392 1546
Note: Notes: Medium insulation schedule is typical for average low ambient
temperatures from 20 degrees F to 40 degrees F. Insulation for hot service
would be applied to designated surfaces of 51 degrees F or hotter.
To use the table:
23-6
1
2
3
4
Hot Insulation - Heavy Schedule (H): I-P
Units
Nominal
Pipe
Diameter
1.5
2
2.5
3
Inches
3.5
4
4.5
5
5.5
6
7
8
0.75
150
250 345
596
915
1317
1821 2000
1
150
215 302
516
808
1175
1650 2000
1.5
150
197 280
478
756
1113
1571 2000
2
150
179 260
440
705
1052
1493 2000
2.5
150
164 240
405
661
987
1420 1882 2000
3
150 220
370
617
922
1347 1764 2000
4
150 185
309
533
818
1212 1601 2000
6
150
248
459
717
1088 1450 1905 2000
8
150
195
382
629
969
1310 1738 2000
10
150
318
539
865
1176 1576 2000
12
150
258
460
766
1062 1432 1844 2000
14
150
199
388
675
949
1305 1692 2000
16
150
321
572
845
1174 1550 2000
18
150
259
512
750
1059 1416 2000
20
150
202
446
661
952
1292 2000
22
150
368
579
853
1176 1794 2000
24
150
302
503
760
1068 1594 2000
26
150
261
432
674
966
28
150
1413 2000
194
367
594
872
1243 1796
30
150
306
502
784
1092 1585
36
150
306
502
784
1092 1585
Note: Heavy insulation schedule is typical for average low ambient
temperatures less than 20 degrees F. Insulation for hot service would be
applied to designated surfaces of 51 degrees F or hotter.
To use the table:
1
2
3
4
23-7
Cold Insulation - 1 to 5.5 INCH Thicknesses
Nominal Insulation Thickness - INCHES
Pipe
Diameter 1
1.5
2
2.5
3
3.5
Inches
4
4.5
5
5.5
0.75
50
25
-10
-25
-70
-135
-225 -225 -300 -459
1
50
25
-10
-25
-70
-130
-180 -225 -300 -459
1.5
50
30
15
-15
-45
-100
-120 -185 -230 -290
2
50
30
15
-15
-45
-90
-120 -185 -225 -290
2.5
50
30
15
-10
-35
-60
-105 -135 -175 -235
3
50
30
15
-10
-35
-60
-105 -135 -175 -235
4
50
30
20
0
-30
-55
-85
-135 -160 -235
6
50
45
25
0
-25
-45
-70
-105 -125 -160
8
50
45
25
0
-15
-35
-60
-85
-115 -145
10
50
45
30
10
-10
-25
-50
-70
-105 -125
12
50
45
30
15
-5
-25
-45
-65
-105 -125
14
50
45
30
15
0
-25
-40
-55
-80
-105
16
50
45
30
20
0
-25
-35
-55
-75
-105
18
50
45
30
20
0
-25
-35
-50
-70
-105
20
50
30
20
0
-25
-35
-45
-65
-95
22
50
30
20
0
-25
-35
-45
-65
-95
24
50
30
20
0
-25
-35
-45
-65
-95
26
50
30
20
5
-10
-25
-40
-60
-75
28
50
30
20
5
-10
-25
-40
-60
-75
30
50
30
20
5
-10
-25
-40
-60
-75
36
50
30
20
10
-5
-25
-40
-55
-75
Note: The hot insulation schedule adjustment (L,M, or H) does not apply to
cold insulation. Insulation for cold service would be applied to designated
surfaces of 50 degrees F or colder.
For cold insulation, joints are caulked and a vapor barrier is applied.
To use the table:
23-8
1
2
3
4
Cold Insulation - 6 to 10 INCH Thicknesses
Nominal
Pipe
Diameter
6
6.5
Inches
7
7.5
8
8.5
9
9.5
10
0.75
1
1.5
-345 -459
2
-340 -459
2.5
-290 -340 -459
3
-290 -340 -459
4
-265 -300 -459
6
-205 -240 -290 -325
8
-175 -215 -225 -295
-325
-459
10
-150 -185 -225 -235
-300
-459
12
-140 -170 -205 -230
-285
-325
-459
14
-130 -160 -190 -225
-265
-305
-352
-459
16
-125 -150 -180 -210
-250
-285
-310
-459
18
-115 -145 -175 -200
-235
-275
-295
-325 -459
20
-110 -135 -165 -190
-225
-260
-290
-315 -459
22
-105 -130 -155 -180
-205
-240
-270
-300 -459
24
-105 -130 -155 -180
-205
-240
-270
-300 -459
26
-105 -120 -140 -170
-190
-225
-250
-285 -305
28
-105 -120 -140 -170
-190
-225
-250
-285 -305
30
-105 -120 -140 -170
-190
-225
-250
-285 -305
36
-105 -115 -135 -160
-175
-215
-240
-280 -300
-459
Note: The hot insulation schedule adjustment (L,M, or H) does not apply to
surfaces of 50 degrees F or colder.
To use the table:
1
2
3
4
23-9
Hot Insulation - Light Schedule (L): Metric
Units
Nominal
Pipe
Diameter
Insulation Thickness - MM
25
38
50
63
MM
75
88
100
113 125
138
150
Temperatures - Degrees C
20
131
237 421
632
967
1093
25
65
234 415
627
863
1087
1093
40
65
210 305
565
765
982
1093
50
65
151 292
465
638
893
1002 1093
65
65
122 260
453
620
878
970
1093
80
65
113 227
359
509
666
847
1030 1093
100
65
102 198
314
453
616
763
947
1093
150
65
73
152
256
376
510
669
826
987
1093
200
65
72
146
246
367
490
611
751
926
1093
250
65
72
143
229
331
439
542
686
846
1050 1093
300
65
72
135
212
307
413
515
668
811
1007 1093
350
65
124
200
291
397
511
636
770
968
1093
400
65
121
195
283
385
497
619
751
931
1093
450
65
117
189
276
374
488
607
740
896
1093
500
65
114
185
269
368
478
598
738
864
1093
550
65
114
185
269
368
478
598
730
834
980
600
65
107
176
260
357
467
587
720
806
930
650
65
107
176
260
357
467
587
720
780
883
700
65
107
171
260
327
454
555
676
755
841
750
65
107
171
260
327
454
555
676
755
841
900
65
107
171
260
327
454
555
676
755
841
Note: Light insulation schedule is typical for average low ambient
temperatures from above 4 degrees C. Insulation for hot service would be
applied to designated surfaces of 11 degrees C or hotter.
To use the table:
23-10
1
2
Read across line to locate the operating temperature (degrees C).
3
4
Hot Insulation - Medium Schedule (M):
Metric Units
Nominal
Pipe
Diameter
25
38
50
63
MM
75
88
100 113
125
138
150 163
20
98
151 271
403
640
791
903
1043 1093
25
65
150 258
388
566
759
864
996
1093
40
65
110 198
351
506
692
847
974
1093
50
65
108 187
296
432
633
784
952
1093
65
65
94
166
284
413
613
778
932
1060 1093
80
65
89
146
232
348
496
671
880
1027 1093
100
65
83
132
200
303
447
600
801
982
1093
150
65
69
108
161
248
373
525
706
887
1067 1093
200
65
68
106
156
228
342
471
636
818
1020 1093
250
65
68
104
147
198
299
412
575
741
975
1093
300
65
68
100
138
186
269
376
538
691
935
1050 1093
350
65
95
132
178
245
354
496
640
900
1007 1093
400
65
93
130
174
225
329
460
601
863
968
1093
450
65
91
127
171
220
307
437
568
832
931
1093
500
65
90
125
167
217
286
414
545
802
896
1093
550
65
90
125
167
217
272
392
517
775
864
1093
600
65
86
121
163
211
266
371
491
748
834
980
650
65
86
121
163
211
266
357
471
725
806
930
700
65
86
118
163
196
260
322
431
702
780
883
750
65
86
118
163
196
260
310
414
677
755
841
900
65
86
118
163
196
260
310
414
677
755
841
Note: Medium insulation schedule is typical for average low ambient
temperatures from -6 degrees C to 4 degrees C. Insulation for hot service
would be applied to designated surfaces of 11 degrees C or hotter.
To use the table:
1
2
3
4
23-11
Hot Insulation - Heavy Schedule (H): Metric
Units
Nominal
Pipe
Diameter
38
50
63
75
MM
88
100
113 125
138
150
175
200
20
65
121 173
313
490
713
993
1093
25
65
101 150
268
431
635
898
1093
40
65
91
137
247
402
600
855
1093
50
65
81
126
226
373
566
811
1093
65
65
73
115
207
349
530
771
1027 1093
80
65
104
187
325
494
730
962
1093
100
65
85
153
278
436
655
871
1093
150
65
120
237
380
586
787
1040 1093
200
65
90
194
331
520
710
947
250
65
158
281
462
635
857
1093
300
65
125
237
407
572
777
350
65
1093
1006 1093
92
197
357
509
707
922
1093
400
65
160
300
451
634
843
1093
450
65
126
266
398
570
768
1093
500
65
94
230
349
511
700
1093
550
65
186
303
456
635
978
1093
600
65
150
261
404
575
867
1093
650
65
27
222
356
518
767
1093
700
65
90
186
312
466
672
980
750
65
152
261
417
588
862
900
65
152
261
417
588
862
Note: Heavy insulation schedule is typical for average low ambient
temperatures less than -6 degrees C. Insulation for hot service would be
applied to designated surfaces of 11 degrees C or hotter.
To use the table:
23-12
1
2
3
4
thicknesses in the last line in the table
Nominal
Pipe
Diameter
25
38
50
63
MM
75
88
100
113 125
138
150
163
20
10
-3
-23
-31
-56
-92
-142 -159 -184 -273
25
10
-3
-23
-31
-56
-90
-117 -159 -184 -273
40
10
-1
-9
-26
-42
-73
-84
-120 -145 -178 -209 -273
50
10
-1
-9
-26
-42
-67
-84
-120 -142 -178 -206 -273
65
10
-1
-9
-23
-37
-51
-76
-92
-114 -148 -178 -206
80
10
-1
-9
-23
-37
-51
-76
-92
-114 -148 -178 -206
100
10
-1
-6
-17
-34
-48
-64
-92
-106 -131 -164 -184
150
10
7
-3
-17
-31
-42
-56
-76
-87
-106 -131 -151
200
10
7
-3
-17
-26
-37
-51
-64
-81
-98
-114 -137
250
10
7
-1
-12
-23
-31
-45
-56
-76
-87
-101 -120
300
10
7
-1
-9
-20
-31
-42
-53
-76
-87
-95
-112
350
10
7
-1
-9
-17
-31
-39
-48
-62
-76
-89
-106
400
10
7
-1
-6
-17
-31
-37
-48
-59
-76
-87
-101
450
10
7
-1
-6
-17
-31
-37
-45
-56
-76
-81
-98
500
10
-1
-6
-17
-31
-37
-42
-53
-70
-78
-92
550
10
-1
-6
-17
-31
-37
-42
-53
-70
-76
-89
600
10
-1
-6
-17
-31
-37
-42
-53
-70
-76
-89
650
10
-1
-6
-14
-23
-31
-39
-51
-59
-76
-84
700
10
-1
-6
-14
-23
-31
-39
-51
-59
-76
-84
750
10
-1
-6
-14
-23
-31
-39
-51
-59
-76
-84
900
10
-1
-6
-12
-20
-31
-39
-48
-59
-76
-81
Note: The hot insulation schedule adjustment (L, M, or H) does not apply to
surfaces of 10 degrees C or colder.
To use the table:
1
2
3
4
23-13
Cold Insulation - 178 to 254 Thicknesses
Nominal
Pipe
Diameter 175 188 200 213 225
238
MM
250
20
25
40
50
65
-273
80
-273
100
-273
150
-178 -198 -273
200
-159 -181 -198 -273
250
-142 -148 -184 -273
300
-131 -145 -176 -198 -273
350
-123 -142 -164 -187 -198
-273
400
-117 -134 -156 -176 -189
-273
450
-114 -128 -148 -170 -181
-198
-273
500
-109 -123 -142 -162 -178
-192
-273
550
-103 -117 -131 -151 -167
-184
-273
600
-103 -117 -131 -151 -167
-184
-273
650
-95
-112 -123 -142 -156
-176
-187
700
-95
-112 -123 -142 -156
-176
-187
750
-95
-112 -123 -142 -156
-176
-187
900
-92
-106 -114 -137 -151
-173
-184
Note: The hot insulation schedule adjustment (L, M, or H) does not apply to
surfaces of 10 degrees C or colder.
To use the table:
23-14
1
2
3
4
Customizing Insulation
Specifications
In order to assign an appropriate insulation thickness to a piece of equipment
or section of pipe (if thickness is not specified by the user), the system refers
to tables that relate thickness to temperature and pipe diameter. External
versions of these tables are available for customization in an ASCII format file.
This file also includes a table that lets you define how much insulation is
allocated for valves and fillings.
Template Insulation Specification Files
There are three template files (IP units, Metric units, and blank) available in
one of the following locations:
Aspen Capital Cost Estimator or Aspen In-Plant Cost Estimator:
C:\Documents and Settings\All Users\Documents\AspenTech\Shared
Economic Evaluation V8.0\Insulation
The files are named INSSPC_IP.DAT, INSSPC_METRIC.DAT, and
INSSPC_BLANK.DAT. The files contain identical tables, but the default
temperature and equivalent length parameters (alterable fields) are either in
IP units, Metric units, or are absent. These files are inactive; the system refers
to internal representations of the insulation tables during a project estimate if
there are no customized copies of the insulation specs file in the Administrator
or project directories.
You can copy whichever file is the most convenient as a starting point for your
customized insulation specs file(s). In Aspen Capital Cost Estimator and Aspen
In-Plant Cost Estimator (while no projects are open), view the Libraries view
tab on the Palette. In the Customer External Files folder, open the
Insulation Thickness and Rules subfolder. Right-click on the template of
your choice and click Duplicate. Rename the file. It will be the starting point
for your custom insulation specs file. In other products, you must manually
copy and rename the file.
Customizing the Insulation Specs File
You can edit the newly created file by using any ASCII text editor. The editor
must not introduce non-printing characters other than a space or CR/LF, that
is, no tabs are allowed. The file format is shown on the following page.
23-15
Overall Units
Section
Diameter Units
Section
The picture above shows the top of the file and the first insulation thickness
table. Lines which contain comments start with a “#”. Lines which are read in
by the system during a project run begin with a “l”. YOu must be sure to avoid
shifting any of the vertical pipe sysboles “l” while altering the fields.
The following are the only fields that may be altered:
•
23-16
Unit of Measurement option fields at the top of the file
•
Temperature values within Tables 1 thru 4
•
Maximum diameter and A, B, C parameter values in Table 5
Unit of Measurement Basis Options
The first choice you must make when customizing an insulation specs table is
the overall unit of measurement basis. The available options are “IP” or
“METRIC”. If you choice IP units by entering “IP” into the space provided, the
temperature values in Tables 1 thru 4 will be read by the system as degrees
Fahrenheit. With and IP basis the parameters in Table 5 will be used to
calculate equivalent insulation in feet of pipe. Conversely, if you enter
“METRIC” in the units field provided, the temperatures will be read as degrees
Centigrade, and the values in Table 5 will be used to calculate equivalent
meters of pipe insulation.
You must also select a unit of measurement basis for pipe diameter. The
available options are “INCH” or “MM”. This choice does not affect Tables 1
through 4. It determines whether the maximum pipe diameters in Table 5 are
in Inches or Millimeters. The option also determines the equivalent length
equations (formed from the A, B, C parameters you provide) are calculated
using pipe diameters in Inches or Millimeters.
Customizing the Insulation Thickness Tables
There are four thickness tables in the file - three for hot insulation and one for
cold. Tables 1, 2, and 3 correspond to the Light, Medium, and Heavy schedules
from which you may choose in the Project Design Basis menu. (For example, if
you select Heavy schedule insulation when defining your project, the system
will refer to Table 3 when generating a cost estimate). Table 4 is for cold
insulation.
The tables are arranged with pipe diameter along the left hand side and
insulation thickness along the top. For a given pipe diameter (table row), each
temperature value represents the maximum temperature for which the
corresponding thickness will be used. The last row of each table (36 inch/900
MM. row) is used for both 36 inch diameter pipe and equipment insulation.
Note: You may only adjust the temperature cells in the insulation thickness
tables, not the pipe diameters or insulation thickness.
You do not have to fill Tables 1 through 4 out completely. If you leave a
temperature cell blank, but there are values given somewhere to the left and
right, or above and below, the system will interpolate linearly between the
given values to fill the blanks. (These values will be maintained internally; the
system will not fill the blank values in the external data file). Interpolation is
not possible for outer blanks that have no surrounding given values; these
spaces are filled by copying the last given value over to fill the remainder of
the table.
To avoid confusion, it is recommended that you fill out all four insulation
thickness tables according to your insulating practices even if you do not
intend on using all three schedules. If a table is left completely blank the
system will refer to the internal default tables for an estimate requiring that
schedule.
23-17
Customizing the Valve and Fitting Insulation Table
Table 5 (the valve and fitting insulation table) is shown below.
The table lets you determine how much additional insulation is allotted for
valves and fittings. Any parameters you provide for valves will apply to all
valves in the project (all valves are considered equal when calculated
insulation requirements). Likewise, the fittings correlations will be applied to
all fittings in the project (all valves are considered equal when calculated
insulation requirements). Likewise, the fittings correlations will be applied to
all fittings in the project. You can account for insulation differently for varying
pipe diameters by defining three size categories (Small, Medium, and Large).
Each range is defined by the maximum diameters you place in the fields
provided. For example, in the above picture the Medium correlations would be
used to calculate the insulation required for any valve or fitting on a section of
pipe with diameter larger than 4 inches but smaller than (and including) 12
inches.
Table 5 is designed so you can make your insulation correlation simple or
complex. The parameters A, B and C are used in the following equation to
calculate the length of pipe which would have to be insulated to account for
one valve or one fitting.
Equivalent Pipe Length = A + B * (Pipe Diameter)c
Any of the three parameters may be set to zero to simplify the correlation. For
example, according to the picture of Table 5 above, each fitting on a section of
23-18
2-inch diameter pipe would increase the total insulation length by 4 feet. (B
and C are zero - correlation has no dependence on pipe diameter).
Enabling the Insulation Specfication File
There are two options for enabling customized insulation specs files: You can
place a copy in the system administrator directory (as the default for all
projects), or you can copy a customized file into the directory of a specific
project. When generating a cost estimate, the system will use the
specifications in the current project directory if an insulation specs file resides
there. Otherwise, the copy in the administrator directory will be used. (The
administrator copy is therefore the system default - it will be referred to for
any project that does not have its own insulation specs file).
To activate your customized file for use in a specific project in Aspen Capital
Cost Estimator or Aspen In-Plant Cost Estimator, right-click the Insulation
Thickness option in the Basis for Capital Cost/Customer External Files
directory on the Project Basis Tab. Click the desired file on the menu of
choices; then click OK. The file is copied into the directory for the currently
open project.
In all other cases, the file must be copied and renamed manually to the
appropriate folder. These directory locations are described below:
Administrator Directory (for use as system default):
Aspen Capital Cost Estimator, Aspen In-Plant Cost Estimator: C:/Aspen
Tech/Aspen Icarus xxx/Data/PIDS
Project Directory (activation for a specific project only):
Aspen Capital Cost Estimator, Aspen In-Plant Cost Estimator: Right-click/
Click desired file as described above
In order to enable a customized file in either of the above locations, you
must name the file INSSPC.DAT.
23-19
23-20
24 Paint
(G6)
Introduction to Paint
Paint Plant Bulks
How Icarus Systems Paint Equipment
24 Paint (G6)
24-1
Introduction to Paint
Icarus systems can calculate default paint areas for piping, equipment and
steelwork. The default paint is provided for all piping, but is only provided on
equipment and steelwork if specifically requested.
Paint is provided typically for carbon steel materials only, but can be obtained
for any material if specifically requested.
Paint areas and number of coats can be modified or added for any item.
Icarus systems do not provide different grades of paint; however, costs can be
adjusted appropriately by code of account material indexing.
Paint Plant Bulks
24-2
Description
Type
Paint for existing surface: printer, final coats
PAINT AREA
Paint for existing piping: primer; final coats
PAINT PIPE
Paint for existing structural steel: primer, final coats
PAINT SSTL
24 Paint (G6)
How Icarus Systems Paint
Equipment
24 Paint (G6)
24-3
Legend:
1. HE: HEATER ELC, HEATER STM, ONE SCREW, SUC HEATER, TWO SCREW
2. HO: HAND NT, 1 SP;EED, 5 SPEED
3. Also: AT: COND CELL. FLOAT CELL & SE: WATER CYCL.
Not affected by paint specification for shop fabricated equipment
4. Method determined by specification for paint “Application Method”:
S (spray) or B (brush)
5. Method determined by specification for paint “Application Method”:
S (sandblasting) or B (wire brush)
6. Surface area is calculated by mode; you must enter the number of primer
and/or final coats.
24-4
24 Paint (G6)
25 Site Development
(G6)
Introduction to Site Development
Demolition
Drainage
Earthwork
General
Excavation
Fencing
Landscaping
Roads-Slabs-Paving
Piling
Railroads
25 Site Development (G6)
25-1
Introduction to Site
Development
Site development may be used to specify items within eight major categories:
•
Earthwork
•
Drainage
•
Fencing
•
Demolition of existing structures
•
Landscaping
•
Roads/slabs/paving
•
Piling
•
Railways
It is important to recognize the two distinctly different applications for which
the site development may be used to introduce site development information
into a project. The desired application is determined by appropriate selection
of the site development item type.
The first application is based on the use of site development work item models,
which are contained within the system. You describe the type and extent of
work to be performed, item-by-item, consistent with the scope of each work
item model. The system in turn develops material quantities and manpower
resources and their associated costs, and additionally, equipment rental and
engineering requirements.
The second application allows the introduction of quoted estimates for material
and manpower costs into a project as supplemental site development cost
items. Item models are not used. Entries of this nature are charged to codes of
account in the amounts of material and manpower you specify.
Site development items, either developed by the system through work item
models or as user-entered costs, may be specified as either project-related
items or area-related items.
Site Development Work Items
Within the eight categories of site development, numerous individual work
item models are available for selection depending on the desired type and
extent of work to be performed.
Economy of scale is very important for many site development items (e.g., you
can select from bulk excavation, structural excavation or hand structural
excavation). In addition, the system addresses a large extent of work, defined
by you in a single work item request, differently from the way it addresses
several work item requests, each of small extent. That is, work item models
re-select an appropriately configured crew, by developing man-hour
requirements and by providing the crew members with construction equipment
properly sized for the work to be performed.
Terrain, soil conditions and other project environment factors significantly
affect the quantity and type of site work required. To reflect this, site
25-2
development work items are presented to accommodate particular, welldefined tasks. For example, instead of a single site preparation item, you are
offered individual items, such as clearing and grubbing, excavation, grading
and landscaping. This provides the ability to “fine tune” the project to actual
conditions.
Excavation items are assumed to be requirements in excess of the normal
excavation required for equipment and building foundations and structural
footings, since excavation for these items (when defined as part of a unit area)
are ordinarily system-determined.
Demolition
Description
Type
Demolish building w/disposal, no salvage
DEMOLITION
Demolition of individual structure without salvage but including
disposal. Specify frame type (steel, concrete, masonry, wood).
Disposal includes loading and hauling waste from site. Dump charge
not included.
Demolish building w/disposal and salvage
DISPOSAL
Demolition of individual structures with separation of reusable
materials for specified frame type. Loading and hauling waste material
is included. Dump charge not included.
Explosive bldg. demol, no salvage/disposal
Demolition of structures by explosives. Does not
include salvage or disposal.
EXPL DEMOL
Gutting & disposal of building interior
Gutting building interiors and loading and hauling the
refuse for either commercial or residential structures.
Dump charge not included.
REMOVAL
Lump sum quotation - demolition
Enter Total Cost or Mat’l and MH.
See code of accounts (Civil only).
DEMOL
25-3
Drainage
Description
Type
Catch basin, manhole
BASINS
Catch basins or manholes of either brick, block, poured concrete, or
precastconcrete. Includes footing and excavation with an option of
slab tops or lightweight frames and covers. All types have 4 FEET
[1.25 M] internal diameter.
Pump and hose for open excavations
DEWATERING
Pumping water from open excavations. Unattended pumps except for
daily servicing. Suction line to 20 FEET [6 M] and discharge line to
100 FEET [30 M]
in length.
Drainage piping
DRAINS
Installation of selected diameter pipe of asbestos cement, corrugated
steel, concrete, or vitrified clay with an adjustment for the
percentage of curved or radius pipe. Includes trenching, gravel bed
and compacted backfill.
Septic tank and drain field
SEPTIC TNK
No. of distrib'n = no. per tank;
Length of drain line = length per tank.
Septic tank installation. Precast concrete tanks of specified capacity
with the option of 5 outlet concrete distribution boxes. The drainfield,
including pipe, trenching, gravel and backfill, is input as total length
of drain required.
SUBDRAIN
Foundation subdrain with perforated pipe
Installation of foundation subdrainage of selected diameter pipe of
asbestos cement, corrugated steel, porous wall concrete, or vitrified
clay with an adjustment for quantity of curved or radius pipe. All
types except concrete are perforated.
Includes trenching, gravel bed and compacted backfill.
SUMP PIT
Sump pit
Construction of sump pits including excavation and gravel bottom.
Option of wood
lining to a depth of 4 FEET [1.25 M].
Cased water supply well with pump
WATER WELL
Domestic water wells drilled and cased. Includes down-hole pump,
surface grouting, and utility runs, if specified. Does not include
plumbing fixtures and connections.
25-4
Drainage - continued
Description
Type
Wellpoints with header and pump
WELLPOINTS
Single stage wellpoint system for deterring to an average 15 FEET [5
M] depth.
Includes installation, operation, equipment rental and system
removal. Two INCH [50 MM] wellpoints on 5 FEET [1.5 M] centers.
Diameter of header is proportional to length:
6 INCHES [150 MM] for 100 FEET [30 M]
8 INCHES [200 MM] for 200-500 FEET [60-150 M]
10 INCHES [250 MM] for 1000 FEET [300 M].
9 Dewatering wells with pump
WELLS
Dewatering wells; 2 INCH [50 MM] diameter bore with
steel casing.
Includes 2 INCH [50 MM] centrifugal pump per well for
a specified period.
10 Lump sum quotation - drainage
DRAINAGE
25-5
Earthwork
General
Description
Type
Test borings with engineer’s report
BORINGS
Includes field stake-out and elevations, 2.5 INCH [65 MM] auger holes
with samples of earth, drawings and professional engineer’s (P.E.)
report.
Clear brush - manual or dozer
BRUSH
Brush clearing by hand with saw and rake (HAND) or by dozer with ball
and chain (MACH).
Clearing and grubbing
Mechanized clearing and grubbing.
CLEAR GRUB
OptionIncludes removal of trees to
LIGHT
6 INCH [150 MM] diameter
MEDIUM
HEAVY
Includes on-site cutting, chipping and stump removal.
Dike construction including stabilizing
Construction of dikes on level grade. Includes placing of fill, soil
poisoning with polybor chlorate on grade, slopes, and top; 2 INCHES
[50 MM] of sand asphalt on top and slopes.
DIKE
Gunite slope protection
GUNITE
Slope protection using 3 INCH [75 MM] thickness of gunite (air-blown
mortar) to finished slopes. Includes bond beam on top, key footing at
toe and all reinforcing.
25-6
Pond with bedding, lining, fencing-no pipe
Specify piping with bulk yard pipe item.
Evaporation or holding pond. Includes excavation, gravel and sand
bedding, fencing and optional lining. Piping not included.
POND
Cantilevered concrete retaining wall
No embankment cut and fill included,
See excavation items.
Reinforced concrete cantilevered retaining wall. Includes excavation
and backfill for wall footings only.
RETAIN
Sprayed asphalt soil stabilization
Erosion protection and soil stabilization by spraying with asphalt.
STABILIZE
Lump sum quotation - earthwork
EARTHWORK
Excavation
Description
Type
Backfill and compact excavation
BACKFILL
Backfilling of trenches or footings. Fill material is assumed to be
stockpiled locally, with no hauling. For numerous small items, manhours can be adjusted by specifying the number of items in addition to
the unit cubic yards. Filling equipment may be wheeled loader/
backhoe (WH-LD), crawler loader or dozer. Compaction, if required,
may be hand rammer, manual or self-propelled vibrating drum roller.
Drill and blast rock - no disposal
Drill and shoot rock in trenches, pits, or open areas; includes crawler
trackdrill, compressor, and blasting materials but no disposal of shot
rock. Rock types include gypsum, slate, limestone, sandstone and
granite.
BLASTING
Fill compaction with towed roller
COMPACT
Compaction of fill in layers by towed sheepsfoot roller. Options
available for watering during compaction and for rough spreading of fill
by dozer, scraper or grader. For fine grading and surface compaction,
see PAVING, BASE PREP.
Cut & fill with spreading no compaction
Dozer:
maximum haul 500 FEET [150 M]
Scraper:
minimum haul 100 FEET [31M]
Bulk site excavation using dozers or scrapers on a cut and fill cycle,
including spreading and rough grading but no compaction. Scraper
selection varies with volume, material and haul distance. Soil type
ROCK refers to already ripped or shot rock.
CUT FILL
Hand excavation, no backfill/shoring, etc.
HAND EXCV
Excavation by hand of trenches or pits, in sand, earth, or clay. Manhours will be adjusted for depth of excavation and for volume per item
(pits). If shoring is required, see SHORING. Dewatering for wet
conditions, allowance for wet conditions, disposal and/or backfill are
not included.
Truck haul-disposal or purchased fill
HAULING
Material cost may be input for purchased fill or dump charge.
Hauling by dumptrucks (lorries) with option of loading from stockpiles.
Does not include excavation, spreading, or backfill. Soil type will
determine bulking factor. For purchased fill or dump charge, the user
may specify the cost (in user-defined currency at User Base Index) per
loose CY [M3].
25-7
Excavation - continued
Description
Type
Manual jackhammer work - no disposal
Breaking or trimming of rock or concrete by hand-held jackhammer,
including compressor and operating crew. Concrete may be plain or
reinforced. Rock types include gypsum, slate, limestone, sandstone
and granite. Does not include disposal.
J HAMMER
Rock excavation with tractor and ripper for hauling, Both the haul
distance and the loading equipment type must be input Rock
excavation by D9 crawler tractor with ripper attachment. In addition,
the user may specify truck loading (by crawler backhoe or wheeled
front-end leader) and hauling. Rock types are gypsum, slate,
limestone, sandstone and granite. Ripping costs may be increased
(greater fragmentation) to facilitate truck loading.
RIP ROCK
Shoring of excavations
Max shored depth:
40 FEET [12M] - sheet, HPILE;
20 FEET [6M] - close; 10 FEET [3M] - open bracing.
Installation, adjustment, accessories, removal, cleaning, rental or
owning cost and waste are included. Dewatering not included. Types
available:
SHORING
•
Steel interlocking sheet piling, 30 PSF [145 KG/M2],
including bracing (SHEET).
•
Steel H piles driven on 8 FEET [2.4 M] centers, timber
planks and spacers horizontally between flanges, including
bracing (HPILE).
•
Solid timber sheeting supported by timber waling and
braces (CLOSE).
•
Single vertical planks spaced on 3 FEET [0.9 M] centers
with bracing (OPEN).
Excavation with stockpile or disposal
SITE EXCVN
The haul distance should be input if the disposal option is chosen.
Bulk site excavation using crawler loader, dragline, or crawler
backhoes. If the disposal and distance fields are not used, it will be
assumed that the excavated material is to be stockpiled within 100
FEET [30 M] of the excavation. The disposal options are:
• HAUL - generates a truck-loading cycle, dumptruck, sizing, off-road
hauling the user specified distance and dumping.
• SPREAD - generates (in addition to truck hauling) spreading in the
fill area by
• D8 dozer and rough grading, with no compaction.
Soil type ROCK refers to already ripped or shot rock.
25-8
Excavation - continued
Description
Strip and stockpile soil - no hauling
Type
STRIP SOIL
Strip and stockpile site topsoil to a specified average depth. Equipment
options include crawler loader, elevating scraper, or dozer. Truck
hauling or spreading not included. Man-hours are adjusted for area,
depth and equipment used.
Machine excavation, no backfill/shoring, etc.
STRUC EXC
Machine excavation (with hand trimming) of basements, footings, etc.
Equipment options include: 0.75 CY [0.6 M3] wheeled loader/backhoe
(WH-LD), crawler backhoe, or crawler crane with clamshell bucket
suitable for excavations deeper
than 30 FEET [10 M]. If shoring is required, see SHORING. Soil type
ROCK refers to already ripped or shot rock. Dewatering, disposal and/
or backfilling are not included.
Ditching no backfill/shoring, etc.
TRENCH EXC
Machine excavation (with hand trimming) using
wheeled loader/backhoe (WH-LD), crawler backhoe, or
trenching machine. If shoring is required, see
SHORING.
Soil type ROCK refers to already ripped or shot rock.
Dewatering, disposal, and/or backfill are not included.
25-9
Fencing
Description
Type
Barbed wire topping for fence
BARBED
No. of sides = wire on one or both sides of fence;
No. of strands = no. each side
Installation of barbed wire on chain link, mesh, or security fence. Two
or three-strand galvanized or aluminum wire on either 1 or 2 sides.
Boundary or Perimeter fencing in which the user can specify both
fence and gates has been added.
BOUNDARY
Chain link fence with concrete footing
CHAIN LINK
Installation of chain link fence, including excavation and concrete for
posts on 10 FEET [3 M] centers and braced and trussed line posts at
100 FEET [30 M] centers. Galvanized or aluminum wire or vinyl-coated
steel.
Wood fencing
FENCE
WOOD
Permanent wood fencing of cedar picket, redwood basket-weave, or
oak rustic rail with appropriate gates.
Lump sum quotation - fencing
FENCING
Free standing wall
Default one course thickness - all types;
Double may be input for brick and block.
Materials are:4 INCH [100 MM] common brick
8 INCH[200 MM] concrete block
18 INCH[450 MM] decorative random stone
8 INCH[200 MM] concrete.
FS WALL
Industrial gate for fence
GATES
Industrial gates of galvanized steel, aluminum, or vinyl-coated steel
with posts excavated and set in concrete. Barbed wire and motor
operation are optional.
Gates are assumed to be double widths if 8 FEET [2.5 M] or more.
MESH
Wire mesh fencing
Galvanized steel mesh fencing and gates with posts on 5 FEET [1.5 M]
centers.
No bracing or concrete.
Heavy duty security fencing
SECURITY
Heavy duty security fence, security grade, set in concrete and trussed
and braced.
25-10
Landscaping
Description
Type
Mesh or netting erosion control
EROSION
Erosion control by placing and securing either jute mesh, plastic
netting, polypropylene mesh, or tobacco netting.
Placing peat or wood chip mulch
MULCH
Placing a 2 INCH [50 MM] deep layer of either wood chips or peat moss
as mulch.
Planting trees or shrubs
PLANTING
Planting either 8-10 FEET [2.5-3 M] trees or 4-5 FEET [1.2-1.5 M]
shrubs. Siting, placing, fertilizing, and watering plantings are included.
Fine grade, seed, lime, fertilize
SEEDING
Fine grading, seeding, liming, fertilization, and final watering.
Furnish, place sod on prepared area
SODDING
Furnish, place, and water sod (1 INCH [25 MM) deep) on pregraded
area.
Polybor chlorate soil sterilization
STERILIZE
Sterilization of cleared areas using polybor chlorate.
Furnish, place and fine grade topsoil
TOPSOIL
Furnish, place and fine-grade topsoil.
Lump sum quotation - landscaping
LANDSCAPE
25-11
Roads - Slabs - Paving
Description
Type
Paving - asphalt base and wearing courses
ASPHALT
either base or wearing course depth must be input; Material option sand topping.
Assumes paver for roadways or spreader for parking and other small
areas (PARK). A base course and/or a fine aggregate wearing course
thickness must be selected. A 0.75 INCH
[20 MM] sand finish may be added. Includes hauling to site, grading,
and compaction.
Grade and compact base for paving
BASE PREP
Grade and compact areas to correct elevation to plus or minus 0.1
FEET [0.03 M].
Concrete paving - no base preparation
CONC PAVNG
Paving with 4500 PSI [31,000 KN/M2] concrete. Preparation of
compacted subgrade and/or paving not included. Includes finishing
and curing, with optional steel
reinforcing mats. Placing by slipform machine may be specified for
concrete roadways.
Slipformed or manual cross gutter
CROSS GUTT
Six INCH [150 MM] thick concrete cross-guttering of selected width
and length.
Optional forming, pouring, finishing, and expansion joints, or
slipforming by machine for widths up to 10 FEET [3 M], if specified.
Slipformed or manual placed curb
CURB
Concrete curb (kerb) only, 14 INCHES [350 MM] deep by 9 INCHES
[225 MM] wide overall. Optional either forming, pouring and finishing
by hand with expansion joints on 30 FEET [9 M] centers or
slipforming by machine, if specified.
25-12
Description
Type
Slipformed or manual curb and gutter
CURB GUTT
Monolithic concrete curbing (kerbing) and gutter. Optional forming,
pouring, and
expansion joints on 30 FEET [9 M] centers or slipform by machine, if
specified.
Concrete canal or gutter
CANALGUTTR
Concrete canal or gutter with concrete cover. Inside length, Inside
width and Inside
depth must be input. If not specified, system calculates Cover
(default: 8 IN [200 MM] prefab concrete slab); Hand Excavation;
Machine Excavation; Blinding slab; Concrete;
Formwork; Rebar; Anchors and embedments. Excavation Material
(Default: EARTH); End Wall Requirement (Default: *B*, O, N);
Sealcoat or Liner area (Default: 0); and
Liner Type (Default: GM, C1, C2, * NO*) can be also specified.
The material and manhour per volume of concrete will be calculated
based on the factors used for BASIN (Type 10). If civil external file is
used, the factors from the external file will be used.
25-13
Roads - Slabs - Paving - continued
Description
Type
Coal tar pitch emulsion (2 coats)
SEALCOAT
Application of sealcoating. Includes cleaning and preparing the existing
surface and applying two coats of coal tar pitch emulsion.
Sidewalk base and paving
SIDEWALKS
Installation of concrete or asphalt sidewalks or pavements with an
option of a bank run gravel base.
Gravel base course - no base prep
SUBPAVING
Soil cement treatment option available for subgrade.
Subpaving base course. Options include crushed stone, bank run
gravel, and macadam penetration. Soil cement treatment may also be
selected. Subgrade preparation is not included.
TAR CHIP
Resurfacing with sealant and gravel
Tar and chip. Placing sealant and binder on an existing surface and
covering with screened gravel. Includes surface cleaning and rolling
following treatment.
Parking Area
PARKING
Paving, Sub Paving and Excavation. Optional Shoulder, Sidewalk,
Median, Concrete Curb, Guard Rail, Lining and compaction. Paving
material can be Asphalt, Concrete,
Concrete Block, Prefabricated concrete tile, or Stone pavers.
Lump sum quotation - paving/roads
PAVING
Enter Total Cost or Mat’l and MH. See code of accounts (Civil only).
Main, secondary and minor Roads
ROAD
Paving, Sub Paving, Shoulder and Excavation. Optional Sidewalk,
Median, Concrete Curb, Guard Rail, Lining and compaction. Default is
Main Road with Asphalt paving, Gravel Base course, and One side
Shoulder. The width and depth are based on the road type.
Paving options - Asphalt, Concrete, Concrete Block, Prefabricated
concrete tile, or Stone pavers. Shoulder options - Asphalt, Gravel or
Crushed stone. Sidewalk options - Asphalt, Concrete, Tiles, or Stone
pavers.
Site Preparation for paving has been added. This includes Grubbing
and cleaning, Hand and Machine Excavation, Fill of Subgrade and
Compaction.
25-14
SITEPREP
Piling
Description
Type
Drilled bell-type caisson
CAISSON
Open-style machine-drilled bell-caissons, including mobilization,
concrete, reinforcement, drilling equipment rental, and load testing, in
the following ground conditions:
OptionDescription
EARTH Dry, stable soils
CLAY Wet, unstable soils
ROCK Soft, weathered rock.
Driven pipe piles
PIPE
Driving set pipe piles of selected diameter with an option of concrete
filling.
Equipment rental includes rental of drilling equipment.
Drilled and cast-in-place concrete piles
POURED
Cast-in-place concrete piles with 4000 PSI[27.5 N/MM2] concrete.
Includes equipment setup and breakdown and load testing.
Pile Types:
POUR - Poured 12"[300MM] to 20"[500MM], capacity: 72 Tons [65
Tonne] Cast-in-place constant diameter concrete piles.
FRNK - Frank 16"[400MM] to 24"[600MM], capacity: 220 Tons[200
Tonne] Bored large size piles, enlarged base, reinforced with steel
cages.
AUGR - Auger-Cast 12"[300MM] to 24"[600MM], capacity 250
Tons[225 Tonne] Auger drilled and then grouted under pressure as
the auger is withdrawn. Rebar installed when grout is fluid.
Driven precast concrete piles
PRECAST
Driving precast concrete piles, either solid square shaped or,
optionally, hollow cylindrical shaped. Includes equipment rigging and
derigging, splicing, if required, and cutoff.
Capacity: 90 Tons
Driven Raymond step-taper piles
RAYMOND
Driving Raymond step-taper piles. Piles furnished and
installed on a subcontract basis by Raymond
International, Inc. Testing not included.
25-15
Piling - continued
Description
Type
Driven steel H-PILES
STEEL H
Example:
heavy duty pile - 57 LB/FT [85 KG/M]
instead of 42 [62] for 10 INCH [250 MM] pile
Driving steel H-section piles of selected cross-section including
equipment rigging and derigging, points, splicing, if required, and
cutoff. Heavy duty option available (e.g., for 10 x 10 INCHES [250 MM
x 250 MM], heavy duty, 57 LB/FT
[85 KG/M] is used instead of standard 42 LB/FT [62 KG/M] for steel).
Driven wood piles
WOOD
Driving wood piling either friction or point bearing. Includes rigging
and derigging equipment, boots, points, and splices, if required.
Creosote treated or concrete and mesh encased piles may be selected.
Cutoff included. Load testing is not included.
Lump sum quotation - piling
Enter Total Cost or Mat’l MH.
25-16
PILING
Railroads
Description
Type
Bumper at siding end
BUMPER
Installation of bumpers on a siding end. Heavy duty bumpers available
as an option.
Single line siding crossing
CROSSING
Single line siding crossing including special track mat, timber, and
crossing signal installed on level grade.
Single track yard siding
Installation of a single track yard siding on level ground, including
rails, hardware, timber ties and ballast. New or relay rail and rail
weight option available.
SIDING
Heavy duty siding for mining application
SIDING HVY
Heavy duty single track for mining applications. Six INCH [150 MM]
steel WF ties set in 10 INCH [250 MM] concrete bed, 9 FEET [2.7 M]
wide. Includes fasteners, plates, rebar and 100 LB/YD [50 KG/M] new
rail.
Crossing signal with barrier, etc.
SIGNAL
Track crossing signal with road barrier and flashing light.
Wheel stops on siding
STOPS
Installation of wheel stops on a yard siding.
#8 turnout, switch-hitting, etc.
TURNOUT
Installation of #8 turnouts, including rails, plates, bars, frogs, switchpoints, timbers and ballast.
Lump sum quotation - railroads
RAILROADS
Enter Total Cost or Mat’l MH.
25-17
25-18
26 Buildings
(G6)
Introduction to Buildings
Adding a Building
Building Types and Defaults
Default Floor Heights/Levels
Building Construction Range Adjustment
Calculating Building Costs and Labor
Figure 1
Figure 2
26 Buildings (G6)
26-1
Introduction to Buildings
Building data is used to incorporate a number of independent buildings and/or
their associated services into the project. Enclosed buildings are distinguished
from steel structures (areas, plant bulks) in that they are not designed to
support equipment loads. An enclosed building may house equipment, but this
does not affect the resulting building design or cost.
The cost of a building is based upon its size, type, structural style and the
requested services. The default costs and electrical load for each building type
are indicated in the “Building Types and Defaults” table on the following page.
You may revise the level of each service (none, L, M, H or V) and/or the cost of
that service. All costs are assumed to be direct field costs assigned to the
prime contractor, except in the case of contract jobs, in which they are
assigned to the contractor specified.
Adding a Building
A building can be added under Plant Bulks, Civil, or under Buildings. Defaults
are identical and material costs, man-hours and labor costs are calculated the
same way.
If you are using Aspen Capital Cost Estimator, the underlying data for these
costs can be defined in an external file under Administrator control. See Aspen
Capital Cost Estimator User’s Guide, Chapter 10, “Administrative Operations,”
for details.
Buildings are not designed items, but are developed as costs per surface area
(Unit Cost) items.
You can specify your building using one of three general approaches:
1
Select any Total cost adjust. value that uses some default value, then
accept the resulting unit costs.
2
Select the ‘—’ in Total cost adjust., then enter your unit costs for each of
the five general categories.
3
Start with method (1), above, then override selected categories (e.g., Total
super-structure cost) or elements of a category (e.g., Frame, etc.) with
your unit cost.
If you specify the unit cost for any element in a category, this suppresses all
other elements in that same category, but does not affect other categories. For
example, if you specify the unit cost for the Floor element in the Total superstructure category, all other elements in that category are set to zero cost -- if
you want to generate a cost for the Stair element, then you must specify a unit
cost for that element.
If you specify a value for both a category and one or more elements in that
category, the costs are not additive- only the unit cost specified for the
category is used and the elements are ignored.
Costs are split between material and labor according to percentages in the
internal (system defaults) or in the external (Administrator specified) file.
The split for the internal table varies from a high of 62% to a low of 38% for
26-2
26 Buildings (G6)
material. Building overhead and profit are separately specifiable for each
building type.
The fields Explosion Pressure, Foundation Type, and Roof Type have no effect
on the design and cost of the building; they are included for informational
purposes only.
Field Descriptions:
Gross floor area: Default: calculated from length, width, height, number of
levels, and building type.
Building type: see Building Types earlier in this chapter.
Building height: Default: determined from number of levels and
building type.
Number of levels: Default: calculated from length, width, height, area, and
building type.
Explosion gauge pressure: For control buildings only, design pressure for
explosion resistance. Default: *0.0* PSIG; MAX: 30.0 PSIG.
Electrical load: W/SF
Total cost adjustment symbol: Invokes either the built-in system values for
a Medium item (blank or M), a down-adjustment (L), an up-adjustment (H or
V), or suppresses the default costs (—).
(blank)System Defaults
—No System Defaults, user data only
L - Low adjustment for system defaults (range varies from 45-98% of M)
M - Medium adjustment for system defaults (the default value= 100%)
H - High adjustment for system defaults (range varies from 106-216% of M)
V - Very high adjustment for system defaults (range varies from 159-324%
of M)
Foundation type:
*NORMAL*- Spread footings.
PIERS- 10 FEET [3M] deep piers to footings.
PILES- Floors on piles
Roof type:
*FLAT*- Flat roof.
TRUSS- Truss roof.
SAW- Sawtooth roof.
Labor adjustment required: When calculating the labor hours and costs to
report, the system can take a variety of parameters into account: wage rate in
external file or in project; time and currency difference between external file
and project; user man-hour indexing and productivity adjustments. Specify in
this field which of these to take into account. If you are using an external file,
it is best to select YES.
*YES*- Adjust labor cost by system rate, productivity; use external file
wage rates.
26 Buildings (G6)
26-3
NO- No adjustment of labor cost.
Total substructure cost: foundation cost per unit area.
Total superstructure cost: enter either total super-structure or individual
structure component cost for the following:
°
Exterior door and window
°
Exterior wall
°
Floor
°
Frame
°
Int door and window
°
Roof
Stair internal table varies from a high of 62% to a low of 38% for material.
Building overhead and profit are separately specifiable for each building type.
Total interior finish cost: enter either total internal finish cost or individual
finish component cost.
Total fitting and furniture cost: enter either total fittings, furniture cost.
Total services cost: enter either total services cost or individual service
component cost.
Overhead and Profit: enter total overhead and profit cost.
26-4
26 Buildings (G6)
26 Buildings (G6)
12.17
0.00
4.40
5.68
2.78
3.67
1.87
0.00
0.00
0.00
0.00
18.25
0.00
7.41
8.11
3.00
5.10
1.87
0.00
0.00
0.00
0.00
12.17
0.00
4.40
3.19
2.78
3.67
1.87
0.00
0.00
0.00
0.00
15.21
0.00
6.95
5.68
3.00
5.10
1.37
0.00
0.00
0.00
0.00
12.17
0.00
4.40
8.11
2.78
3.67
1.87
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
15.21
0.00
6.95
8.11
3.00
5.10
1.87
0.00
0.00
0.00
0.00
FITTING & FURNISHING TOTAL 12.71
0.00
4.40
5.47
2.78
3.79
1.87
0.00
0.00
0.00
0.00
0.00
SERVICE TOTAL
- Air Conditioning
- Lighting and Electrical
- Heating/Ventilation
- Plumbing & Fixtures
- Fire Protection
- Lift Installation
- Security Installation
- Special Installation
- Builders Work
OVERHEAD AND PROFIT
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
19.69
0.00
0.00
0.00
0.00
0.00
0.00
0.00
31.56
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
18.69
0.00
0.00
0.00
0.00
0.00
0.00
0.00
26.88
0.00
0.00
0.00
0.00
0.00
0.00
0.00
INTERNAL FINISH TOTAL
- Wall Finishes
- Floor Finishes
- Ceiling Finishes
24.88
0.00
0.00
0.00
0.00
0.00
0.00
0.00
31.17
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.5
0.00
4
0.00
21.05
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.5
0.00
2
0.00
SUBSTRUCTURE TOTAL
- Frame
- Floor
- Roof
- Stairs
- External Walls
- External Doors & Windows
- External Doors & Windows
4
0.00
5
SUBSTRUCTURE TOTAL
0.00
4
0.00
ELECTRICAL UNIT LOAD
0.00
0.00
7.41
8.11
3.00
5.60
1.87
0.00
0.00
0.00
0.00
48.67
0.00
0.00
4.40
5.68
2.78
4.51
1.37
0.00
0.00
0.00
0.000
12.17
0.00
0.00
0.00
0.00
21.05
0.00
0.00
0.00
0.00
0.00
0.00
0.00
32.09
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
1
0.00
0.00
6.95
8.11
3.00
5.10
1.87
0.00
0.00
0.00
0.00
17.69
0.00
0.00
0.00
0.00
0.00
0.00
4.40
5.68
2.78
4.51
1.37
0.00
0.00
0.00
0.00
12.17
0.00
0.00
0.00
0.00
21.05
0.00
0.00
0.00
0.00
0.00
0.00
0.00
30.59
0.00
0.00
0.00
0.00
0.00
0.00
0.00
1
0.00
0.00
1
0.00
0.00
4.40
5.68
2.78
4.51
1.37
0.00
0.00
0.00
0.00
12.17
1998
1998
1998
1998
1998
1998
1998
1998
1998
1998
1998
21.33
20.77
22.59
21.64
20.31
21.36
22.59
22.59
18.64
18.64
0
1998
1998
1998
1998
1998
1998
1998
1998
1998
1998
1998
1998
1998
1998
18.64
19.12
19.12
19.12
19.12
19.12
19.12
19.12
19.12
19.12
19.12
19.12
19.12
21.05
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
19.12
0.00
1
CLOSED SANTRY EXIST SHELL WAGE YEAR
0.00
5
SHOP OFFICE COMPR CAFE WARE CONTRL GARAGE LAB
Building Types and Defaults
26-5
Default floor Heights/Levels
Building Type
Type Symbol
Height per Floor or Level
Cafeteria
CAFE
12.0
3.5
Enclosed Building
CLOSED
20.0
6.0
Compressor Building
COMPR
20.0
6.0
Control Room
CONTRL
10.0
3.0
Existing Building
EXIST
20.0
6.0
Garage
GARAGE
15.0
4.5
Laboratory
LAB
10.0
3.0
FEET
M
Office Building
OFFICE
10.0
3.0
Sanitary Enclosed
SANTRY
20.0
6.0
Building Shell*
SHELL
20.0
6.0
Shop
SHOP
20.0
6.0
Warehouse
WARE
20.0
6.0
Building Construction Range
Adjustment
26-6
Adjustment Construction Frame
Symbol
Type
Roof
L
Pre-Fabricated Light Steel
Light Steel Transite
or metal
sheet
M
Pre-fabricated Medium
Concrete
steel frame
and trusses
Concrete Concrete Average
walls or
good
brick
H
Custom
designed
Face
brick on
concrete
block
Heavy
steel,
heavy
sidings
Concrete
Walls
Floors
Finishes
Concrete Minimum
Concrete Expensive
26 Buildings (G6)
Calculating Building Costs and
Labor
When calculating the cost of a building, the system uses either the internal file
conditions or those specified in the external file. If the external file is used, the
system first reads in that file, then:
•
Converts all the costs in the external file to the currency of the project base country
location using the Currency Conversion in the external file.
•
Escalates these to the same time point as the cost base of the system using the
yearly cost indices by country location, by major account. A summary of these is
reported in the “Release Notes” for each version.
•
Converts these into the reporting currency units for the current project using the
Conversion Rate specified in the project.
This allows you to use an external file built using any currency and at any date
known to the system (see Chapter 33, “Base Indices”) in a project with any
reporting currency. For analytical purposes, you may want to Year in the
external file to be the same as the base year of your system to allow you to
trace your numbers through a complete computation.
In order to calculate the various hours and costs, the system must first adjust
all items to be at the same basis: same currency and same time point. The
costs for each element and/or category are calculated according to the
methodologies indicated in Figure 1 (“How Building Costs are Calculated Using
the External File”- general procedures that focus on adjusting for currency and
time differences); Figure 2 (“How Building Material Costs are Calculated Using
the External File”); and Figure 3 (“How Building Labor Hours & Costs are
Calculated Using the External File”). The following generalizations are
important:
•
The critical item to understand is that it is necessary for the system to move all
costs to the same currency (one of the three known to the system: USD, PS or KY)
and to the same time point (SBI is the time at which all the system-generated costs
are valid). Because of this, you must thoroughly understand the escalation
concepts used by the system (SBI, UBI and EI) and be very consistent in your use
of dates and parity rates valid at those dates.
•
It follows from this that it is very important for you to enter at least the UBI for
your project.
•
When used with systems where these escalation concepts do not apply, or if you do
not use them in Aspen Capital Cost Estimator, it is important to appreciate potential
time-based discrepancies between user-entered numbers that are valid “now” and
those computed by the system that are valid at the base year of the system being
used.
•
It is usually best to let the system pick the unit costs based on your inputs and set
Labor adjust=YES.
•
Since the numbers in the external file are always adjusted to the year of the current
version, the final numbers reported are rarely, if ever, the same as those entered in
the external file.
26 Buildings (G6)
26-7
Figure 1
26-8
26 Buildings (G6)
Figure 2
26-9
26 Buildings (G6)
Figure 3
26 Buildings (G6)
26-10
26 Buildings (G6)
26-11
26-12
26 Buildings (G6)
27 Quoted Equipment and
Libraries
(G6)
Introduction
Quoted Equipment
User Libraries
27 Quoted Equipment and Libraries (G6)
27-1
Introduction
There are two methods for specifying specialty items or items not included in
system:
•
Quoted equipment
•
User libraries
Quoted Equipment
Quoted equipment items can be used for unique, special, non-standard and
proprietary types of process equipment. Since quoted equipment items are
unknown to the system, an account code must be provided when entering
the quote.
If you enter a COA that is known to the system as one containing “rotating
equipment” (COAs 150-179 and 220-229), then the system calculates an
allowance for spares and adds it to COA 107. This does not happen if you are
using your own complete COA set in a project.
User Libraries
User libraries are meant to hold your important personalized cost data. There
are two kinds of libraries:
•
Unit Cost Library - Holds information related to material and labor costs
(per unit quantity) for equipment, bulks or indirects.
•
Equipment Model Library (EML) - Holds information related to the
process equipment. You can store cost vs. capacity data for special kinds of
process equipment.
You can add Piping and Instrumentation drawings to the EML in Aspen
Capital Cost Estimator. For instructions, see “Tutorial: Assigning Default
P&IDs to User Entered Equipment” on page 10-20 of the Aspen Capital
Cost Estimator User’s Guide.
If your library requirements are extensive, you should consider building
several libraries, placing like items in the same library. All items in a library
share the same currency basis and are converted as appropriate when added
to a project.
27-2
27 Quoted Equipment and Libraries (G6)
28 Material Selections
(G10)
ASME Design Code - Plate Materials
ASME Ferrous Plate Materials - Carbon Steel
ASME Ferrous Plate Materials - Heat Treated Steel
ASME Ferrous Plate Materials - Low Alloy Steel
ASME Ferrous Plate Materials - High Alloy Steel
ASME Non-Ferrous Plate Materials
ASME Design Code - Clad Plate Materials
ASME Design Code - Tube Materials
ASME Ferrous Tube Materials - Carbon Steel
ASME Ferrous Tube Materials - Low Alloy Steel
ASME Ferrous Tube Materials - High Alloy Steel
ASME Non-Ferrous Tube Materials
BS Design Code - Plate Materials
BS Ferrous Plate Materials - Heat Treated Steel
BS Ferrous Plate Materials - Low Alloy Steel
BS Ferrous Plate Materials - High Alloy Steel
BS Non-Ferrous Plate Materials
BS Design Code - Clad Plate Materials
BS Design Code - Tube Materials
BS Ferrous Tube Materials - Carbon Steel
BS Ferrous Tube Materials - Heat Treated Steel
BS Ferrous Tube Materials - Low Alloy Steel
BS Ferrous Tube Materials - High Alloy Steel
BS Non-Ferrous Tube Materials
JIS Design Code - Plate Materials
JIS Ferrous Plate Materials - Carbon Steel
JIS Ferrous Plate Materials - Heat Treated Steel
JIS Ferrous Plate Materials - Low Alloy Steel
28 Material Selections (G10)
28-1
JIS Ferrous Plate Materials - High Alloy Steel
JIS Non-Ferrous Plate Materials
JIS Design Code - Clad Plate Materials
JIS Design Code - Tube Materials
JIS Ferrous Tube Materials - Carbon Steel
JIS Ferrous Tube Materials - Low Alloy Steel
JIS Ferrous Tube Materials - High Alloy Steel
JIS Non-Ferrous Tube Materials
DIN Design Code - Plate Materials
DIN Ferrous Plate Materials - Carbon Steel
DIN Ferrous Plate Materials - Heat Treated Steel
DIN Ferrous Plate Materials - Low Alloy Steel
DIN Ferrous Plate Materials - High Alloy Steel
DIN Non-Ferrous Plate Materials
DIN Design Code - Clad Plate Materials
DIN Design Code - Tube Materials
DIN Ferrous Tube Materials - Carbon Steel
DIN Ferrous Tube Materials - Low Alloy Steel
DIN Ferrous Tube Materials - High Alloy Steel
DIN Non-Ferrous Tube Materials
EN 13445 Design Code - Plate Materials
EN Ferrous Plate Materials - Carbon Steels
EN Ferrous Plate Materials - Low Alloy Steels
EN Ferrous Plate Materials - High Alloy Steels
EN 13445 Design Code - Tube Materials
EN Ferrous Tube Materials - Carbon Steels
EN Ferrous Tube Materials - Low Alloy Steels
EN Ferrous Tube Materials - High Alloy Steels
GB 150 Design Code - Plate Materials
GB 150 Plate Materials - Carbon Steels
GB 150 Plate Materials - Low Alloy Steels
GB 150 Plate Materials - High Alloy Steels
GB 150 Design Code - Tube Materials
GB 150 Tube Materials - Carbon Steels
GB 150 Tube Materials - Low Alloy Steels
GB 150 Tube Materials - High Alloy Steels
Lining Materials
Brick: Acid-Resistant Applied Over Membrane-Lined Carbon Steel
28-2
Brick: Firebrick
Monolithic Lining
Abrasion Resistant Linings: Replaceable
Linings: Organic, Glass, Metallic
Casting Materials
Packing Materials
ASME Design Code - Plate
Materials
ASME Ferrous Plate Materials - Carbon Steel
ASTM
Spec
Description and
System Internal Pressure External Pressure
Nominal Composition Material Maximum Temp. Maximum Temp.
(Grade)
F
C
F
C
A-36
(Structural Steel)
A 36
650
343
900
482
A-283
(c)
Low and intermediate
strength carbon steel
plates of structural
quality
A 283C
650
343
900
482
A-285
(C)
plates for pressure
vessels
A 285 or
A 285 C
or CS
900
482
900
482
A-299
Carbon-manganesesilicon steel plates for
plates for pressure
vessels
A 299
1000
537
900
482
A-455
(A)
Pressure vessel plates,
carbon steel, high
strength manganese
A 455
650
343
650
343
A-515
(70)
Carbon steel plates for A 515
pressure vessels for
intermediate and higher
temperature service:
C-Si
1000
537
900
482
A-516
(70)
Carbon steel plates for
moderate and lower
temperature service C-Si
A 516
1000
537
900
482
A-537
pressure vessels for low
temperature service
C-Mn-Si
1292
700
300
148
na = Material not selectable for vacuum design
28-3
ASME Ferrous Plate Materials - Heat Treated
Steel
ASTM
Spec
Description and
(Grade)
F
C
F
C
Nine percent nickel alloy A353
steel plates, double
normalized and
tempered for pressure
vessels:
9Ni
250
121
900
484
Eight and nine percent
A553
nickel alloy steel plates,
(Type 1) quenched and
tempered, for pressure
vessels:
9Ni
250
121
900
484
650
650
650
650
343
343
343
343
650
650
650
650
343
343
343
343
A-353
A-553
A-517
High strength alloy steel
plates, quenched and
vessels:
(A)
(B)
(E)
(F)
Cr-Mn-Si
Cr-Mn-Si
Cr-Mn-Si
Cr-Mn-Si
A517A
A517B
A517E
A517F
28-4
ASME Ferrous Plate Materials - Low Alloy
Steel
ASTM
Spec
Description and
Nominal
(Grade) Composition
A-202
(A)
(B)
A-203
(A)
(B)
(D)
(E)
A-204
(A)
(B)
(C)
A-302
Chromiummanganese-silicon
alloy steel plates for
pressure vessels
Nickel alloy steel
plates for pressure
vessels:
2.5Ni
2.5Ni
3.5Ni
3.5Ni
Molybdenum alloy
steel plates for
pressure vessels:
C-.5Mo
C-.5Mo
C-.5Mo
(A)
(B)
Manganesemolybdenum and
manganesemolybdenum-nickel
pressure vessels:
Mn-.5Mo
Mn-.5Mo
(C)
(D)
Mn-.5Mo-Ni
Mn-.5Mo-Ni
Material Maximum Temp. Maximum Temp.
F
C
F
C
A202A
A 202
or
A202B
1000
1000
537
537
900
900
482
482
A203A
A203B
A203D
A203E
1000
1000
1000
1000
537
537
537
537
900
900
900
900
482
482
482
482
A204A
A204B
A 204
or A204C
1000
1000
1000
537
537
537
900
900
900
482
482
482
A302A
A 302
or
A302B
A302C
A302D
1000
1000
537
537
900
900
482
482
1000
1000
537
537
900
900
482
482
- continued on next page -
28-5
ASME Ferrous Plate Materials - Low Alloy Steel - continued
ASTM
Spec
Description and
Nominal
(Grade) Composition
F
C
F
C
A-387
alloy steel, chromiummolybdenum:
(2 CL 1)
(2 CL 2)
(12 CL 1)
(12 CL 2)
(11 CL 1)
(11 CL 2)
(22 CL 1)
(22 CL 2)
(21 CL 1)
(21 CL 2)
.5Cr-.5Mo
.5Cr-.5Mo
1Cr-.5Mo
1Cr-.5Mo
1.25Cr-.5Mo-Si
1.25Cr-.5Mo-Si
2.25Cr-1Mo
2.25Cr-1Mo
3Cr-1Mo
3Cr-1Mo
5Cr-.5Mo
5Cr-.5Mo
A387A
A387G
A387B
A387H
A387C
A387J
A387D
A387K
A387E
A387L
A387F
A387M
1000
1000
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
537
537
648
648
648
648
648
648
648
648
648
648
900
900
900
900
900
900
900
900
900
900
900
900
482
482
482
482
482
482
482
482
482
482
482
482
A-533
alloy steel plates,
quenched and
tempered, for
pressure vessels:
C-Mn-Mo
C-Mn-Mo-Ni
C-Mn-Mo-Ni
A533A
A533B
A533C
1000
800
800
537
426
426
650
650
650
343
343
343
(A CL 1)
(B CL 1)
(C CL 1)
28-6
ASME Ferrous Plate Materials - High Alloy
Steel
ASTM
Spec
Description and
(Grade)
F
F
C
648
1200
648f
1500
815
1200
648
316L
850
454
800
426
SS316
1500
815
1200
648
16Cr - 12Ni - 2Mo-Ti
316TI
1500
815
1200
648
18Cr - 10Ni - 3Mo
SS317
1500
815
1200
648
(321)
18Cr - 10Ni - Ti
SS321
1500
815
1200
648
(347)
18Cr - 10Ni - Cb
SS347
1500
815
1200
648
(348)
18Cr - 10Ni - Cb
SS348
1500
815
1200
648
(648)
20 Cr - 18 Ni - 6 Mo
SS6MO
1382
750
1200
648
(2205)
Duplex
22Cr - 5Ni - 3Mo
S2205
600
315
650
343
(410)
13Cr
SS410
1200
648
900
482
(430)
17Cr
SS430
1200
648
1200
648
A-240
Chromium and
chromium-nickel
stainless steel plate,
sheet, and strip for
fusion-welded unfired
pressure vessels:
(304L)
18Cr - 8Ni
304L
1200
(304)
18Cr - 8Ni
SS304
(or SS)
(316L)
16Cr - 12Ni - 2Mo
(316)
16Cr - 12Ni - 2Mo
(316Ti)
(317)
C
28-7
ASME Non-Ferrous Plate Materials
ASTM
Spec
Description and
(Grade)
F
B-209
Aluminum-alloy sheet
and plate:
(1100)
(3003)
(5052)
(5083)
(5086)
(6061)
Al
Al
Al
Al
Al
Al
B-171
Copper and copper
alloys - Naval brass
(464)
B-11
Copper plates for
locomotive fireboxes
(110)
Cu
B-96
Copper-silicon alloy
plate and sheet for
pressure vessels:
(655)
Cu - Zn
B-152
Copper sheet, strip,
plate, and rolled bar:
(122)
Cu
B-171
Copper-nickel alloy plate
and sheet for pressure
vessels:
(715)
Cu - Ni 70/30
C
F
C
A1100
A3003
A5052
A5083
A5086
A6061
400
400
400
150
150
204
204
204
204
66
66
204
400
400
400
150
150
400
204
204
204
66
66
204
CA464
400
204
350
177
CU or
CA110
400
204
150
66
CA655
350
176
350
176
CA122
400
204
150
66
CA715
700
371
700
371
na = material not selectable for vacuum design
28-8
ASME Non-Ferrous Plate Materials - continued
ASTM
Spec
Description and
(Grade)
F
B-333
(B)
Hastelloy:
Ni - Mo
B-575
(C-276)
Hastelloy:
Ni - Mo - Cr
B-409
Specification for nickeliron-chromium alloy
plate, sheet, and strip:
(800)
Ni - Fe - Cr
B-424
Nickel-iron-chromiummolybdenum-copper
alloy plate, sheet, and
strip:
(825)
Ni - Fe - Cr - Mo - Cu
B-463
Carpenter 20 alloy plate,
sheet and strip:
(20Cb)
Cr-Ni-Fe-Mo-Cu-Cb
B-168
Nickel-chromium-iron
strip,
(600)
Inconel:
Ni - Cr - Fe
B-162
Nickel plate, sheet, and
strip:
(200)
Ni
(201)
Ni-Low C
B-127
Nickel-copper alloy
Ni - Cu
(400)
B-265
Titanium and titanium
alloy strip, sheet, and
plate:
(1)
(2)
Ti
Ti
HAST or
HASTB
C
F
C
800
426
800
426
HASTC
1000
537
1000
537
I800
1500
815
800
426
I825
1000
537
700
371
C 20
800
426
800
426
INCNL
or
I600
1200
648
800
426
NI or
NI200
NI201
600
600
1200
315
315
648
600
600
1000
315
315
537
MONEL
or
M400
900
482
800
426
TI35A
Tl
or
TI50A
600
600
315
315
600
600
315
315
600
315
600
315
28-9
ASME Design Code - Clad Plate
Materials
Material Classification
Description*
Grade
System
Material
Symbol
Vessel Base (Backing
Material)**
ASTM A-285
ASTM A-285
A-204
A-515
A-516
A-387
A-387
A-387
A-387
A-387
A-387
C
B
C
70
70
12
12
11
11
22
22
CL
CL
CL
CL
CL
CL
1
2
1
2
1
2
A285C
A204B
A204C
A 515
A 516
A387B
A387H
A387C
A387J
A387D
A387K
Cladding Material (Process
Side)
Stainless steel type
*
304
304L
316
316L
321
347
410
430
SS304
304L
SS316
316L
SS321
SS347
SS410
SS430
Nickel alloy
200
201
NI200
NI201
Monel
400
MONEL
Inconel
600
INCNL
Ni-Fe-Cr
800
I800
Ni-Fe-Cr-Mo-Cu
825
I825
Carpenter 20
20Cb
C 20
Titanium
2
Ti
Hastelloy B
B
HASTB
Hastelloy C
C-276
HASTC
See Plate Materials (ASME Code) for further material descriptions.
** Only these base materials may be used with the above list of cladding
materials.
No other combination may be selected.
28-10
ASME Design Code - Tube
Materials
ASME Ferrous Tube Materials - Carbon Steel
ASTM
Spec
Description and
System
Internal
Nominal Composition MaterialSymb Pressure
ol
Maximum
(Grade)
Temp.
F
A-179
C
External
Pressure
Maximu
m Temp.
F
System
Default
Tubesheet
Material
C (Plate)
Seamless cold-drawn
low-carbon steel heat
exchanger and
condenser tubes.
CS (seamless)
A 179
A-192
Seamless carbon steel
boiler tubes for highpressure service
A 192
1000 537 900 482 A 515
A-210
Seamless medium
carbon steel boiler and
superheater tubes
(A-1)
A210A
1000 537 900 482 A515
(C)
A210C
1000 537 900 482 A515
CS (welded)
A 214
1000 537 900 482 A515
A-214
Electric-resistancewelded carbon steel
heat exchanger and
condenser tubes
900
900
482 900 482 A285C
482 900 482 A285C
1000 537 900 482 A515
A-334
(1)
(6)
tubes for low
temperature service
A334A
A334B
700
700
371 700 371 A 442
371 700 371 A 442
28-11
ASME Ferrous Tube Materials - Low Alloy
Steel
ASTM
Spec
Description and
Nominal
(Grade) Composition
External
Pressure
Maximum
Temp.
System
Default
Tubesheet
Material
(Plate)
F
C
F
C
A199C
A199D
A199E
A199F
1200
1200
1200
1200
648
648
648
648
900
900
900
900
482
482
482
482
A387C
A387D
A387E
A387F
A-199
Seamless cold-drawn
intermediate alloy
steel heat exchanger
and condenser tubes:
(T11)
(T22)
(T21)
(T5)
1.25Cr - .5Mo - Si
2.5Cr - 1Mo
3Cr - .9Mo
5Cr - .5Mo
A-209
Seamless carbonmolybdenum alloy
steel boiler and
superheater tubes:
(T1)
(T1A)
(T1B)
C - .5Mo
C - .5Mo
C - .5Mo
A 209
A209A
A209B
1000
1000
1000
537
537
537
900
900
900
482
482
482
A 204
A 204
A 204
A-213
Seamless ferritic and
austenitic alloy steel
boiler, superheater,
and heat exchanger
tubes:
.5Cr - .5Mo
1Cr - .5Mo
1.25Cr - .5Mo - Si
2.25Cr - 1Mo
3Cr - .9Mo
5Cr - .5Mo
A213A
A213B
A213C
A213D
A213E
A213F
1000
1200
1200
1200
1200
1200
537
648
648
648
648
648
900
900
900
900
900
900
482
482
482
482
482
482
A387A
A387B
A387C
A387D
A387E
A387F
(T2)
(T12)
(T11)
(T22)
(T21)
(T5)
28-12
System Internal
Material Pressure
Symbol Maximum
Temp.
ASME Ferrous Tube Materials - High Alloy
Steel
ASTM
Spec
Description and
Nominal
(Grade) Composition
System
Material
Symbol
Internal
Pressure
Maximum
Temp.
External
Pressure
Maximum
Temp.
System
Default
Tubesheet
Material
(Plate)
F
C
F
C
1500
815
1000
537
SS304
1200
1500
648
815
1200
1000
648
537
304L
SS316
TP304
Seamless Ferritic
and austenitic alloy
steel boiler,
superheater, and
heat exchanger
tubes:
18Cr - 8Ni
TP304L
TP316
18Cr - 8Ni
16Cr - 12Ni - 2Mo
304S
(or SS)
304LS
316S
TP316L
TP321
TP347
16Cr - 12Ni - 2Mo
18Cr - 10Ni - Ti
18Cr - 10Ni - Cb
316LS
321S
347S
850
1500
1500
454
815
815
850
1000
1000
454
537
537
316L
SS321
SS347
A-249
TP304
TP304L
TP316
Welded austenitic
steel boiler
superheater, heat
exchanger, and
condenser tubes:
18Cr - 8Ni
18Cr - 8Ni
16Cr - 12Ni - 2Mo
304W
304LW
316W
1500
1200
1500
815
648
815
1000
1200
1000
537
648
537
SS304
SS304
SS316
TP316L
TP321
TP347
16Cr - 12Ni - 2Mo
18Cr - 10Ni - Ti
18Cr - 10Ni - Ti
316LW
321W
347W
850
1500
1500
454
815
815
815
1000
1000
426
537
537
316L
SS321
SS347
Seamless tubes
13C
Welded tubes
13C
410S
1200
648
900
482
SS410
410W
1200
648
900
482
SS410
600
315
650
343
S2205
A-213
A-268
TP410
TP410
A-789
Welded duplex
(S31803) austenitic steel
tubes:
22Cr - 5Ni - 3Mo
2205W
28-13
ASME Non-Ferrous Tube
Materials
ASTM
Spec
Description and
Nominal
(Grade) Composition
B-111
Seamless copper
and copper alloy
tubes for use in
surface condensers,
evaporators and
heat exchangers:
(122)
(687)
(706)
(715)
Cu
Cu - Al
Cu - Ni 90/10
Cu - Ni 70/30
Admiralty Brass
(443)
(444)
(445)
28-14
System
Material
Internal
Pressure
Maximum
Temp.
External
Pressure
Maximum
Temp.
F
C
F
C
System
Default
Tubesheet
Material
(Plate)
CA122
CA687
CA706
CA715
400
450
600
700
204
232
315
371
150
150
150
100
66
66
66
37
A285C
A285C
A285C
A285C
CA443
CA444
CA445
450
450
450
232
232
232
350
350
350
176
176
176
A285C
A285C
A285C
Symbol
B-163
Seamless colddrawn nickel tubes
for general
corrosive service:
(200)
(201)
Ni
Ni-Low C
NI200
NI201
600
1200
315
648
600
1000
315
537
NI200
NI201
B-163
(400)
Monel
Ni - Cu
MONEL
800
426
800
426
MONEL
B-163
(600)
Inconel
Ni - Cr - Fe
INCNL
or
I600
1200
648
1000
537
INCNL
B-163
(800)
(825)
Incoloy
Ni - Fe - Cr
Ni - Fe - Cr - Mo Cu
I800
I825
1500
1000
815
537
1000
700
537
371
I800
I825
B-619
(B)
Hastelloy
Ni - Mo
800
426
800
426
HASTB
(C-276)
Ni - Mo - Cr
1000
537
800
426
HASTC
B-468
(20Cb)
Carpenter 20
Cr - Ni - Fe - Mo Cu - Cb
C 20
800
426
800
426
C 20
B-338
(2)
Titanium
Ti
TI50A
600
315
600
315
TI50A
HAST or
HASTB
HASTC
BS Design Code - Plate
Materials
BS* or
ASTM
Spec
and
Description and
Symbol
F
C
F
C
(Grade)
650
343
-
-
622
327
na
na
A 285 or
A 285C
or CS
752
400
752
400
A 299
752
400
752
400
A 455
752
400
752
400
752
400
725
400
A-36
(Structural steel)
A-283
strength carbon
steel plates of structural A 283C
quality
154430*
A-285
plates for pressure
vessels
151400*
161400*
A-299
164400*
A-455
pressure vessels:
C - Mn - Si
carbon steel, high
strength manganese
225460*
A-515
224460*
A-516
224490*
A 36
temperature service:C Si
moderate and lower
C - Si
A 515
A 516
725
400
725
400
28-15
BS Ferrous Plate Materials - Heat Treated
Steel
BS* or
ASTM
Spec
and
Description and
Symbol
F
C
F
C
(Grade)
A-353
Nine percent nickel alloy
steel plates, double
normalized and
tempered for pressure
vessels:
510N*
9Ni
A 353
250
121
na
na
A-553
Eight and nine percent
nickel alloy steel plate,
quenched and
vessels:
9Ni
A 553
250
121
na
na
A517A
A517B
A517E
A517F
650
650
650
650
343
343
343
343
650
650
650
650
343
343
343
343
510*
A-517
High strength alloy steel
plates, quenched and
vessels:
(A)
(B)
(E)
(F)
Cr
Cr
Cr
Cr
-
Mn
Mn
Mn
Mn
-
Si
Si
Si
Si
28-16
BS* or
ASTM
Spec
and
Description and
Symbol
F
C
F
C
(Grade)
A-202
(A)
(B)
Chromium-manganesesilicon alloy steel plates
for pressure vessels
A202A
A 202
or
A202B
1000
1000
537
537
900
900
482
482
A203A
A203B
A203E
A203D
1000
1000
1000
122
537
537
537
50
900
900
900
122
482
482
482
50
A-203
Nickel alloy steel plates
for pressure vessels:
(A)
(B)
(E)
503*
2.5Ni
2.5Ni
3.5Ni
3.5Ni
A-204
Molybdenum alloy steel
plates for pressure
vessels:
(C)
C - .5Mo
A 204
1000
537
900
482
240*
261*
C - .5Mo
C - .5Mo
A204C
A204A
A204B
752
752
400
400
752
752
400
400
A-302
(A)
(B)
pressure vessels:
Mn - .5Mo
Mn - .5Mo
1000
1000
537
537
900
900
482
482
(C)
(D)
Mn - .5Mo - Ni
Mn - .5Mo - Ni
A302A
A 302
or
A302B
A302C
A302D
1000
1000
537
537
900
900
482
482
28-17
(continued)
BS* or
ASTM
Spec
and
Description and
Nominal
Composition
Symbol
F
C
F
C
(Grade)
A-387
(2 CL 1)
(2 CL 2)
Pressure vessel
plates, alloy steel,
chromiummolybdenum:
.5Cr - .5Mo
.5Cr - .5Mo
A387A
A387G
842
842
450
450
842
842
450
450
620*
1Cr - .5Mo
(12 CL 2) 1Cr - .5Mo
A387B
A387H
842
896
450
480
842
896
450
480
621*
1.25Cr - .5Mo - Si
(11 CL 2) 1.25Cr - .5Mo - Si
A387C
A387J
842
896
450
480
842
896
450
480
622515*
2.25Cr - 1Mo
(22 CL 2) 2.25Cr - 1Mo
A387D
A387K
842
896
450
480
842
896
450
480
(21 CL 1) 3Cr - 1Mo
(21 CL 2) 3Cr - 1Mo
A387E
A387L
896
896
480
480
896
896
480
480
(5 CL 1)
(5 CL 2)
5Cr - .5Mo
5Cr - .5Mo
A387F
A387M
896
896
480
480
896
896
480
480
A-533
alloy steel plates,
quenched and
tempered, for
pressure vessels:
C - Mn - Mo
C - Mn - Mo - Ni
C - Mn - Mo - Ni
A533A
A533B
A533C
1000
800
800
537
426
426
650
650
650
343
343
343
(A CL 1)
(B CL 1)
(C CL 1)
28-18
BS Ferrous Plate Materials - High Alloy Steel
BS* or
ASTM
Spec and
Description and
Nominal
Composition
Symbol
F
C
F
C
(Grade)
A-240
(317)
(348)
Chromium and
chromium-nickel
pressure vessels:
18Cr - 10Ni - 3Mo
18Cr - 10Ni - Cb
SS317
SS348
1292
1292
700
700
1200
1200
648
648
318-S13*
Duplex
22Cr - 5Ni - 3Mo
S2205
600
315
650
343
(410)
(430)
13Cr
17Cr
SS410
SS430
1200
1200
648
648
900
1200
482
648
304-S31*
304-S11*
316-S31*
18Cr - 8Ni
18Cr - 8Ni
16Cr - 12Ni - 2Mo
SS304
304L
SS316
1292
752
1292
700
400
700
1200
752
1200
648
400
648
316-S11*
320-517*
321-S31*
347-S31*
16Cr
16Cr
18Cr
18Cr
316L
316TI
SS321
SS321
752
1292
1292
1292
400
700
700
700
752
1200
1200
1200
400
648
648
648
-
12Ni
12Ni
10Ni
10Ni
- 2Mo
- 2Mo - Ti
- Ti
- Cb
28-19
BS Non-Ferrous Plate Materials
BS* or
ASTM
Spec
and
Description and
Symbol
F
C
F
C
(Grade)
1470*
Aluminum-alloy sheet
and plate:
(1100)*
(3003)*
(5052)*
(5083)*
(5086)*
(6061)*
Al
Al
Al
Al
Al
Al
B-171
Copper and copper
alloys - Naval brass
(464)
B-11
(110)
A1100
A3003
A5052
A5083
A5086
A6061
400
400
400
150
150
400
204
204
204
66
66
204
na
na
na
na
na
na
na
na
na
na
na
na
400
204
200
93
CU or
CA110
400
204
150
66
CA655
350
176
200
93
CA122
400
204
150
66
CA715
700
371
200
93
CA464
Copper plates for
locomotive fireboxes:
Cu
B-96
Copper-silicon alloy
plate and sheet for
pressure vessels:
(655)
Cu - Zn
B-152
Copper sheet, strip,
plate, and rolled bar:
(122)
Cu
B-171
Copper-nickel alloy plate
and sheet for pressure
vessels:
(715)
Cu - Ni 70/30
28-20
BS Non-Ferrous Plate Materials (continued)
BS* or
ASTM
Spec
and
Description and
Symbol
F
C
F
C
(Grade)
B-333
(B)
Hastelloy:
Ni - Mo
B-575
(C-276)
Hastelloy:
Ni - Mo - Cr
B-409
Specification for nickeliron-chromium alloy
(800)
Ni - Fe - Cr
B-424
Nickel-iron-chromiummolybdenum-copper
strip:
NA15*
Ni-Fe-Cr-Mo-Cu
B-463
sheet and strip:
Cr - Ni - Fe - Mo - Cu - C 20
Cb
(20Cb)
B-168
Nickel-chromium-iron
strip:
(600)
Ni-Cr-Fe
B-162
strip:
(200)
(201)
Ni
Ni-Low C
B-127
Nickel-copper alloy
Ni - Cu
(400)
B-265
(1)
(2)
Titanium and titanium
alloy strip, sheet,
Ti
Ti
HAST or
HASTB
800
426
800
426
HASTC
1000
537
800
426
I800
1292
700
800
426
I825
500
260
400
204
800
426
800
426
INCNL
or
I600
1200
648
800
426
NI or
NI200
NI201
600
600
1200
315
315
648
600
600
800
315
315
426
MONEL
or
M400
900
482
800
426
TI35A
TI or
TI50A
600
600
600
315
315
315
na
600
600
na
315
315
28-21
BS Design Code - Clad Plate
Materials
Description
Grade
System
Material
Symbol
Vessel Base (Backing Material)**
161-400
ASTM
A-285
C
A285C
261
A-204
B
A204B
A-204
C
A204C
224-460
A-515
70
A 515
224-490
A-516
70
A 516
620
A-387
12 CL 1
A387B
620
A-387
12 CL 2
A387H
621
A-387
11 CL 1
A387C
621
A-387
11 CL 2
A387J
622-515
A-387
22 CL 1
A387D
622-515
A-387
22 CL 2
A387K
304-S31
304
SS304
304-S11
304L
304L
316-S31
316
SS316
316-S11
316L
316L
321-S31
321
SS321
347-S31
347
SS347
410
SS410
430
SS430
Cladding Material (Process Side)
Nickel alloy
200
NI200
201
NI201
Monel
400
MONEL
Inconel
600
INCNL
Ni-Fe-Cr
800
I800
Ni-Fe-Cr-Mo-Cu
825
I825
Carpenter 20
20Cb
C 20
Titanium
2
TI
Hastelloy B
B
HASTB
Hastelloy C
C-276
HASTC
*
See Plate Materials (BS Code) for further material descriptions.
materials. No other combination may be selected.
28-22
BS Design Code - Tube
Materials
BS Ferrous Tube Materials - Carbon Steel
BS*
Description and
or ASTM Nominal
Spec and Composition
(Grade)
A-179
F
(A-1)
(C)
A-214
360*
F
C
System
Default
Tubesheet
Material
(Plate)
A 179
752
400
752
400
A285C
A 192
752
400
752
400
A 515
A210A
A210C
1000
1000
537
537
900
900
482
482
A 515
A 515
A 214
842
450
842
450
A 515
700
700
371
371
700
700
371 A 442
371 A 442
410*
A-210
C
External
Pressure
Maximum
Temp.
Seamless cold-drawn
exchanger and
condenser tubes
320*
A-192
System Internal
Material Pressure
Symbol Maximum
Temp.
Seamless medium
carbon steel boiler
and superheater
tubes
heat exchanger and
condenser tubes
tubes for low
410-LT50* temperature service
A334A
(6)
A334B
A-334
28-23
BS Ferrous Tube Materials - Low Alloy Steel
BS*
Description and
or ASTM Nominal
(Grade)
28-24
System Internal
Material Pressure
Symbol Maximum
Temp.
F
A-199
Seamless cold-drawn
intermediate alloy
(T11)
(T22)
(T21)
(T5)
1.25Cr - .5Mo - Si
2.5Cr - 1Mo
3Cr - .9Mo
5Cr - .5Mo
A-209
steel boiler and
superheater tubes:
(T1)
245-450*
(T1B)
C - .5Mo
C - .5Mo
C - .5Mo
A-213
and heat exchanger
tubes:
(T2)
(T21)
620-460*
620-460*
622-490*
625-450*
External
Pressure
Maximum
Temp.
C
F
C
System
Default
Tubesheet
Material
(Plate)
A199C
A199D
A199E
A199F
1022
1022
1022
1022
550
550
550
550
900
900
900
900
482
482
482
482
A387C
A387D
A387E
A387F
A 209
A209A
A209B
1000 537
752
400
1000 537
900
752
900
482
400
482
A 204
A 204
A 204
.5Cr - .5Mo
3Cr - .9Mo
A213A
A213E
1000 537
1022 550
900
900
482
482
A387A
A387E
1Cr - .5Mo
1.25Cr - .5Mo - Si
2.25Cr - 1Mo
5Cr - .5Mo
A213B
A213C
A213D
A213F
1022
1022
1022
1022
900
900
900
900
482
482
482
482
A387B
A387C
A387D
A387F
550
550
550
550
BS Ferrous Tube Materials - High Alloy Steel
BS* or
Description and
ASTM
Nominal
(Grade)
System Internal
Material Pressure
Symbol Maximum
Temp.
F
C
External
Pressure
Maximum
Temp.
F
C
System
Default
Tubesheet
Material
(Plate)
304-S18*
304-S14*
316-S18*
Seamless Ferritic
steel boiler,
superheater, and
heat exchanger
tubes:
18Cr - 8Ni
18Cr - 8Ni
16Cr - 12Ni - 2Mo
304S
304LS
316S
842
752
842
450
400
450
842
752
842
450
400
450
SS304
304L
SS316
316-S14*
321-S18*
347-S18*
16Cr - 12Ni - 2Mo
18Cr - 10Ni - Ti
18Cr - 10Ni - Cb
316LS
321S
347S
842
842
842
450
450
450
800
842
842
426
450
450
316L
SS321
SS347
A-249
Welded austenitic
steel boiler
superheater, heat
exchanger,
and condenser
tubes:
304-S25*
304-S22*
316-S26*
18Cr - 8Ni
18Cr - 8Ni
16Cr - 12Ni - 2Mo
304W
304LW
316W
842
752
842
450
400
450
842
752
842
450
400
450
SS304
304L
SS316
316-S22*
321-S22*
347-S17*
16Cr - 12Ni - 2Mo
18Cr - 10Ni - Ti
18Cr - 10Ni - Cb
316LW
321W
347W
842
842
842
450
450
450
800
842
842
426
450
450
316L
SS321
SS347
Seamless tubes
13 Cr
Welded tubes
13 Cr
410S
752
400
752
400
SS410
410W
752
400
752
400
SS410
2205W
600
315
A-213
A-268
TP410
TP410
A-789
(S31803)
Welded duplex
austenitic steel
tubes:
22Cr - 5Ni - 3Mo
650
343
S2205
28-25
BS Non-Ferrous Tube Materials
BS*or
Description and
ASTM
Nominal
(Grade)
28-26
System Internal
Material Pressure
Symbol Maximum
Temp.
External
Pressure
Maximum
Temp.
F
C
F
C
System
Default
Tubesheet
Material
(Plate)
B-111
Seamless copper and
copper alloy tubes for
use in surface
condensers,
evaporators and heat
exchangers:
(122)
(687)
(708)
(715)
Cu
Cu - Al
Cu - Ni 90/10
Cu - Ni 70/30
CA122
CA687
CA706
CA715
400
450
600
700
204
230
315
371
150
200
150
200
66
93
66
93
A285C
A285C
A285C
A285C
(443)
(444)
(445)
Admiralty Brass
CA443
CA444
CA445
450
450
450
232
232
232
200
200
200
93
93
93
A285C
A285C
A285C
B-163
Seamless cold-drawn
nickel tubes for
general corrosive
service:
(200)
(201)
Ni
Ni - Low C
NI200
NI201
600
1200
315
648
600
800
315
426
NI200
NI201
B-163
(400)
Monel (Seamless)
Ni - Cu
MONEL
900
482
800
426
MONEL
B-163
(600)
Inconel (Welded)
Ni - Cr - Fe
INCNL
or
I600
1200
648
800
426
INCNL
B-163
(800)
(825)
Incoloy
Ni - Fe - Cr (Welded)
Ni - Fe - Cr - Mo
- Cu (Seamless)
I800
I825
1292
1000
700
537
800
500
426
260
I800
I825
B-619
(B)
Hastelloy (Welded)
Ni - Mo
800
426
800
426
HASTB
(C-276)
Ni - Mo - Cr
1202
650
800
426
HASTC
B-468
(20Cb)
Carpenter 20 (Welded)
Cr - Ni - Fe - Mo- Cu - C 20
Cb
800
426
800
426
C 20
B-338
(2)
Titanium (Welded)
Ti
600
315
600
315
TI50A
HAST or
HASTB
HASTC
TI50A
JIS Design Code - Plate
Materials
JIS Ferrous Plate Materials - Carbon Steel
JIS*or
Description and Nominal
ASTM
Composition
Spec and
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
G-3101*
SS400*
(structural steel)
G-3106*
Low and intermediate strength
carbon steel plates of structural
quality
SM520C*
G-3115*
External
Pressure
Temp.
Degrees
C
F
C
A 36
650
343
-
-
A 283 C
662
350
na
na
A 285 or
A 285C or
CS
662
350
662
350
A 299
662
350
662
350
A 455
650
343
650
343
A 515
662
350
662
350
A 516
662
350
662
350
Low and intermediate strength
steel plates for pressure vessels
SPV355*
G-3115*
Carbon-manganese-silicon steel
plates for pressure vessels:
SPV450*
C - Mn - Si
A-455
Pressure vessel plates, carbon
steel, high strength manganese
(A)
G-3118*
Carbon steel plates for pressure
vessels for intermediate and
higher temperature service
SGV480*
C - Si
G-3126*
Carbon steel plates for pressure
vessels for moderate and lower
SLA360*
C - Si
28-27
JIS Ferrous Plate Materials - Heat Treated
Steel
JIS*or
ASTM
Composition
Spec and
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
G-3127*
C
F
C
na
na
Nine percent nickel alloy steel
plates, double normalized and
tempered for pressure vessels:
SL9N520* 9Ni
G-3127*
External
Pressure
Temp.
Degrees
A 353
392
200
Eight and nine percent nickel alloy
steel plate, quenched and
tempered, for pressure vessels:
SL9N590* 9Ni
A 553
A-517
High strength alloy steel plates,
quenched and tempered, for
pressure vessels:
(A)
(B)
(E)
(E)
Cr
Cr
Cr
Cr
-
Mn
Mn
Mn
Mn
-
Si
Si
Si
Si
A517A
A517B
A517E
A517E
392
650
650
650
650
200
343
343
343
343
na
650
650
650
650
na
343
343
343
343
28-28
JIS Ferrous Plate Materials - Low Alloy Steel
JIS*or
ASTM
Spec and
Composition
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
A-202
(A)
(B)
G-3127*
SL2N255*
(B)
SL3N255*
SL3N275*
Chromium-manganese-silicon
alloy steel plates for pressure
vessels
C
External
Pressure
Temp.
Degrees
F
C
A202A
A 202 or
A202B
1000
1000
537
537
900
900
482
482
A203A
A203B
A203D
A203E
392
1000
392
392
200
537
200
200
392
900
122
392
200
482
50
200
A204A
A204B
A204 or
A204C
1022
1022
1000
550
550
537
752
752
900
400
400
482
A302A
A 302
or A302B
A302C
A302D
977
1022
525
550
900
900
482
482
1022
1022
550
550
900
900
482
482
Nickel alloy steel plates for
pressure vessels:
2.5Ni
2.5Ni
3.5Ni
3.5Ni
G-3103*
Molybdenum alloy steel plates
for pressure vessels:
SB450M*
SB480M*
(C)
C - .5Mo
C - .5Mo
C - .5Mo
G-3119*
Manganese-molybdenum and
manganese-molybdenum-nickel
alloy steel plates for pressure
vessels:
SBV1A*
SBV1B*
Mn - .5Mo
Mn - .5Mo
SBV2*
SBV2*
Mn - .5Mo - Ni
Mn - .5Mo - Ni
28-29
JIS*or
ASTM
Spec and
Composition
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
G-4109*
C
External
Pressure
Temp.
Degrees
F
C
Pressure vessel plates, alloy
steel, chromium-molybdenum:
SCMV1(A)* .5Cr - .5Mo
SCMV1(N)* .5Cr - .5Mo
A387A
A387G
1022
1022
550
550
900
900
482
482
SCMV2(A)* 1Cr - .5Mo
SCMV2(N)* 1Cr - .5Mo
A387B
A387H
1157
1157
625
625
842
842
450
450
SCMV3(A)* 1.25Cr - .5Mo - Si
SCMV3(N)* 1.25Cr - .5Mo - Si
A387C
A387J
1157
1157
625
625
896
896
480
480
SCMV4(A)* 2.25Cr - 1Mo
SCMV4(N)* 2.25Cr - 1Mo
A387D
A387K
1067
1067
575
575
896
896
480
480
SCMV5(A)* 3Cr - 1Mo
SCMV5(N)* 3Cr - 1Mo
A387E
A387L
1157
1157
625
625
896
896
480
480
SCMV6(A)* 5Cr - .5Mo
SCMV6(N)* Cr - .5Mo
A387F
A387M
1157
1157
625
625
896
896
480
480
A533A
A533B
A533C
1022
797
797
550
425
425
na
na
na
na
na
na
G-3120*
Manganese-molybdenum and
manganese-molybdenum-nickel
alloy steel plates, quenched and
SQV1A*
SQV2A*
SQV3A*
C - Mn - Mo
C - Mn - Mo-Ni
C - Mn - Mo-Ni
28-30
JIS Ferrous Plate Materials - High Alloy
Steel
JIS*or
ASTM
Composition
Spec and
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
G-4303*
G-4304*
G-4305*
C
External
Pressure
Temp.
Degrees
F
C
Chromium and chromium-nickel
stainless steel plate, sheet, and
strip for fusion-welded unfired
pressure vessels:
SUS304L* 18Cr - 8Ni
SUS304* 18Cr - 8Ni
304L
SS304
797
1472
425
800
752
1200
400
648
SUS316L* 16Cr - 12Ni - 2Mo
SUS316* 16Cr - 12Ni - 2Mo
SUS316* 16Cr - 12Ni - 2Mo-Ti
316L
SS316
SS316TI
842
1472
1472
450
800
800
752
1200
1200
400
648
648
SUS317*
SUS321*
SUS347*
(348)
18Cr
18Cr
18Cr
18Cr
3Mo
Ti
Cb
Cb
SS317
SS321
SS347
SS348
1472
1472
1472
1500
800
800
800
815
1200
1200
1200
1200
648
648
648
648
(2205)
Duplex
22Cr - 5Ni - 3Mo
S2205
600
315
650
343
SUS410*
SUS430*
13Cr
17Cr
SS410
SS430
1202
1202
650
650
900
1200
482
648
-
10Ni
10Ni
10Ni
10Ni
-
28-31
JIS Non-Ferrous Plate Materials
JIS*or
ASTM
Composition
Spec and
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
C
External
Pressure
Temp.
Degrees
F
C
H-4000*
A1100P*
A3003P*
A5052P*
A5083P*
A5086P*
A6061P*
Aluminum-alloy sheet and plate:
Al
Al
Al
Al
Al
Al
A1100
A3003
A5052
A5083
A5086
A6061
392
392
392
150
150
392
200
200
200
66
66
200
na
na
na
na
na
na
na
na
na
na
na
na
H-3100*
C4640P*
Copper and copper alloys - Naval CA464
brass
392
200
350
177
H3100*
Copper plates for locomotive
fireboxes:
C1100P*
Cu
CU or
CA110
392
200
150
66
B-96
Copper-silicon alloy plate and
sheet for pressure vessels:
(B55)
Cu - Zn
CA655
350
176
350
176
H-3100*
Copper sheet, strip, plate, and
rolled bar:
C1220P*
Cu
CA122
392
200
150
66
H-3100*
Copper-nickel alloy plate and
C7150P*
Cu - Ni 70/30
CA715
662
350
662
350
28-32
JIS Non-Ferrous Plate Materials - continued
JIS*or
ASTM
Composition
Spec and
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
B-333
(B)
Hastelloy:
Ni - Mo
B-575
(C-276)
Hastelloy:
Ni - Mo - Cr
G-4902*
Specification for nickel-ironchromium alloy plate, sheet, and
strip:
NCF800*
Ni - Fe - Cr
B-424
Nickel-iron-chromiummolybdenum-copper alloy plate,
sheet, and strip:
(825)
B-463
Carpenter 20 alloy plate, sheet
and strip:
(20Cb)
Cr - Ni - Fe - Mo - Cu - Cb
G-4902*
Nickel-chromium-iron alloy plate,
sheet, and strip,
NCF600*
Inconel:
B-162
(200)
Nickel plate, sheet, and strip:
Ni
(201)
Ni-Low C
H-4551*
Nickel-copper alloy plate, sheet,
and strip:
NCuP*
Ni - Cu
H-4600*
Titanium and titanium alloy strip,
sheet, and plate:
TP28*
TP35*
Ti
Ti
Ni - Cr - Fe
C
External
Pressure
Temp.
Degrees
F
C
426
HAST or
HASTB
800
426
800
HASTC
1000
537
1000 537
I800
1472
800
1000 537
I825
1000
537
700
371
C 20
800
426
800
426
INCNL
or
I600
1202
650
1000 537
NI or
NI200
NI201
600
600
1200
315
315
648
600
315
600
315
1000 537
MONEL
or
M400
932
500
800
426
TI35A
TI or
TI50A
662
662
662
350
350
350
na
600
600
na
315
315
28-33
JIS Design Code - Clad Plate Materials
Material Classification Description
Grade
System
Material
Symbol
ASTM A-285
A-204
A-204
A-515
C
B
C
70
A285C
A204B
A204C
A 515
A-516
A-387
A-387
A-387
A-387
A-387
A-387
70
12
12
11
11
22
22
A 516
A387B
A387H
A387C
A387J
A387D
A387K
SPV350
SB480M
SGV480
SLA360
SCMV2(A)
SCMV2(A)
SCMV3(A)
SCMV3(A)
SCMV4(A)
SCMV4(A)
CL
CL
CL
CL
CL
CL
1
2
1
2
1
2
SUS304
SUS304L
SUS316
SUS316L
SUS321
SUS321
SUS321
SUS430
Nickel alloy
Monel
NCUP
Inconel
NCF600
Ni-Fe-CR
Ni-Fe-Cr-Mo-Cu
Carpenter 20
Titanium
Hastelloy B
Hastelloy C
*
304
304L
316
316L
321
347
410
430
200
201
SS304
304L
SS316
316L
SS321
SS347
SS410
SS430
NI200
NI201
400
MONEL
600
800
825
20 CB
2
B
C-276
INCNL
I800
I825
C 20
Ti
HASTB
HASTC
See Plate Materials (JIS Code) for further material descriptions.
materials.
No other combination may be selected.
28-34
JIS Design Code - Tube
Materials
JIS Ferrous Tube Materials - Carbon Steel
JIS*
Description and
or ASTM Nominal
(Grade)
G-3461*
STB340*
Seamless cold-drawn
exchanger and
condenser tubes
System Internal
Material Pressure
Symbol Maximum
Temp.
External
Pressure
Maximum
Temp.
F
C
F
C
System
Default
Tubesheet
Material
(Plate)
A 179
1022
550
752
400
A285C
A-192
Seamless carbon steel A 192
1000
537
900
482
A 515
G-3461*
Seamless medium
superheater tubes
A210A
A210C
1022
1022
550
550
900
900
482
482
A 515
A 515
A 214
1022
550
900
482
A 515
A334A
A334B
700
700
371
371
700
700
371
371
A 442
A 442
STB510*
STB410*
G-3461*
heat exchanger and
condenser tubes
STB340*
G-3464*
tubes for low
temperature service
(1)
STBL380*
28-35
JIS Ferrous Tube Materials - Low Alloy Steel
JIS*
Description and
System Internal
Nominal
Composition
Material Pressure
or ASTM
Spec and
Symbol Maximum
Degrees
(Grade)
F
C
28-36
G-3462*
Seamless cold-drawn
intermediate alloy steel
heat exchanger and
condenser tubes:
STBA23*
STBA24*
(T21)
STBA25*
1.25Cr - .5Mo - Si
2.5Cr - 1Mo
3Cr - .9Mo
5Cr - .5Mo
G-3462*
Seamless carbonmolybdenum alloy steel
boiler and superheater
tubes:
STBA12*
STBA13*
(T1B)
C - .5Mo
C - .5Mo
C - .5Mo
G-3462*
boiler, superheater, and
heat exchanger tubes:
STBA20*
STBA20*
(T11)
(T22)
(T21)
(T5)
.5Cr - .5Mo
1Cr - .5Mo
1.25Cr - .5Mo - Si
2.25Cr - 1Mo
3Cr - .9Mo
5Cr - .5Mo
External
Pressure
Temp.
Degrees
F
C
System
Default
Tubesheet
Material
(Plate)
A199C
A199D
A199E
A199F
1202
1202
1200
1202
650
650
648
650
900
900
900
900
482
482
482
482
A 209
A209A
A209B
1022
1022
1000
550
550
537
900
900
900
482 A 204
482 A 204
482 A 204
A213A
A213B
A213C
A213D
A213E
A213F
1022
1202
1200
1200
1200
1200
550
650
648
648
648
648
900
900
900
900
900
900
482
482
482
482
482
483
A387C
A387D
A387E
A387F
A387A
A387B
A387C
A387D
A387E
A387F
JIS Ferrous Tube Materials - High Alloy
Steel
JIS*
or ASTM
Spec and
Description and
Nominal
Composition
(Grade)
System Internal
Material Pressure
Symbol Maximum
Temp.
External
Pressure
Maximum
Temp.
System
Default
Tubesheet
Material
(Plate)
F
C
F
C
Seamless Ferritic
steel boiler,
superheater, and
heat exchanger
tubes:
SUS304TB* 18Cr - 8Ni
304S
SUS304LTB* 18Cr - 8Ni
304LS
SUS316TB* 16Cr - 12Ni - 2Mo 316S
1472
797
1472
800
425
800
842
752
842
450
450
450
SS304
304L
SS316
SUS316LTB* 16Cr - 12Ni - 2Mo
SUS321TB* 18Cr - 10Ni - Ti
SUS347TB* 18Cr - 10Ni - Cb
316LS
321S
347S
842
1472
1472
450
800
800
842
842
842
450
400
450
316L
SS321
SS347
SUS304TB* 18Cr - 8Ni
SUS304LTB* 18Cr - 8Ni
SUS316TB* 16Cr - 12Ni - 2Mo
304W
304LW
316W
1472
797
1472
800
425
800
842
752
842
450
400
450
SS304
304L
SS316
SUS316LTB* 16Cr - 12Ni - 2Mo
SUS321TB* 18Cr - 10Ni - Ti
SUS347TB* 18Cr - 10Ni - Cb
316LW
321W
347W
842
1472
1472
450
800
800
842
842
842
450
450
450
316L
SS321
SS347
A-268
TP 410
Seamless tubes
13Cr
410S
752
400
752
400
SS410
TP 410
Welded tubes
13Cr
410W
752
400
752
400
SS410
A-789
Welded duplex
austenitic steel
tubes:
(S31803)
22Cr - 5Ni - 3Mo
2205W
600
315
650
343
S2205
G-3463*
G-3463*
Welded austenitic
steel boiler
superheater, heat
exchanger, and
condenser tubes:
28-37
JIS Non-Ferrous Tube Materials
JIS*or
ASTM
Spec and
Description and
Nominal
Composition
(Grade)
External
Pressure
Maximum
Temp.
F
C
F
C
System
Default
Tubesheet
Material
(Plate)
H-3300*
Seamless copper and
copper alloy tubes for
use in surface
condensers,
evaporators and heat
exchangers:
C1220T*
C6871T*
C7060T*
C7150T*
Cu
Cu - Al
Cu - Ni 90/10
Cu - Ni 70/30
CA122
CA687
CA706
CA715
392
392
572
662
200
200
300
350
150
150
150
700
66
66
66
371
A285C
A285C
A285C
A285C
C4430T*
(444)
(445)
Admiralty Brass
CA443
CA444
CA445
437
450
450
225
232
232
350
350
350
176
176
176
A285C
A285C
A285C
B-163
Seamless cold-drawn
nickel tubes for
general corrosive
service:
(200)
(201)
Ni
Ni-Low C
NI200
NI201
600
1200
315
648
600
1000
315
537
NI200
NI201
H-4552*
NCuT*
Monel
Ni - Cu
MONEL
887
475
752
400
MONEL
INCNL
or
I600
1202
650
1000
537
INCNL
I800
I825
1472
1000
800
537
1000
700
537
371
I800
1825
800
426
800
426
HASTB
1000
537
1000
537
HASTC
800
426
800
426
C 20
662
350
600
315
TI50A
G-4904*
Inconel
NCF600TB* Ni - Cr - Fe
Incoloy
G-4904*
NCF800TB* Ni - Fe - Cr
NCF825TB* Ni - Fe - Cr - Mo - Cu
28-38
System Internal
Material Pressure
Symbol Maximum
Temp.
B-619
(B)
Hastelloy
Ni - Mo
(C-276)
Ni - Mo - Cr
B-468
(20Cb)
Carpenter 20
Cr - Ni - Fe - Mo - Cu - C 20
Cb
H-4650*
TB35*
Titanium
Ti
HAST or
HASTB
HASTC
TI50A
DIN Design Code - Plate
Materials
DIN Ferrous Plate Materials - Carbon Steel
DIN*or ASTM
Spec and
(Grade)
Description and Nominal System Internal
Composition
Material Pressure
Symbol Maximum
Degrees
F
DIN EN 1002591*
S235JRG1*
(structural steel)
DIN EN 1002591*
plates of structural quality
S235JRG2*
DIN 17155*
HII*
strength steel plates for
pressure vessels
External
Pressure
Temp.
Degrees
C
F
C
A 36
650
343
-
-
A 283C
662
350
na
na
1022
550
896
480
A 285 or
A 285C or
CS
DIN 17102*
Carbon-manganese-silicon
steel plates for pressure
vessels:
St E 355*
C - Mn - Si
A 299
662
350
662
350
A-455
carbon steel, high strength
manganese
A 455
650
343
650
343
A 515
662
350
662
350
A 516
662
350
662
350
(A)
DIN 17155*
19Mn5*
DIN 17102*
moderate and lower
SIE315*
C - Si
28-39
DIN Ferrous Plate Materials - Heat Treated
Steel
DIN*
or ASTM
Spec and
Composition
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
C
External
Pressure
Temp.
Degrees
F
C
SEW 680* Nine percent nickel alloy steel
plates, double normalized and
tempered for pressure vessels:
X8Ni9*
A 353
392
200
na
na
A 553
392
200
na
na
A517A
A517B
A517E
A517E
650
650
650
650
343
343
343
343
650
650
650
650
343
343
343
343
SEW 680* Eight and nine percent nickel alloy
steel plate, quenched and
X8Ni9*
A-517
High strength alloy steel plates,
quenched and tempered, for
pressure vessels:
(A)
(B)
(E)
(F)
Cr
Cr
Cr
Cr
-
Mn
Mn
Mn
Mn
-
Si
Si
Si
Si
28-40
DIN Ferrous Plate Materials - Low Alloy
Steel
DIN*or
ASTM Spec and
(Grade)
Description and
Nominal
Composition
System Internal
Material Pressure
Symbol Maximum
Degrees
F
A 202
(A)
(B)
SEW 680*
(D)
(E)
Chromiummanganese-silicon
pressure vessels
Nickel alloy steel
plates for pressure
vessels:
14Ni6*
10Ni14*
3.5Ni
3.5Ni
DIN 17155*
Molybdenum alloy
steel plates for
pressure vessels:
(B)
(C)
15Mo3*
C - .5Mo
C - .5Mo
C
External
Pressure
Temp.
Degrees
F
C
A202A
1000
A 202 or 1000
A202B
537
537
900
900
482
482
A203A
A203B
A203D
A203E
392
1000
392
392
200
537
200
200
392
900
122
392
200
482
50
200
A204A
1022
A204B
1022
A 204 or 1000
A204C
550
550
537
752
752
900
400
400
482
977
A 302 or 1022
A302B
1022
A302C
1022
A302D
525
550
900
900
482
482
550
550
900
900
482
482
pressure vessels:
VdTUV Wbl.376 WB35* 17Mn Mo V64*
VdTUV Wbl.377 WB36* 15Ni Cu Mo Nb5*
VdTUV Wbl.378*
VdTUV Wbl384 WB34*
12Mn Ni Mo55*
13Mn Ni Mo54*
A302A
28-41
DIN*or
ASTM Spec and
(Grade)
Description and
Nominal
Composition
System Internal
Material Pressure
Symbol Maximum
Degrees
F
C
External
Pressure
Temp.
Degrees
F
C
Pressure vessel
plates, alloy steel,
chromiummolybdenum:
(A)
(G)
.5Cr - .5Mo
.5Cr - .5Mo
A387A
A387G
1022
1022
550
550
900
900
482
482
DIN 17155*
DIN 17155*
13Cr Mo44*
13Cr Mo44*
A387B
A387H
1157
1157
500
625
842
842
450
450
(C)
(J)
1.25Cr - .5Mo - Si
1.25Cr - .5Mo - Si
A387C
A387J
1157
1157
625
625
896
896
480
480
DIN 17155*
VdTUV Wbl.404*
10Cr Mo910*
12Cr Mo910*
A387D
A387K
1067
1067
500
575
896
896
480
480
VdTUV Wbl.007*
VdTUV Wbl.007*
12Cr Mo195*
12Cr Mo195*
A387E
A387L
1157
1157
625
625
896
896
480
480
(F)
(M)
5Cr - .5Mo
Cr - .5Mo
A387F
A387M
1157
1157
625
625
896
896
480
480
SEW 640*
alloy steel plates,
quenched and
tempered, for
pressure vessels:
C - Mn - Mo
20 Mn Mo Ni55*
12 Mn Ni Mo55*
A533A
A533B
A533C
1022
797
797
550
425
425
na
na
na
na
na
na
(A)
28-42
DIN Ferrous Plate Materials - High Alloy
Steel
DIN*
or ASTM
Spec and
Composition
(Grade)
DIN
17440*
System Internal
Material Pressure
Symbol Maximum
Degrees
F
C
External
Pressure
Temp.
Degrees
F
C
Chromium and chromium-nickel
stainless steel plate, sheet, and
strip for fusion-welded unfired
pressure vessels:
X2 Cr Ni1911*
X5 Cr Ni1810*
304L
SS304
797
1472
425
800
752
1200
400
648
X2 Cr Ni Mo17132*
X5 Cr Ni Mo17122*
X6 Cr Ni Mo Ti 17122*
316L
SS316
316TI
842
1472
1472
450
800
800
752
1200
1200
400
648
648
X2 Cr Ni Mo18164*
X6 Cr Ni Ti1810*
X6 Cr Ni Nb1810*
SS317
SS321
SS347
SS348
1472
1472
1472
1500
800
800
800
815
1200
1200
1200
1200
648
648
648
648
(2205)
Duplex
22Cr - 5Ni - 3Mo
S2205
600
315
650
343
DIN
17440*
X10 Cr13*
X6 Cr17*
SS410
SS430
1202
1202
650
650
900
1200
482
648
(348)
28-43
DIN Non-Ferrous Plate Materials
DIN*or
ASTM Spec Compostion
and
(Grade)
System Internal
Material Pressure
Symbol Maximum
Degrees
F
DIN 1745
A1100P*
(655)
DIN 1787*
C
A1100
A3003
A5052
A5083
A5086
A6061
392
392
392
150
150
392
200
200
200
66
66
200
na
na
na
na
na
na
na
na
na
na
na
na
CA464
392
200
350
177
Copper plates for locomotive
fireboxes:
E Cu58* or
E Cu59*
CU or
CA110
392
200
150
66
Copper-silicon alloy plate and
Cu - Zn
CA655
350
176
350
176
Copper sheet, strip, plate, and
rolled bar:
SF-Cu
CA122
392
200
150
66
CA715
662
350
662
350
HAST or
HASTB
800
426
800
426
1000
537
1000
537
Mn
Mg
Mg
Mg
Mg
Cu*
2.5*
4.5* Mn*
4
Mn*
7.5 Si Cu*
DIN 17660* Copper and copper alloys Naval brass
Cu Zn38 Sn1*
B-96
F
Aluminum-alloy sheet and
plate:
Al
Al
Al
Al
Al
Al
DIN 1787*
C
External
Pressure
Temp.
Degrees
DIN 17664* Copper-nickel alloy plate and
Cu Ni 30 Mn1 Fe*
B-333
(B)
Hastelloy:
Ni - Mo
B-575
(C-276)
Hastelloy:
Ni - Mo - Cr
HASTC
28-44
DIN Non-Ferrous Plate Materials -continued
DIN*or ASTM
Spec and
(Grade)
Description and Nominal System Internal
Compostion
Material Pressure
Symbol Maximum
Degrees
F
C
External
Pressure
Temp.
Degrees
F
C
VdTUV Wbl.412* Specification for nickeliron-chromium alloy plate,
sheet, and strip:
NCF800*
X10 Ni Cr Al Ti 3220*
B-424
Nickel-iron-chromiummolybdenum-copper alloy
(825)
B-463
(20Cb)
I800
1472
800
1000
537
I825
1000
537
700
371
sheet and strip:
Cr - Ni - Fe - Mo - Cu - Cb
C 20
800
426
800
426
INCNL
or
I600
1202
650
1000
537
NI or
NI200
NI201
600
600
1200
315
315
648
600]
600
1000
315
315
537
MONEL
or
M400
932
500
800
426
662
662
662
350
350
350
na
600
600
na
315
315
VdTUV Wbl.305* Nickel-chromium-iron
strip, Inconel:
Ni Cr15 Fe
B-162
(200)
strip:
Ni
(201)
Ni-Low C
DIN 17750*
Nickel-copper alloy plate,
sheet, and strip:
Ni Cu 30 Fe F45*
DIN 17860*
3.7025.10*
3.7035.10*
Titanium and titanium alloy
strip, sheet, and plate:
Ti
TI35A
Ti
TI or
TI50A
28-45
DIN Design Code - Clad Plate Materials
Material Classification Description
Grade
System Material Symbol
C
B
C
70
70
12
12
11
11
22
22
A285C
A204B
A204C
A 515
A 516
A387B
A387H
A387C
A387J
A387D
A387K
DIN 17102
A-204 (B)
DIN 17155
DIN 17102
DIN 17155
DIN 17155
A-387 (C)
A-387
DIN 17155
DIN 17155
St E 355
ASTM A-204
ASTM A -204
19 Mn5
SIE 315
13Cr Mo44
13Cr Mo44
ASTM A-387
ASTM A-387
10Cr Mo 910
10Cr Mo 910
CL
CL
CL
CL
CL
CL
1
2
1
2
1
2
DIN 17440
X5 Cr Ni189*
X2 Cr Ni189*
X5 Cr Ni Mo1810*
X2 Cr Ni Mo1810*
X10 Cr Ni Ti189*
X10 Cr Ni Nb1810*
X10 Cr13*
X8 Cr17*
304
304L
316
316L
321
347
410
430
SS304
304L
SS316
316L
SS321
SS347
SS410
SS430
200
201
NI200
NI201
Monel
NCUP
400
MONEL
VdTUV Wbl.305*
Ni Cr15 Fe
600
INCNL
Ni-Fe-Cr
800
I800
Ni-Fe-Cr-Mo-Cu
825
I825
Carpenter 20
20Cb
C 20
Titanium
2
Ti
Hastelloy B
Hastelloy C
B
C-276
HASTB
HASTC
Nickel alloy
*
See Plate Materials (German Code) for further material descriptions.
materials. No other combination may be selected.
28-46
DIN Design Code - Tube
Materials
DIN Ferrous Tube Materials - Carbon Steel
DIN*
or ASTM
Spec and
(Grade)
Description and
System Internal
Nominal Compostion Material Pressure
Symbol Maximum
Temp.
C
System
Default
Tubesheet
Material
(Plate)
752
400
A285C
537
900
482
A 515
1022
1022
550
550
900
900
482
482
A 515
A 515
1022
550
900
482
A 515
700
700
371
371
700
700
371
371
A 442
A 442
F
C
A 179
1022
550
DIN 1629* Seamless carbon steel
St 37.0*
A 192
1000
DIN 1629* Seamless medium
superheater tubes
St 44.0*
A210A
St 52.0*
A210C
DIN 2391* Seamless cold-drawn
exchanger and
condenser tubes
St 35GBK
NBK*
DIN 2393* Electric-resistancewelded carbon steel
heat exchanger and
condenser tubes
St 37-2
NBK*
SEW 680*
TTSt 35N*
(B)
A 214
tubes for low
temperature service
A334A
A334B
External
Pressure
Maximum
Temp.
F
28-47
DIN Ferrous Tube Material - Low Alloy Steel
DIN*or
Description and
ASTM Spec Nominal
and
Compostion
(Grade)
System Internal
Material Pressure
Symbol Maximum
Temp.
External
Pressure
Maximum
Temp.
System
Default
Tubesheet
Material
(Plate)
F
C
F
C
A199C
A199D
A199E
A199F
1202
1202
1200
1202
650
650
648
650
900
900
900
900
482
482
482
482
A387C
A387D
A387E
A387F
A 209
A209A
A209B
1022
1022
1000
550
550
537
900
900
900
482
482
482
A 204
A 204
A 204
A213A
A213B
A213C
A213D
A213E
A213F
1022
1202
1200
1200
1200
1200
550
650
648
648
648
648
900
900
900
900
900
900
482
482
482
482
482
482
A387A
A387B
A387C
A387D
A387E
A387F
Seamless cold-drawn
intermediate alloy
DIN 17175*
DIN 17175*
(T21)
VdTUV007*
13Cr Mo44*
10Cr Mo910*
3Cr - .9Mo
12Cr Mo195G
steel boiler and
superheater tubes:
DIN 17175* 15 Mo3*
(T1A)
C - .5Mo
(T1B)
C - .5Mo
and heat exchanger
tubes:
(T2)
DIN17175*
DIN17175*
DIN17175*
(T21)
VdTUV007*
28-48
.5Cr - .5Mo
13Cr Mo44*
13Cr Mo44*
10Cr Mo910*
3Cr -.9Mo
12Cr Mo195G*
DIN Ferrous Tube Materials - High Alloy
Steel
DIN*or
Description and
ASTM Spec Nominal
and
Compostion
(Grade)
System Internal
Material Pressure
Symbol Maximum
Temp.
External
Pressure
Maximum
Temp.
F
C
F
C
System
Default
Tubesheet
Material
(Plate)
DIN 17458* Seamless Ferritic and
and heat exchanger
tubes:
X5Cr Ni1810*
X2Cr Ni1911*
X5Cr Ni Mo17122*
304S
304LS
316S
1472
797
1472
800
425
800
842
752
842
450
400
450
SS304
304L
SS316
X2Cr Ni Mo18143*
X6Cr Ni Ti1810*
X6Cr Ni Nb1810*
X10 Cr13*
316LS
321S
347S
410S
842
1472
1472
752
450
800
800
400
842
842
842
752
450
450
450
400
316L
SS321
SS347
SS410
X5Cr Ni1810*
X2Cr Ni1911*
X5Cr Ni Mo17122*
304W
304LW
316W
1472
797
1472
800
425
800
842
752
842
450
400
450
SS304
304L
SS316
X2Cr Ni Mo18143*
X6Cr Ni Ti1810*
X6 Cr Ni Nb 1810*
X10 Cr 13*
316LW
321W
347W
410W
842
1472
1472
752
450
800
800
400
842
842
842
752
450
450
450
400
316L
SS321
SS347
SS410
600
315
650
343
S2205
DIN 17457* Welded austenitic
steel boiler
superheater, heat
exchanger, and
condenser tubes:
A-789
(S31803)
Welded duplex
austenitic steel tubes:
22Cr - 5Ni - 3Mo
2205W
28-49
DIN Non-Ferrous Tube Materials
DIN*or ASTM Description and
Spec and
Nominal
Compostion
(Grade)
DIN
DIN
DIN
DIN
1787*
1785*
17664*
17664*
DIN 1785*
(444)
(445)
Seamless copper
and copper alloy
tubes for use in
surface
condensers,
evaporators and
heat exchangers:
SF Cu*
Cu Zn20 Al2*
Cu Ni10 Fe1 Mn*
Cu Ni30 Mn1 Fe*
Admiralty Brass
Cu Zn28 Sn1*
System Internal
Material Pressure
Symbol Maximum
Temp.
External
Pressure
Maximum
Temp.
System
Default
Tubesheet
Material
(Plate)
F
C
F
C
CA122
CA687
CA706
CA715
392
392
572
662
200
200
300
350
150
150
150
700
66
66
66
371
A285C
A285C
A285C
A285C
CA443
CA444
CA445
437
450
450
225
232
232
350
350
350
176
176
176
A285C
A285C
A285C
Seamless colddrawn nickel tubes
for general
corrosive service:
DIN 17752*
(201)
LC Ni 99F34*
Ni-Low C
NI200
NI201
600
1200
315
648
600
1000
315
537
NI200
NI201
DIN 17751*
Monel
Ni Cu30 Fe F45
MONEL
887
475
752
400
MONEL
INCNL
or
I600
1202
650
1000
537
INCNL
I800
1472
800
1000
537
I800
I825
1000
537
700
371
I825
800
426
800
426
HASTB
1000
537
1000
537
HASTC
800
426
800
426
C 20
662
350
600
315
T150A
VdTUV
Wbl.305*
Inconel
Ni Cr15 Fe*
VdTUV
Wbl.412
Incoloy
X10 Ni Cr Al Ti
3220*
Ni Cr21 Mo*
VdTUv
Wbl.432*
28-50
B-619
(B)
Hastelloy
Ni - Mo
(C-276)
Ni - Mo - Cr
B-468
(20Cb)
Carpenter 20
Cr - Ni - Fe - Mo - C 20
Cu - Cb
B-338
(2)
Titanium
Ti
HAST or
HASTB
HASTC
T150A
EN 13445 Design Code - Plate
Materials
EN Ferrous Plate Materials - Carbon Steel
EN or
Description and
ASTM
Specific
F
C
F
C
ation
EN
10028-2
P235GH
1.0345
N
plates of structural
quality
A 36
752
400
752
400
EN
10028-2
P235GH
1.0345
N
plates for pressure
vessels
A 285 or
A 285 C
or CS
752
400
752
400
EN
10028-2
P235GH
1.0345
N
plates for pressure
vessels
A 299
752
400
752
400
A 455
752
400
752
400
EN
10028-3
P355NH
1.0565 n
C-Si
752
400
752
400
EN
10028-3
P355NH
1.0565
moderate and lower
temperature service C-Si
A 516
752
400
752
400
EN
10028-2
P235GH
1.0345
N
pressure vessels for low
temperature service
C-Mn-Si
752
400
752
400
EN
10028-2 carbon steel, high
P235GH strength manganese
1.0345
N
28-51
EN Ferrous Plate Materials - Low Alloy Steel
EN or
Description and
ASTM
Nominal
Specific Composition
ation
F
C
F
C
Manganese molybdenum and
pressure vessels:
EN
Mn - .5Mo
10028-2
16Mo3
1.5415 N
A302A
932
500
932
500
EN
Mn - .5Mo
10028-2
16Mo3
1.5415 N
A302B
932
500
932
500
EN
.5Cr - .5Mo
10028-6
P460QH
1.8871
QT
A387A
572
300
572
300
EN
.5Cr - .5Mo
10028-6
P460QH
1.8871
QT
A387G
572
300
572
300
EN
.1Cr - .5Mo
10028-2
13CrMo4
-5
1.7335
NT
A387B
932
500
932
500
EN
.1Cr - .5Mo
10028-2
13CrMo4
-5
1.7335
NT
A387H
932
500
932
500
ally steel. chromium molybdenum:
28-52
EN or
Description and
ASTM
Nominal
ation
F
C
F
C
EN
2.25Cr - .1Mo
10028-2
10CrMo9
-10
1.7380
NT
A387D
932
500
932
500
EN
2.25Cr - .1Mo
10028-2
10CrMo9
-10
1.7380
NT
A553K
932
500
932
500
28-53
EN Ferrous Plate Materials - High Alloy Steel
EN or
Description and
ASTM
Specific
F
C
F
C
ation
Chromium and
chromium-nickel
pressure vessels:
28-54
EN
18Cr -8Ni
10028-7
X2CrNi
18-10
1.4301A
T
340L
1022
550
1022
550
18Cr -8Ni
EN
10028-7
X2CrNi
18-10
1.4301A
T
SS304
1022
550
1022
550
EN
16Cr - 12Ni - 2Mo
10028-7
X5CrNiM
o 17-122
1.4401
AT
316L
1022
550
1022
550
EN
16Cr - 12Ni - 2Mo
10028-7
X5CrNiM
o 17-122
1.4401
AT
SS316
1022
550
1022
550
EN
18Cr - 10Ni - Ti
10028-7
X6CrNiTi
18-10
1.4541
AT
SS321
1022
550
1022
550
EN
18Cr - 10Ni - Cb
10028-7
X6CrNiN
b18-10
1.4550
AT
SS347
1022
550
1022
550
EN or
Description and
ASTM
Specific
F
C
F
C
ation
EN
18Cr - 10Ni - Cb
10028-7
X6CrNiN
b18-10
1.4550
AT
SS348
1022
550
1022
550
EN
22Cr - 5Ni - 3Mo
10028-7 (Duplex)
X2CrNiM
oN22-53
1.4462
AT
S2205
482
250
482
250
28-55
EN 13445 Design Code - Tube
Materials
EN Ferrous Tube Materials - Carbon Steel
EN or
Description and
System
ASTM
Nominal Composition MaterialSymb
Specific
ol
ation
Internal
Pressure
Maximu
m Temp.
F
EN
10216-2
P235GH
1.0345
N
Seamless cold-drawn
exchanger and
condenser tubes.
F
System
Default
Tubesheet
Material
C (Plate)
A-179
842 450 842 450 A 516
EN
10216-2 boiler tubes for highP235GH pressure service
1.0345
N
A-192
842 450 842 450 A 516
EN
Seamless medium
10216-2 carbon steel boiler and
P235GH superheater tubes
1.0345
N
A-210
842 450 842 450 A 516
EN
10216-2
P235GH
1.0345
N
A-214
752 400 752 400 A 516
A-334
842 450 842 450 A 516
heat exchanger and
condenser tubes
EN
10216-2 tubes for low
P235GH temperature service
1.0345
N
28-56
C
External
Pressure
Maximu
m Temp.
EN Ferrous Tube Materials - Low Alloy Steel
EN or
Description and
ASTM
Nominal
ation
System Internal
Material Pressure
Symbol Maximum
Temp.
External
Pressure
Maximum
Temp.
F
C
F
C
System
Default
Tubesheet
Material
(Plate)
Seamless cold-drawn
intermediate alloy
EN
1.25Cr - .5 Mo - Si
10216-2
X11CrMo
5
1.7362 I
A-199C
932
500
932
500
A387C
EN
3Cr-.9Mo
10216-2
10CrMo9
-10
1.7380
NT or QT
A199E
932
500
932
500
A387E
and heat exchanger
tubes:
EN
.5Cr
10216-2
14MoV63
1.7715
NT or QT
- .5Mo
A213A
1022
550
1022
550
A387A
EN
1Cr
10216-2
13CrMo4
-5
1.7335
NT or QT
- .5Mo
A213B
932
500
932
500
A387B
EN
2.25Cr - 1Mo
10216-2
10CrMo9
-10
1.7380
NT or QT
A213D
932
500
932
500
A387D
EN
5Cr
10216-2
X11CrMo
5
1.7362 I
A213F
932
500
932
500
A387F
- .5Mo
28-57
EN Ferrous Tube Materials - High Alloy Steel
EN or
Description and
ASTM
Nominal
ation
System
Material
Symbol
Internal
Pressure
Maximum
Temp.
External
Pressure
Maximum
Temp.
F
C
F
C
System
Default
Tubesheet
Material
(Plate)
Seamless Ferritic
steel boiler,
superheater, and
heat exchanger
tubes:
28-58
EN
18Cr - 8Ni
10216-5
X5CrNi18
-10
1.4301
AT
304S
1022
550
1022
550
SS304
EN
10216-5
X5CrNi
19-11
1.4306
AT
304LS
1022
550
1022
550
304L
EN
16Cr - 12Ni - 2Mo
10216-5
X5CrNiM
o17-12-2
1.4401
AT
316S
1022
550
1022
550
SS316
EN
16Cr - 12Ni - 2Mo
10216-5
X2CrNiM
o17-12-2
1.4404
AT
316LS
1022
550
1022
550
316L
EN
18Cr - 10Ni - Ti
10216-5
X6CrNiTi
18-10
1.4541
AT
321S
1022
550
1022
550
SS321
EN
18Cr - 10Ni - Cb
10216-5
X6CrNiNb
18-10
1.4550
AT
347S
1022
550
1022
550
SS347
18Cr - 8Ni
EN or
Description and
ASTM
Nominal
ation
System
Material
Symbol
Internal
Pressure
Maximum
Temp.
External
Pressure
Maximum
Temp.
F
C
F
C
System
Default
Tubesheet
Material
(Plate)
Welded austenitic
steel boiler
superheater, heat
exchanger, and
condenser tubes:
EN
18Cr - 8Ni
10217-7
X5CrNi18
-10
1.4301
AT
304W
1022
550
1022
550
SS304
EN
18Cr - 8Ni
10217-7
X2CrNi19
-11
1.4306
AT
304LW
1022
550
1022
550
304L
EN
16Cr - 12Ni - 2Mo
10217-7
X5CrNiM
o17-12-2
1.4401
AT
316W
1022
550
1022
550
SS316
EN
16Cr - 12Ni - 2Mo
10217-7
X5CrNiM
o17-12-2
1.4404
AT
316LW
1022
550
1022
550
316L
EN
18Cr - 10Ni - Ti
10217-7
X6CrNiTi
18-10
1.4541
AT
321W
1022
550
1022
550
SS321
28-59
EN or
Description and
ASTM
Nominal
ation
EN
18Cr - 10Ni - Cb
10217-7
X6CrNiNb
18-10
1.4550
AT
EN
10217-7
X2CrNiM
olN22-53
1.4462
AT
28-60
System
Material
Symbol
347W
Internal
Pressure
Maximum
Temp.
External
Pressure
Maximum
Temp.
System
Default
Tubesheet
Material
(Plate)
F
C
F
C
1022
550
1022
550
SS347
482
250
482
250
S2205
Welded duplex
austenitic steel
tubes:
22Cr - 5Ni - 3Mo
2205W
GB 150 Design Code - Plate
Materials
GB 150 Ferrous Plate Materials - Carbon
Steel
GB Material GB Material
Standard
Designation
Description/
Composition/
Notes
System
Material
Symbol
Internal Pressure External Pressure
Maximum Temp. Maximum Temp.
F
C
F
C
GB 3274
Q235B
Steel plates for
A 36
pressure vessels and
boilers
662
350
900
482
GB 66541996
GB 7132008
16MnR
Q345R
Steel plates for
A 299
boilers
887
475
900
482
GB 66541996
GB 7132008
16MnR
Q345R
Steel plates for
A 515
boilers
887
475
900
482
GB 66541996
GB 7132008
16MnR
Q345R
Steel plates for
A 516
boilers
887
475
900
482
GB 3274
Q235-C
Carbon and low alloy A283C
structural steel,
rolled plates, and
strip
752
400
900
482
GB 66541996
GB 7132008
20R
Q245R
Steel plates for
A285C
boilers
887
475
900
482
GB 66541996
GB 7132008
20R
Q245R
Steel plates for
CS
boilers
887
475
900
482
28-61
GB 150 Ferrous Plate Materials - Low Alloy
Steel
Standard
Designation
Description/
Composition/
Notes
F
C
F
C
GB 7132008
15CrMoR
Steel plates for
A387H
boilers
1022
550
900
482
GB 7132008
14Cr1MoR
Steel plates for
A387J
boilers
1022
550
900
482
28-62
System
Material
Symbol
GB150 Ferrous Plate Materials - High Alloy
Steel
Standard
Designation
Description/
Composition/
Notes
System
Material
Symbol
F
C
F
C
GB 7132008
15CrMoR
Steel plates for
A387B
boilers
1022
550
900
482
GB 7132008
14CrMoR
Steel plates for
A387C
boilers
1022
550
900
482
GB 7132008
18MnMoNbR
Steel plates for
A553A
boilers
887
475
650
343
GB 66541996
GB 7132008
13MnNiMoR
Steel plates for
A553B
13MnNiMoNbR pressure vessels and
boilers
752
400
650
343
GB 66541996
GB 7132008
13MnNiMoR
Steel plates for
A553C
13MnNiMoNbR pressure vessels and
boilers
752
400
650
343
28-63
GB150 Design Code - Tube
Materials
GB150 Ferrous Tube Materials - Carbon
Steel
Standard
Designation
Description/
Composition/
Notes
F
C
F
C
GB/T 81632008
10
Seamless steel tubes A 179
for liquid service
842
450
900
482
GB/T 81632008
10
Seamless steel tubes A 192
for liquid service
842
450
900
482
GB/T 81632008
10
A 214
842
450
900
482
GB/T 53002008
20G
Seamless steel tubes A210A
and pipes for high
pressure boilers
842
450
900
482
GB/T 53002008
16Mn
High-pressure
A210C
seamless steel tubes
for chemical fertilizer
equipments
887
475
900
482
GB/T 81632008
10
Seamless steel tubes CS
and pipes for high
pressure boilers
842
450
900
482
GB 6479
15MnV
High-pressure
A334A
equipments
752
400
650
343
GB 6479
15MnV
High-pressure
A334B
equipments
752
400
650
343
28-64
System
Material
Symbol
GB150 Ferrous Tube Materials - Low Alloy
Steel
Standard
Designation
Description/
Composition/
Notes
F
C
F
C
GB/T 53102008
12Cr1MoVG
Seamless steel tubes A199C
and pipes for high
pressure boilers
1067
575
900
482
GB/T 53102008
12Cr2Mo
Seamless steel tubes A199D
and pipes for high
pressure boilers
1067
575
900
482
GB/T 53102008
12CrMo
Seamless steel tubes A213A
and pipes for high
pressure boilers
977
525
900
482
GB/T 53102008
15CrMo
Seamless steel tubes A213B
and pipes for high
pressure boilers
1022
550
900
482
GB/T 53102008
12Cr1MoVG
Seamless steel tubes A213C
and pipes for high
pressure boilers
1067
575
900
482
GB/T 53102008
12Cr2Mo
Seamless steel tubes A213D
and pipes for high
pressure boilers
1067
575
900
482
GB/T 53102008
1Cr5Mo
High-pressure
A213F
equipments
1112
600
900
482
System
Material
Symbol
28-65
GB150 Ferrous Tube Materials - High Alloy
Steel
Standard
Designation
Description/
Composition/
Notes
System
Material
Symbol
F
C
F
C
GB/T 12771- 06Cr19Ni10
2008
Seamless stainless
304S
steel tubes for liquid
delivery
1292
700
1000
538
GB/T 12771- 022Cr19Ni10
2008
Welded stainless
304W
delivery
1292
700
1000
538
GB/T 12771- 022Cr19Ni10
2008
Seamless stainless
304LS
delivery
797
425
800
427
GB/T 12771- 022Cr19Ni10
2008
Welded stainless
304LW
delivery
797
425
800
427
GB/T 12771- 06Cr17Ni12Mo Seamless stainless
316S
2008
2
delivery
1292
700
1000
538
GB/T 12771- 06Cr17Ni12Mo Welded stainless
316W
2008
2
delivery
1292
700
1000
538
GB/T 12771- 022Cr17Ni12M Seamless stainless
316LS
2008
o2
delivery
842
450
850
454
GB/T 12771- 022Cr17Ni12M Welded stainless
316LW
2008
o2
delivery
842
450
850
454
GB/T 12771- 06Cr18Ni11Ti
2008
Seamless stainless
321S
delivery
1292
700
100
538
GB/T 12771- 06Cr18Ni11Ti
2008
Welded stainless
321W
delivery
1292
700
100
538
GB/T 12771- 06Cr13
2008
Seamless stainless
410S
delivery
1112
600
900
482
GB/T 12771- 06Cr13
2008
Welded stainless
410W
delivery
1112
600
900
482
28-66
Lining Materials
Brick: Acid-Resistant Applied Over
Membrane-Lined Carbon Steel
Lining Material Description
Inches
MM
System
Material
Symbol
Red shale brick
2.5
4.5
8.0
62
112
200
25RSB
45RSB
80RSB
Fireclay, 30 percent alumina
2.5
4.5
9.0
62
112
225
25AFC
45AFC
45AFC
Inches
MM
System
Material
Symbol
Insulating firebrick
2.5
4.5
9.0
62
112
225
25IFB
45IFB
90IFB
60 percent alumina firebrick
2.5
4.5
9.0
62
112
225
25FB6
45FB6
90FB6
90 percent alumina firebrick
2.5
4.5
9.0
62
112
225
25FB9
45FB9
90FB9
Brick: Firebrick
28-67
Monolithic Lining
System
Material
Symbol
Applied to surface with anchors on 12 INCH [300 MM] centers
50 percent alumina refractory gunning mix
GUNA5
GUNA9
90 percent alumina castable refractory
CASA9
Applied to bare surface
90 percent alumina castable refractory
GUN50
GUN90
CAS90
Applied over wire mesh reinforcement
GUNIT
Gunite
Abrasion Resistant Linings; Replaceable
Only for use with:
•
equipment items – water cyclones and linings
•
plant bulk items – steel fabricated plate
System
Material
Symbol
Replaceable ceramic liner backed with urethane elastomer for CERML
light abrasion and light impact
Replaceable ceramic liner backed with urethane elastomer for CERMM
medium abrasion and light impact
Replaceable ceramic liner backed with urethane elastomer for CERMH
heavy abrasion and light impact
Replaceable ceramic liner backed with urethane elastomer for CERMV
heavy abrasion and heavy impact
28-68
Replaceable abrasion-resistant steel plate lining (1 INCH [25
MM] thick unless otherwise specified)
ABRPL
Replaceable rubber lining (1 INCH [25 MM] thick unless
otherwise specified)
REPRB
Replaceable SS304 plate lining (1 INCH [25 MM] thick unless
LS304
Replaceable SS316 plate lining (1 INCH [25 MM] thick unless
LS316
Linings: Organic, Glass, Metallic
System
Material
Symbol
Asphaltic Resin Lining (over Carbon Steel)
ASRSN
Epoxy Resin Lining (over Carbon Steel)
EPLCS
Phenolic Resin Lining (over Carbon Steel)
PHRSN
Kynar Sheet Lining (over Carbon Steel)
PVDF
Teflon Sheet Lining (over Carbon Steel)
TFELS
Glass Lining (over Carbon Steel)
GSLCS
1/4 INCH [6 MM] Butyl Rubber Lining (over Carbon Steel)
BUTYL
1/4 INCH [6 MM] Neoprene Sheet Lining (over Carbon Steel)
NEPNE
1/4 INCH [6 MM] Soft Natural Rubber Sheet Lining (over Carbon Steel)
NATRB
1/4 INCH [6 MM] Nitrile Rubber Lining (over Carbon Steel)
NITRL
1/4 INCH [6 MM] Hypalon Rubber Lining (over Carbon Steel)
HYPLN
1/4 INCH [6 MM] Ebonite Lining (over Carbon Steel)
EBONT
16 PSF [80 KG/M2] Chemical Lead Lining
CLEAD
Inorganic Zinc Coating applied by brush to 3 M [0.08 MM] thickness
I-ZN
Flame sprayed Zinc Coating 8 MIL [0.20 MM] thickness
ZNMZL
28-69
Casting Materials
Casting Material Description System Material
Symbol
Aluminum Alloys
Aluminum
Iron and Steel Alloys
Low-Alloy
Low-Alloy
Low-Alloy
Low-Alloy
AL
Steel Grade B
Steel Grade E
Steel Grade C
Steel
Carbon Steel
Low-Alloy Steel
Low-Alloy Steel
Low-Alloy Steel
Low-Alloy Steel
B
A
B
C
A 299
A 302
A387A
A387B
A387C
Low-Alloy Steel Grade D
Low-Alloy Steel Grade E
Carbon Steel Grade 60
Carbon Steel
A387D
A387E
A 442
A 455
A 515
Low-Alloy Steel Grade 1A
Low-Alloy Steel Grade 1B
Low-Alloy Steel Grade 1C
9 Percent Nickel Steel
Carbon Steel
A 516
A533A
A533B
A533C
A 553
A285S
or CS
CI
Grade
Grade
Grade
Grade
Cast Iron
Stainless Steel Alloys
A203B
A203E
A 204
A 283
Type 304 Stainless Steel
Type 304L Stainless Steel
Type 316 Stainless Steel
SS304
or SS
304L
SS316
Type
Type
Type
Type
Type
316L
SS321
SS347
SS410
SS430
316L Stainless Steel
321 Stainless Steel
347 Stainless Steel
410 Stainless Steel
430 Stainless Steel
- continued next page -
28-70
Casting Material Description System Material
Symbol
Other Alloys
Nickel
Inconel
Monel
Titanium
Carpenter 20
NI
INCNL
MONEL
TI
C 20
Other Materials Available
Only On Pumps Where
Designated
SS304 Impeller, CS Casing
SS316 Impeller, CS Casing
Goulds Alloy 20
High Nickel Alloy
High Nickel Alloy
304SF
316SF
GAL20
ISO B
ISO C
CASTS
Cast Steel
28-71
Packing Materials
Packing Type
Size
Inches
Packing Material
Packing Type
Symbol
MM
Activated carbon
-
-
Carbon
ACT-C
Alumina
-
-
Alumina
ALMNA
Berl saddles
0.5
0.75
1.0
1.5
15
20
25
40
Ceramic
0.5CBS
.75CBS
1.0CBS
1.5CBS
Berl saddles
0.5
0.75
1.0
1.5
15
20
25
40
Porcelain
0.5PBS
.75PBS
1.0PBS
1.5PBS
Calcium chloride
-
-
Calcium chloride
CACL
Coke
-
-
Coke
COKE
Crushed limestone
-
-
Limestone
LIME
Crushed stone
-
-
Stone
STONE
Dirt (earth)
-
-
Earth
DIRT
Gravel
-
-
Gravel
GRAVEL
INTALOX saddles
0.5
1.0
1.5
2.0
15
25
40
50
Ceramic
0.5CIS
1.0CIS
1.5CIS
2.0CIS
INTALOX saddles
0.5
1.0
1.5
2.0
15
25
40
50
Porcelain
0.5PIS
1.0PIS
1.5PIS
2.0PIS
Pall rings
0.5
1.0
1.5
2.0
15
25
40
50
Polypropylene
0.5PPR
1.0PPR
1.5PPR
2.0PPR
Pall rings
0.5
1.0
1.5
2.0
15
25
40
50
Stainless steel
0.5SPR
1.0SPR
1.5SPR
2.0SPR
Raschig rings
0.5
0.75
1.0
1.5
2.0
3.0
15
20
25
40
50
75
Ceramic
0.5CRR
.75CRR
1.0CRR
1.5CRR
2.0CRR
3.0CRR
- Continued on next page-
28-72
Packing Type
Size
Inches
Packing Material
Packing Type
Symbol
MM
Raschig rings
1.0
1.5
2.0
3.0
25
40
50
75
Porcelain
1.0PRR
1.5PRR
2.0PRR
3.0PRR
Raschig rings
1.0
1.5
2.0
3.0
25
40
50
75
Stainless steel
1.0SRR
1.5SRR
2.0SRR
3.0SRR
Raschig rings
1.0
1.5
2.0
3.0
25
40
50
75
Carbon steel
1.0FRR
1.5FRR
2.0FRR
3.0FRR
Resin
-
-
Resin
RESIN
Sand
-
-
Sand
SAND
Silica gel
-
-
Silica gel
S-GEL
Tellerettes H.D.
1.0
25
Polyethylene
HD-P-T
Tellerettes L.D.
1.0
25
Polyethylene
LD-P-T
13X Molecular Sieve
13XMS
PVC Structured Packing 68 SF/CF [223 M2/M3]
68PVC
CPVC Structured Packing 68 SF/CF [223 M2/M3]
68CPVC
Cascade rings
1.0
2.0
3.0
25
50
75
Ceramic
1.0CCR
2.0CCR
3.0CCR
Cascade rings
1.0
2.0
3.0
25
50
75
Polypropylene
1.0PCR
2.0PCR
3.0PCR
Cascade rings
1.0
1.5
2.0
3.0
4.0
25
40
50
75
100
Stainless steel
1.0SCR
1.5SCR
2.0SCR
3.0SCR
4.0SCR
Steel structured
packing 45° angle
of vertical
orientation
107
76
62
35
350
250
205
115
410S Stainless steel
M107YA
M76YA
M62YA
M35YA
Steel structured
packing 45° angle
of vertical
orientation
107
76
62
35
350
250
205
115
304 Stainless steel
M107YB
M76YB
M62YB
M35YB
Steel structured
packing 45° angle
of vertical
orientation
107
76
62
35
350
250
205
115
316L Stainless steel
M107YC
M76YC
M62YC
M35YC
- continued on next page -
28-73
Packing Type
Size
Inches
28-74
Packing Material
Packing Type
Symbol
MM
Steel structured
packing 60° angle
of vertical
orientation
76
35
250
115
410S Stainless steel
M76XA
M35XA
Steel structured
packing 60° angle
of vertical
orientation
76
35
250
115
304 Stainless steel
M76XB
M35XB
Steel structured
packing 60° angle
of vertical
orientation
76
35
250
115
316L Stainless steel
M76XC
M35XC
28-75
28-76
29 Units of Measure
(G6)
Introduction to Units of Measure
Units of Measure
Length
Area
Volume
Mass
Mass per Length
Mass per Volume
Pressure
Velocity
Flow Rates
Electric
Power
Viscosity
Angular
Other
Miscellaneous Useful Constants
Project Specifications and their Use of Units of Measure
Special Units of Measure
Length and Area Units
Volume Units
Mass and Unit Mass
Pressure Units
Velocity and Flow Rate Units
Power Units
Viscosity Units
29 Units of Measure (G6)
29-1
Introduction to Units of
Measure
Icarus systems provide a choice of two sets of units of measure:
•
I-P (Inch-Pound)
•
METRIC (Metric).
The user must select the desired set indirectly (by specifying the country base
location) or directly. Once the appropriate set is selected, the user may wish to
redefine one or more variables from the base units of measure to some other
measure. The Units of Measure Data provides the means of identifying the
conversion.
The user should refer to units of measure later in this chapter for the basic
definitions of variables and their associated units of measure for I-P and
METRIC sets. Along with these definitions are conversion multipliers for
relating I-P to METRIC units. Each line bearing a two-digit Type Number is a
candidate for user redefinition. The type number is used to identify the specific
unit of measure to be redefined. The user would then provide a new name for
that unit of measure and the appropriate conversion multiplier to convert from
the base unit of measure to the desired unit of measure.
The following special units of measure are not characterized by a Type Number
and simple conversion multiplier:
•
Temperature - User may define temperature to be in DEG C, DEG F or
DEG K.
•
Process Pipe Size (diameter and thickness dimensions only) - User may
specify process pipe to be designed in INCH or MM units of measure,
independently of other linear units of measure.
•
Driver Power - User may specify drivers to be specified, sized, selected,
reported in HP or KW.
Notes of Caution
All user-provided numeric values for dimensions, sizes, extents, intensities,
flows, etc., are considered by the system to conform to those units of measure
selected and/or defined by the user. It is the user’s responsibility to be
constantly aware of the units of measure so selected throughout the entire
exercise of preparing project data for the system. The user is cautioned that
variable redefinition from system base to a user unit of measure could have
unpredictable downstream effects, for example, in selection of plates, wire,
tubing, pipe, etc. Further, the user is cautioned that each base set of units, I-P
and METRIC, has its own special set of default values; the pair of default
values are not necessarily related to one another by usual conversion
relationships; each is established by itself as a reasonable value in the base
unit of measure. Once the user’s set of units of measure is established, default
values are evaluated as follows:
•
29-2
Unit of Measure Conversion: are used to convert the base unit of measure
default value by the user’s numeric value to obtain the value of the revised
default value in the desired units of measure.
•
No Unit of Measure Conversion: the system uses the default value
as tabulated.
Example
•
METRIC base set selected in Project Title Data, and
•
Unit of measure data used to convert pressure in KPA (METRIC) to PSIG
using 0.14504 = 1/6.894757 as conversion for Type No. 18.
•
Turbine steam pressure METRIC default is 2000 KPA, which, converted to
PSIG, is 290.047549 PSIG. The PSIG value is used in sizing the turbine if
the user does not enter the pressure value.
•
Contrast this value with the I-P default value printed in the turbine table as
300 PSIG.
Another Example
The METRIC base user will have all length variables defined in terms of
millimeters, meters, etc. As a consequence, pipe sizes (diameters) and wall
thicknesses will be expected to be specified, sized, selected and reported in
MM. Should the METRIC base user desire pipe to be specified, sized, selected
and reported in MM. Should the METRIC base user desire pipe to be specified,
sized, selected and reported as INCH values, the user must enter the
designator INCH in the field labelled Pipe Size.
This note of caution is tendered for temperature and driver power a well as
pipe sizing.
Final Note of Caution
The user of this section should exercise extreme care and deliberation in
redefining units of measure. Since, once established:
•
All user input is expected in the defined units of measure.
•
Default values subject to conversions will not be in rounded numbers but
will be conversions from base default values.
•
Selection and design criteria may be impacted and affected by user
redefinition of units of measure.
•
All reporting by the system will conform to the selected units of measure.
•
The trail of consequences of redefinitions of the units of measure is one
especially difficult to backtrack, especially if that variable affects size
selection of materials in a non-standard way.
29-3
Units of Measure
Type
No.
Inch/Pound
Conversion
Description
Symbol
01
Inches
INCHES
02
Feet
FEET
03
Miles (statute) MILES
04
Mesh
05
06
Metric
Description
Symbol
x 25.4
= Millimeters
MM
x 0.3048
= Meters
M
x 1.60934
= Kilometers
KM
MESH
x 1.0000
= Mesh
MESH
Square feet
SF
x 0.092903
= Square
meters
M2
Square yards
SY
x 0.836127
= Square
meters
M2
Length
Area
Volume
07
Cubic feet
CF
x 0.028317
= Cubic
meters
M3
08
Cubic yards
CY
x 0.76455
= Cubic
meters
M3
09
US Gallons
(231 cubic
inches, no
units for UK
imperial
gallons)
GALLONS
x 0.00378541 = Cubic
meters
M3
10
Barrels (42
gallons)
BARRELS
x 0.1589873
= Cubic
meters
M3
11
Bags (94
pounds)
BAGS
x 0.852749
= Bags (50
kilograms)
BAG-50KG
48
Board feet
BDFT
x 0.0023597
= Cubic
meters
M3
12
Pounds
LBS
x 0.45359
=Kilograms
KG
13
Tons (2000
pounds)
TONS
x 0.907185
= 1000
Kilograms
TON
Mass
Mass per Length
29-4
14
Pounds per
foot
LB/FT
x 1.488156
= Kilograms/
meter
KG/M
15
Pounds per
yard
LB/YD
x 0.496052
= Kilograms/
meter
KG/M
Type
No.
Conversion
Inch/Pound
Description
Symbol
Metric
Description
Symbol
Mass per Volume
16
Pounds per
batch
LB/BATCH
x 0.45359
= Kilograms
per batch
KG/BATCH
17
Pounds per
cubic foot
PCF
x 16.01829
= Kilograms
per cubic
meter
KG/M3
Pressure
18
Pounds (force) PSIG
per square
inch, gauge
x 6.894757
= Kilopascals KPA
(1000 newtons
per square
meter)
19
Inches of
mercury
IN HG
x 3.38638
= Kilopascals KPA
(1000 newtons
per square
meter)
20
Inches of
water
IN H2O
x 249.082
= Pascals
PA
21
Millimeters of
mercury
(TORR)
MM HG
x 133.322
=Pascals
PA
22
Pounds (force) PSF
per square
foot (loading)
x 0.0478802
= Kilonewtons KN/M2
per square
meter (1
newton = 1 KG
mass under 1
meter/sec2
acceleration)
Velocity
23
Feet per
minute
FPM
x 18.2880
= Meters/hour M/H
24
Miles per hour MPH
x 1.60934
= Kilometers/
hour
KM/H
25
Revolutions
per minute
RPM
x 1.0000
= Revolutions
per minute
RPM
na
Cycles per
second
HZ
x 1.0000
(HZ is
frequently
used to refer
to local power
frequency)
= Hertz
HZ
29-5
Type
No.
Conversion
Inch/Pound
Description
Symbol
Metric
Description
Symbol
Flow Rates
26
Cubic feet per CFM
minute
x 1.69901
= Cubic
meters per
hour
M3/H
27
Cubic feet per CFH
hour
x 0.028317
= Cubic
meters per
hour
M3/H
28
Cubic feet per CFM/SF
minute per
square foot of
surface
x 18.28800
= Cubic
meters per
hour per
square meter
of surface
M3/H/M2
29
Gallons per
minute
GPM
x 0.063090
Litres per
second
L/S
30
Gallons per
hour
GPH
x 0.003785
Cubic meters
per hour
M3/H
31
Pounds per
hour
LB/H
x 0.45359
Kilograms/
hour
KG/H
32
Tons per hour TPH
(short tons, no
unit for long
tons)
x 0.907185
= Tons per
hour
TON/H
33
Tons per day
TPD
x 0.037799
= Tons per
hour
TON/H
Electric
34
Volts
V
x 1.0
= Volts
V
35
Kilovolts
(1000V)
KV
x 1.0
= Kilovolts
KV
36
Amperes
A
x 1.0
= Amperes
A
37
Kiloamperes
(1000A)
KA
x 1.0
= Kiloamperes KA
38
Watts
W
x 1.0
= Watts
W
39
Kilowatts
(1000W)
KW
x 1.0
= Kilowatts
KW
40
Kilovoltamperes
(1000V-A)
KVA
x 1.0
= Kilovoltamperes
KVA
na
Horsepower
HP
x 0.74570
= Kilowatts
KW
41
Tons,
refrigeration
(12000 BTU
per hour)
TONS-REF
x 3.51685
= Kilowatts
KW
42
BTU per hour
BTU/H
x 0.293071
= Watts
W
Power
29-6
Type
No.
Conversion
Inch/Pound
Description
Symbol
Metric
Description
Symbol
43
Millions of BTU MMBTU/H
per hour
x 0.293071
= Megawatts
MEGAW
44
BTU per hour
per square
foot
x 3.15460
= Watts per
square meter
W/M2
45
BTU per pound BTU/LB
x 2.32601
= Kilojoules
per kilogram
KJ/KG
BTU/H/SF
Viscosity
46
Centipoise
CPOISE
x 1.0
= Millipascalseconds
MPA-S
47
Centistoke
CSTOKE
x 1.0
= Millimeters
squared per
second
MM2/S
Degrees
DEGREE
x 1.0
= Degrees
DEGREE
na
Fahrenheit
temperature
DEG F
(F-32)/1.8
= Celsius
temperature
DEG C
na
Fahrenheit
temperature
difference
DEG F
x 0.55555
= Celsius
temperature
difference
DEG C
na
Nominal pipe INCH
size (diameter
and thickness)
not applicable
size
Nominal pipe MM
size (diameter
and thickness)
na
Driver power
not applicable
Driver power
Angular
na
Other
HP
KW
Miscellaneous Useful Constants
1
2
3
Gravitational Constant:
°
Inch-Pound
32.174 lb-ft/lb(force)-sec2
°
Metric
9.80665 kg-m/kg(force)-sec2
Absolute temperatures:
°
Rankine
DEG R = 459.67 + DEG F
°
Kelvin
DEG K = 273.15 + DEG C
Gas Constant, R (basis: 22.4140 liters at 0 degrees C, 1 atm. for the
volume of 1 gram-mole of gas and PV=ZnRT)
°
R = 10.732 psia-ft3/lb-mole degrees R
°
R = 8.3145 KPA-m3/kg-mole degrees K
29-7
Project Specifications and their
Use of Units of Measure
Special Units of Measure
Unit of Measure Name for Temperature: F (INCH-POUND) or C or K
(METRIC)
Use to specify:
•
All items specifying temperature
Unit of Measure Name for pipe size: INCH (INCH-POUND) or MM (METRIC)
Use to specify:
•
Pipe, valves, fittings
Unit of Measure Name for driver power: HP (INCH-POUND) or KW
(METRIC)
Use to specify:
•
Electric motors, turbines
Length and Area Units
Unit of Measure Name for: INCHES (INCH-POUND) or MM (METRIC)
Use to specify:
•
29-8
Vessel components
°
wall/plate thickness
°
tube diameter
°
cladding thickness
•
Conveyor belts - width
•
Conveyors/vibrating - width of pan
•
Centrifuge bowl/basket diameter
•
Dryers, pan type - depth
•
Dust collectors, cyclone diameter
•
Filters, plate/frame size
•
Feeders, rotary - diameter
•
Feeders, vibrating - width
•
Heat exchangers, shell diameter
•
Mills, product, feed size
•
Reboilers, port area
•
Stacks - diameter
•
Towers - tray spacing
•
Insulation thickness
•
Manhole diameter
•
Steel, walkway width
•
Vibrating screens - sifter screen diameter
Unit of Measure Name for: FEET (INCH-POUND) or M (METRIC)
Use to specify:
•
•
Vessel size
°
span, length, height, diameter,
°
tube length
Fluid head- pumps
Unit of Measure Name for: MILES (INCH-POUND) or KM (METRIC)
Use to specify:
•
Site development
Unit of Measure Name for: MESH (INCH-POUND) or MESH (METRIC)
Use to specify:
•
Crushers
•
Filter, tubular
Unit of Measure Name for: SF (INCH-POUND) or M2 (METRIC)
Use to specify:
•
Dryers - tray surface area
•
Dust collectors - cloth area
•
Drum dryers - peripheral area
•
Evaporators - heated surface area
•
Flakers - area
•
Heat exchangers
•
Linings
•
Rotary dryers
•
Tray drying systems, tray surface
•
Vibrating screen
Unit of Measure Name for: SY (INCH-POUND) or M2 (METRIC)
Use to specify:
•
Site development
Volume Units
Unit of Measure Name for: CF (INCH-POUND) or M3 (METRIC)
Use to specify:
•
Centrifuges - capacity
29-9
•
Filters, plate/frame capacity
•
Mixers
•
Rotary dryers, working capacity
•
Vertical tanks, gas holders, live bottom
Unit of Measure Name for: CY (INCH-POUND) or M3 (METRIC)
Use to specify:
•
Site development
Unit of Measure Name for: GALLONS (INCH-POUND) or M3 (METRIC)
Use to specify:
•
Vessel volume, liquids
•
Kneaders
•
Packings
•
Vertical tanks
Unit of Measure Name for: BARRELS (INCH-POUND) or M3 (METRIC)
Use to specify:
•
Vertical tanks
Unit of Measure Name for: BAGS (INCH-POUND) or BAGS-50KG (METRIC)
Use to specify:
•
Field-mixed concrete components
Unit of Measure Name for: BD FT (INCH-POUND) or M3 (METRIC)
Use to specify:
•
29-10
Foundation formwork (shuttering)
Mass and Unit Mass
Unit of Measure Name for: LBS (INCH-POUND) or KG (METRIC)
Use to specify:
•
Cranes
•
Scales
Unit of Measure Name for: TONS (INCH-POUND) or TON (METRIC)
Use to specify:
•
Elevators
•
Cranes, hoists
Unit of Measure Name for: LB/FT (INCH-POUND) or KG/M (METRIC)
Use to specify:
•
Steel member sizes
•
Pile sizes
Unit of Measure Name for: LB/YD (INCH-POUND) or KG/M (METRIC)
Use to specify:
•
Site development - railroad rails
Unit of Measure Name for: LB/BATCH (INCH-POUND) or KG/BATCH
(METRIC)
Use to specify:
•
Centrifuges, batch type
•
Filters
Unit of Measure Name for: PCF (INCH-POUND) or KG/M3 (METRIC)
Use to specify:
•
Density of solids, fluids
•
Blenders
29-11
Pressure Units
Unit of Measure Name for: PSIG (INCH-POUND) or KPA (METRIC)
Use to specify:
•
Gauge pressure
Unit of Measure Name for: IN HG (INCH-POUND) or KPA (METRIC)
Use to specify:
•
Vacuum pumps
Unit of Measure Name for: IN H2O (INCH-POUND) or PA (METRIC)
Use to specify:
•
Draft pressure measurement, ductwork
•
Dust collector, cyclone - pressure drop
Unit of Measure Name for: MM HG (INCH-POUND) or PA (METRIC)
Use to specify:
•
Ejectors, absolute pressure
•
Vacuum pumps, absolute pressure
Unit of Measure Name for: PSF (INCH-POUND) or KN/M2 (METRIC)
Use to specify:
•
29-12
Civil - soil bearing capacity
Velocity and Flow Rate Units
Unit of Measure Name for: FPM (INCH-POUND) or M/H (METRIC)
Use to specify:
•
Conveyors, belt speed
Unit of Measure Name for: MPH (INCH-POUND) or KM/H (METRIC)
Use to specify:
•
Wind velocity
Unit of Measure Name for: RPM (INCH-POUND) or RPM (METRIC)
Use to specify:
•
Agitators, agitated tanks
•
Motors
•
Blenders
Unit of Measure Name for: CFM (INCH-POUND) or M3/H (METRIC)
Use to specify:
•
Air, gas compressors
•
Air dryers
•
Dust collectors, washers, precipitators, cyclone
•
Fans
•
Vacuum pumps
Unit of Measure Name for: CFH (INCH-POUND) or M3/H (METRIC)
Use to specify:
•
Feeders
Unit of Measure Name for: CFM/SF (INCH-POUND) or M3/H/M2 (METRIC)
Use to specify:
•
Dust collectors
Unit of Measure Name for: GPM (INCH-POUND) or L/S (METRIC)
Use to specify:
•
Centrifugal pumps
•
Barometric condenser - water flow rate
•
Filter, cartridge, tubular
•
Gear pumps
•
Positive displacement pumps
•
Towers, cooling
•
Water treatment systems
Unit of Measure Name for: GPH (INCH-POUND) or M3/H (METRIC)
Use to specify:
•
29-13
Unit of Measure Name for: LB/H (INCH-POUND) or KG/H (METRIC)
Use to specify:
•
Dryers, evaporative capacity
•
Drum dryers
•
Evaporators
•
Ejectors - air flow rate
•
Filters
•
Feeders
•
Flakers, drum type
•
Heat exchangers
•
Reactors
•
Rotary dryers
•
Tray drying systems
•
Towers, packed, trayed
•
Water treatment systems - boilers
•
Wiped film evaporators
Unit of Measure Name for: TPH (INCH-POUND) or TON/H (METRIC)
Use to specify:
•
Conveyors
•
Bucket conveyors
•
Crushers
•
Feeders
•
Filters
•
Mills
Unit of Measure Name for: TPD (INCH-POUND) or TON/H (METRIC)
Use to specify:
•
Crystallizers
•
Feeder, vibrating
•
Mills
Electrical Units
Unit of Measure Name for: V (INCH-POUND) or V (METRIC)
Use to specify:
•
Electrical plant bulks
Unit of Measure Name for: KV (INCH-POUND) or KV (METRIC)
Use to specify:
•
29-14
Unit of Measure Name for: A (INCH-POUND) or A (METRIC)
Use to specify:
•
Unit of Measure Name for: KA (INCH-POUND) or KA (METRIC)
Use to specify:
•
Unit of Measure Name for: W (INCH-POUND) or W (METRIC)
Use to specify:
•
Unit of Measure Name for: KW (INCH-POUND) or KW (METRIC)
Use to specify:
•
Electric generators, portable
•
Heat exchangers - tank heaters
Unit of Measure Name for: KVA (INCH-POUND) or KVA (METRIC)
Use to specify:
•
Electric generators
•
Electrical substation equipment
29-15
Power Units
Unit of Measure Name for: TONS-REF (INCH-POUND) or KW (METRIC)
Use to specify:
•
Refrigeration units
Unit of Measure Name for: BTU/H (INCH-POUND) or W (METRIC)
Use to specify:
•
Heat transfer rate
Unit of Measure Name for: MMBTU/H (INCH-POUND) or MEGAW (METRIC)
Use to specify:
•
Furnaces
•
Heating units
•
Reboilers
Unit of Measure Name for: BTU/H/SF (INCH-POUND) or W/M2 (METRIC)
Use to specify:
•
Flarestacks
Unit of Measure Name for: BTU/LB (INCH-POUND) or KJ/KG (METRIC)
Use to specify:
•
Reboilers
•
Flarestacks
Viscosity Units
Unit of Measure Name for: CPOISE (INCH-POUND) or MPA-S (METRIC)
Use to specify:
•
Pumps
•
Agitated vessels
Unit of Measure Name for: CSTOKE (INCH-POUND) or MM2/S (METRIC)
Use to specify:
•
29-16
Pumps, gear
30 Field Manpower Titles
and Wage Rates
(G13)
US Country Base
UK Country Base
JP Country Base
EU Country Base
ME Country Base
30 Field Manpower Titles and Wage Rates (G13)
30-1
The rates in this chapter are escalated by the Construction Index value
specified by the user in the Indexing/Escalation data
US Country Base
Craft
Code
US Craft Name
Unloaded
Wage Rate
($/MH)
Aspen In-Plant Cost
Estimator Loaded Wage
Rate ($/MH) 1
51
Laborer
17.00
37.10
53
*Millwright
30.50
66.60
54
Rigger
29.40
64.20
56
Light Vehicle Driver
19.00
41.50
57
Heavy Vehicle Driver
21.10
46.00
59
Oiler
28.20
61.50
60
Mechanic
28.80
62.80
62
Light Equipment Oper
28.20
61.50
63
Medium Equipment Oper
29.20
63.70
64
Heavy Equipment Oper
30.20
65.90
66
*Pipefitter
28.60
62.40
67
*Pipe Welder
31.50
68.70
69
Cement Finisher
25.00
54.60
70
Carpenter
24.30
53.00
71
Bricklayer
26.70
58.30
72
Ironworker - Rebar
28.20
61.50
74
Ironworker - Structural
26.90
58.70
75
Welder - Structural
26.90
58.70
77
Welder - Special
30.80
67.20
78
*Welder - Fabricator
28.20
61.50
79
*Boilermaker
27.90
60.90
*Instrument Fitter
31.30
68.30
83
*Electrician - Line
31.30
68.30
84
*Electrician - Wiring
29.20
63.70
52
55
58
61
65
68
73
76
80
81
82
85
30-2
Craft
Code
US Craft Name
Unloaded
Wage Rate
($/MH)
Aspen In-Plant Cost
Rate ($/MH) 1
86
*Sheetmetal Worker
26.70
58.30
87
Insulator
21.90
47.80
Painter
21.90
47.80
98
Craft Helper
18.80
41.00
99
Foreman
**
**
88
89
90
91
92
93
94
95
96
97
1
Aspen In-Plant Cost Estimator Loaded Wage Rate excludes equipment rental.
* Principal Crafts.
** Foreman’s rate is 110% of the highest paid craft in the crew in which the
foreman works.
Base Construction Index Value (1Q 2012) = 2030.
30-3
UK Country Base ***
Craft
Code
UK Craft Name
Unloaded
Wage Rate
(PS/MH)
Aspen In-Plant Cost
Rate (PS/MH) 1
51
Laborer
15.60
43.40
53
*Fitter/Millwright
19.70
55.00
54
Rigger
19.70
55.00
56
17.20
47.90
57
17.20
47.90
Plant Fitter
19.70
55.00
52
55
58
59
60
61
62
17.20
47.90
63
18.50
51.40
64
19.70
55.00
65
66
*Plater/Pipefitter
19.70
55.00
67
*Welder
20.80
57.90
Cement Finisher
17.20
47.90
68
69
70
Joiner
19.40
53.90
71
Bricklayer
17.40
48.50
72
Steel Fixer
17.20
47.90
73
74
Steel Erector
19.70
55.00
75
Welder - Structural
19.70
55.00
Welder - Special
20.80
57.90
76
77
78
19.70
55.00
79
*Boilermaker
19.70
55.00
*Instrument Fitter
19.70
55.00
83
*Electrical Technician
21.10
58.80
84
*Electrician
19.10
53.30
86
*Sheetmetal Worker
19.70
55.00
87
Insulator
19.70
55.00
80
81
82
85
88
30-4
Craft
Code
UK Craft Name
Unloaded
Wage Rate
(PS/MH)
Aspen In-Plant Cost
Rate (PS/MH) 1
89
Painter
17.20
47.90
98
Craftsman’s Mate
15.60
43.40
99
Foreman
**
**
90
91
92
93
94
95
96
97
1
* Principal Crafts.
foreman works.
*** Wage Rate Basis: National Agreement for the Engineering Construction
Industry, 2011-2012 Update. Rates include measured incentive bonus
appropriate to large process industry sites. Rates for civil work reflect
"comparability" with rates for engineering trades on large process industry
sites.
Base Construction Index Value (1Q 2012) = 4970
Note: PS indicates Pounds Sterling
30-5
JP Country Base
Craft
Code
JP Craft Name
Unloaded
Wage Rate
(KY/MH)
Aspen In-Plant Cost
Rate (KY/MH) 1
51
Laborer
1.60
3.40
53
*Millwright
2.00
4.20
54
Rigger
2.00
4.20
56
1.80
3.80
57
2.10
4.40
59
Oiler
1.90
4.00
60
Mechanic
2.10
4.40
52
55
58
61
62
2.20
4.60
63
2.20
4.60
64
2.20
4.60
66
*Pipefitter
2.60
5.50
67
*Pipe Welder
2.80
5.90
Cement Finisher
2.20
4.60
65
68
69
70
Carpenter
2.30
4.80
71
Bricklayer
2.60
5.50
72
Ironworker - Rebar
2.10
4.40
73
74
Ironworker - Structural
2.30
4.80
75
Welder - Structural
2.60
5.50
77
Welder - Special
2.60
5.50
78
2.60
5.50
79
*Boilermaker
2.50
5.30
*Instrument Fitter
2.30
4.80
83
*Electrician - Line
2.50
5.30
84
*Electrician - Wiring
2.50
5.30
86
*Sheetmetal Worker
1.90
4.00
87
Insulator
2.30
4.80
76
80
81
82
85
88
30-6
Craft
Code
JP Craft Name
Unloaded
Wage Rate
(KY/MH)
Aspen In-Plant Cost
Rate (KY/MH) 1
89
Painter
2.20
4.60
98
Craft Helper
1.70
3.60
99
Foreman
**
**
90
91
92
93
94
95
96
97
1
* Principal Crafts.
foreman works.
Base Construction Index Value (1Q 2012 = 1130).
Note: KY indicates thousand Yen.
30-7
EU Country Base
Craft
Code
EU Craft Name
Unloaded
Wage Rate
(EUR/MH)
Aspen In-Plant Cost
Rate (EUR/MH) 1
51
Laborer
18.40
43.60
53
*Millwright
23.90
56.70
54
Rigger
23.90
56.70
56
Driver: Light
21.30
50.50
57
Driver: Heavy
21.30
50.50
23.90
56.70
52
55
58
59
Oiler
60
Mechanic
61
62
EquipOp: Light
21.30
50.50
63
EquipOp: Medium
21.50
51.10
64
EquipOp: Heavy
23.90
56.70
66
*Pipefitter
23.90
56.70
67
*Pipe Welder
24.20
57.50
69
Cement Finisher
21.30
50.50
70
Carpenter
24.00
56.90
71
Bricklayer
24.00
56.90
72
Ironworker - Rebar
21.30
50.50
74
Ironworker: Struct
23.90
56.70
75
Welder: Struct
23.90
56.70
77
Welder: Special
24.50
58.00
78
*Welder: Fabr
24.50
58.00
79
*Boilermaker
23.90
56.70
*Instru.Fitter
23.90
56.70
83
*Electr: Line
24.00
56.90
84
*Electr: Wire
23.90
56.70
86
*Sheetmetal Worker
23.90
56.70
87
Insulator
23.90
56.70
65
68
73
76
80
81
82
85
88
30-8
Craft
Code
EU Craft Name
Unloaded
Wage Rate
(EUR/MH)
Aspen In-Plant Cost
Rate (EUR/MH) 1
89
Painter
21.30
50.50
98
Helper
19.50
46.40
99
Foreman
**
**
90
91
92
93
94
95
96
97
1
* Principal Crafts.
foreman works.
ME Country Base
Note: SAR = Saudi Arabian Riyals
Craft
Code
ME Craft Name
Unloaded
Wage Rate
(SAR/MH)
Aspen In-Plant Cost
Rate (SAR/MH) 1
51
Laborer
22.00
55.10
53
*Millwright
28.20
70.40
54
Rigger
28.20
70.40
56
Driver: Light
24.00
60.00
57
Driver: Heavy
24.00
60.00
59
Oiler
28.20
70.40
60
Mechanic
41.60
104.10
52
55
58
61
62
EquipOp: Light
22.00
55.10
63
EquipOp: Medium
25.40
63.40
64
EquipOp: Heavy
29.20
72.90
*Pipefitter
28.20
70.40
65
66
30-9
Craft
Code
ME Craft Name
Unloaded
Wage Rate
(SAR/MH)
Aspen In-Plant Cost
Rate (SAR/MH) 1
67
*Pipe Welder
41.60
104.10
69
Cement Finisher
24.50
61.20
70
Carpenter
23.30
58.20
71
Bricklayer
23.30
58.20
72
Ironworker - Rebar
25.70
64.30
74
Ironworker: Struct
25.70
64.30
75
Welder: Struct
25.70
64.30
77
Welder: Special
25.70
64.30
78
*Welder: Fabr
26.90
67.40
79
*Boilermaker
26.90
67.40
*Instru.Fitter
28.20
70.40
83
*Electr: Line
28.20
70.40
84
*Electr: Wire
28.20
70.40
86
*Sheetmetal Worker
25.70
64.30
87
Insulator
27.60
68.90
Painter
24.50
61.20
Helper
19.00
47.50
68
73
76
80
81
82
85
88
89
90
91
92
93
94
95
96
97
98
99
1
* Principal Crafts.
foreman works.
30-10
30-11
30-12
31 Engineering
(G13)
Design and Construction Engineering Disciplines and Wage Rates
US Country Base
UK Country Base
JP Country Base
EU Country Base
ME Country Base
Engineering Expenses and Indirects
Standard Engineering Drawing Types
User-Specified Drawing Classifications
31 Engineering (G13)
31-1
Design and Construction
Engineering Disciplines and
Wage Rates
US Country Base
Note: $ indicates US dollars
No.
Design* Discipline
$/MH
Basic Engineering:
$/MH
Home Office:
01
Project Engineering
62.70
01
Project Management
65.10
02
Process Engineering
56.90
02
Cost Accounting
49.40
03
Piping Design
55.60
03
Construction Dept.
36.50
04
Instrument Design
54.60
04
Planning, Scheduling
47.10
05
Mechanical Design
55.60
05
Tools, Equipment
37.00
06
Electrical Design
55.20
06
Industrial Relations
37.10
07
Civil Design
54.30
07
Subcontract Admin.
62.00
08
Piping Drafting
47.10
08
Support, Clerical
25.20
09
Instrument Drafting
49.00
Field Office:
10
Mechanical Drafting
50.30
01
Project Constrn. Supt. 54.00
11
Electrical Drafting
50.00
02
Area Superintendents 52.90
12
Civil Drafting
47.10
13
General Drafting
39.20
14
51.70
15
Cost Estimating
53.90
16
Support, Clerical
25.20
Detail Engineering:
31-2
No. Construction**
Discipline
Field Superintendents:
03
Piping
47.90
04
Instrumentation
47.90
05
Electrical
47.90
06
Civil
47.90
07
Mechanical
47.90
01
Project Engineering
62.70
08
QC&A, Inspection
36.20
02
Process Engineering
56.90
09
Subcontract Admin
50.70
03
Piping Design
55.60
10
Cost Engineering
46.20
04
Instrument Design
54.60
11
Field Engineering
42.20
05
Mechanical Design
55.60
12
47.40
06
Electrical Design
55.20
13
Safety & Medical
38.70
07
Civil Design
54.30
14
Field Accounting
39.50
08
Piping Drafting
47.10
15
Materials Control
39.30
09
Instrument Drafting
49.00
16
General Drafting
39.20
10
Mechanical Drafting
50.30
17
Support, Clerical
22.70
11
Electrical Drafting
50.00
Construction Management
(Home):
12
Civil Drafting
47.10
01
Project Management
65.10
No.
Design* Discipline
$/MH
No. Construction**
Discipline
$/MH
13
General Drafting
39.20
02
Cost Accounting
49.40
14
51.70
03
Construction Dept.
36.50
15
Cost Estimating
53.90
04
Subcon. Admin.
(Field)
50.70
16
Support, Clerical
25.20
05
Construction Manager 62.10
17
Model Building
32.30
06
Area Managers
52.90
07
Subcon. Coordinator
45.60
Procurement:
01
Procurement
48.70
08
Field Inspector
36.20
02
Support, Clerical
25.20
09
Cost Engineering
46.20
10
Field Engineering
42.20
11
47.40
12
Safety & Medical
38.70
13
Support, Clerical
25.20
Eng'g Management:
01
Project Engineering
76.30
* These rates are the current (1Q 2012)
System base values, which are escalated
by the Design Engineering Index specified
by the user in the Indexing/Escalation
data.
Start-up, Commissioning:
01
Commissioning Staff
62.70
02
Start-up Staff
56.90
03
Performance Testing
55.60
Base Design Engineering Index = 1530
** These rates are the current (1Q
2012) System base values, which are
escalated by the Construction
Management Index specified by the
user in the Indexing/Escalation data.
Base Construction Management
Index = 1800
31-3
UK Country Base
No.
Design* Discipline
PS/MH
Basic Engineering:
PS/MH
Home Office:
01
Project Engineering
31.20
01
Project Management
36.50
02
Process Engineering
31.90
02
Cost Accounting
21.20
03
Piping Design
29.70
03
Construction Dept.
28.30
04
Instrument Design
29.70
04
25.40
05
Mechanical Design
29.70
05
Tools, Equipment
28.30
06
Electrical Design
29.70
06
28.30
07
Civil Design
29.70
07
Subcontract Admin.
28.30
08
Piping Drafting
22.00
08
Support, Clerical
12.70
09
Instrument Drafting
22.00
Field Office:
10
Mechanical Drafting
22.00
01
11
Electrical Drafting
22.00
02
12
Civil Drafting
22.00
13
General Drafting
22.00
03
Piping
27.20
14
24.30
04
Instrumentation
27.20
15
Cost Estimating
22.00
05
Electrical
27.20
16
Support, Clerical
12.70
06
Civil
27.20
07
Mechanical
27.20
Detail Engineering:
Area Superintendents
27.20
Field Superintendents
01
Project Engineering
31.20
08
QC&A, Inspection
27.20
02
Process Engineering
31.90
09
Subcontract Admin.
27.20
03
Piping Design
29.70
10
Cost Engineering
24.30
04
Instrument Design
29.70
11
Field Engineering
25.20
05
Mechanical Design
29.70
12
24.30
06
Electrical Design
29.70
13
Safety & Medical
20.70
07
Civil Design
29.70
14
Field Accounting
19.30
08
Piping Drafting
22.00
15
Materials Control
19.30
09
Instrument Drafting
22.00
16
General Drafting
20.20
10
Mechanical Drafting
22.00
17
Support, Clerical
12.20
11
Electrical Drafting
22.00
(Home):
12
Civil Drafting
22.00
01
Project Management
36.50
13
General Drafting
22.00
02
Cost Accounting
21.20
14
24.30
03
Construction Dept.
28.60
15
Cost Estimating
22.00
04
Subcon. Admin. (Field) 28.60
16
Support, Clerical
12.70
05
Construction Manager
39.60
17
Model Building
23.80
06
Area Managers
30.40
07
Subcon. Coordinator
28.30
08
Field Inspector
28.60
Procurement:
01
31-4
No. Construction**
Discipline
Procurement
21.30
No.
Design* Discipline
PS/MH
No. Construction**
Discipline
PS/MH
02
Support, Clerical
12.70
09
Cost Engineering
25.40
10
Field Engineering
26.40
11
25.40
12
Safety & Medical
21.70
13
Support, Clerical
12.70
Eng'g Management:
01
Project Engineering
31.20
System base values, which are escalated by
the Design Engineering Index specified by
the user in the Indexing/Escalation data.
01
Commissioning Staff
28.20
02
Start-up Staff
28.20
03
Performance Testing
28.20
2012) System base values, which
are escalated by the Construction
Index = 4860
31-5
JP Country Base
Note: KY indicates thousand Yen
No.
Design* Discipline
KY/MH
Project Engineering
5.0
Project Management
6.7
02
Process Engineering
5.4
03
Piping Design
5.6
02
Cost Accounting
4.3
03
Construction Dept.
4.5
04
Instrument Design
5.6
04
3.9
05
Mechanical Design
5.6
05
Tools, Equipment
4.2
06
07
Electrical Design
5.6
06
4.2
Civil Design
5.6
07
Subcontract Admin.
3.6
08
Piping Drafting
3.5
08
Support, Clerical
2.1
09
Instrument Drafting
3.5
Field Office:
10
Mechanical Drafting
3.5
01
11
Electrical Drafting
3.5
02
12
Civil Drafting
3.5
13
General Drafting
3.5
01
4.0
03
Piping
4.0
14
3.9
04
Instrumentation
4.0
15
Cost Estimating
3.9
05
Electrical
4.0
16
Support, Clerical
2.1
06
Civil
4.0
07
QC&A, Inspection
4.0
Detail Engineering:
01
Project Engineering
5.0
08
Mechanical
4.0
02
Process Engineering
5.4
09
Subcontract Admin.
4.0
03
Piping Design
5.6
10
Cost Engineering
3.7
04
Instrument Design
5.6
11
Field Engineering
3.7
05
Mechanical Design
5.6
12
3.7
06
Electrical Design
5.6
13
Safety & Medical
3.7
07
Civil Design
5.6
14
Field Accounting
3.7
08
Piping Drafting
3.5
15
Materials Control
4.2
09
Instrument Drafting
3.5
16
General Drafting
3.6
10
Mechanical Drafting
3.5
17
Support, Clerical
2.1
11
Electrical Drafting
3.5
(Home):
12
Civil Drafting
3.5
01
Project Management
6.7
13
General Drafting
3.5
02
Cost Accounting
4.3
14
3.9
03
Construction Dept.
4.5
15
Cost Estimating
3.9
04
16
Support, Clerical
2.1
05
5.3
17
Model Building
2.5
06
Area Managers
5.3
07
Subcon. Coordinator
3.6
08
Field Inspector
4.0
Procurement:
01
31-6
KY/MH
Home Office:
Basic Engineering:
01
No. Construction**
Discipline
Procurement
4.6
No.
Design* Discipline
KY/MH
No. Construction**
Discipline
02
Support, Clerical
2.1
09
Cost Engineering
3.7
10
Field Engineering
3.7
6.7
11
3.7
Note: KY indicates thousand YEN
12
Safety & Medical
3.7
13
Support, Clerical
2.1
Eng'g Management:
01
Project Engineering
KY/MH
* These rates are the current (1Q
escalated by the Design Engineering
Index specified by the user in the
Indexing/Escalation data.
01
Commissioning Staff
4.5
02
Start-up Staff
4.3
03
Performance Testing
4.3
Index = 1940
31-7
EU Country Base
Note: EUR indicates Euros
No.
Design* Discipline
EUR/MH
EUR/
MH
Home Office:
Basic Engineering:
01
Project Engineering
50.40
01
Project Management
48.60
02
Process Engineering
38.80
02
Cost Accounting
35.50
03
Piping Design
33.00
03
Construction Dept.
28.60
04
Instrument Design
33.00
04
34.20
05
Mechanical Design
38.10
05
Tools, Equipment
28.60
06
Electrical Design
33.00
06
28.60
07
Civil Design
33.00
07
Subcontract Admin.
28.60
08
Piping Drafting
25.80
08
Support, Clerical
19.90
09
Instrument Drafting
27.20
Field Office:
10
Mechanical Drafting
27.20
01
11
Electrical Drafting
27.20
02
12
Civil Drafting
27.20
13
General Drafting
25.00
14
35.60
15
Cost Estimating
36.90
16
Support, Clerical
20.70
Detail Engineering:
35.70
03
Piping
30.90
04
Instrumentation
30.90
05
Electrical
30.90
06
Civil
30.90
07
Mechanical
30.90
01
Project Engineering
50.40
08
QC&A, Inspection
30.90
02
Process Engineering
38.80
09
Subcontract Admin.
28.60
03
Piping Design
33.00
10
Cost Engineering
35.50
04
Instrument Design
33.00
11
Field Engineering
30.90
05
Mechanical Design
38.10
12
34.20
06
Electrical Design
33.00
13
Safety & Medical
28.60
07
Civil Design
33.00
14
Field Accounting
28.40
08
Piping Drafting
25.80
15
Materials Control
28.40
09
Instrument Drafting
27.20
16
General Drafting
24.10
10
Mechanical Drafting
27.20
17
Support, Clerical
19.90
11
Electrical Drafting
27.20
(Home):
12
Civil Drafting
27.20
01
Project Management
48.60
13
General Drafting
25.00
02
Cost Accounting
35.50
14
35.60
03
Construction Dept.
28.60
15
Cost Estimating
36.90
04
16
Support, Clerical
20.70
05
48.60
17
Model Building
24.70
06
Area Managers
35.70
07
Subcon. Coordinator
28.60
08
Field Inspector
32.10
Procurement:
01
31-8
No. Construction**
Discipline
Procurement
32.80
No.
Design* Discipline
EUR/MH
No. Construction**
Discipline
02
Support, Clerical
20.70
09
Cost Engineering
35.50
10
Field Engineering
30.90
11
34.20
12
Safety & Medical
28.60
13
Support, Clerical
19.90
Eng'g Management:
01
Project Engineering
52.40
* These rates are the current (1Q
escalated by the Design Engineering
Index specified by the user in the
Indexing/Escalation data.
EUR/
MH
01
Commissioning Staff
49.20
02
Start-up Staff
37.80
03
Performance Testing
37.80
Index = 1720
31-9
ME Country Base
Note: SAR indicates Saudi Arabian Rials
No.
Design* Discipline
SAR/
MH
Basic Engineering:
SAR/
MH
Home Office:
01
Project Engineering
300.00
01
Project Management
360.00
02
Process Engineering
280.00
02
Cost Accounting
91.00
03
Piping Design
240.00
03
Construction Dept.
84.50
04
Instrument Design
240.00
04
210.00
05
Mechanical Design
240.00
05
Tools, Equipment
80.70
06
Electrical Design
240.00
06
78.00
07
Civil Design
240.00
07
Subcontract Admin.
78.00
08
Piping Drafting
165.00
08
Support, Clerical
68.30
09
Instrument Drafting
165.00
Field Office:
10
Mechanical Drafting
165.00
01
11
Electrical Drafting
165.00
02
Area Superintendents 75.40
12
Civil Drafting
165.00
13
General Drafting
165.00
14
210.00
15
Cost Estimating
210.00
16
Support, Clerical
100.00
Detail Engineering:
31-10
No. Construction**
Discipline
03
Piping
71.50
04
Instrumentation
71.50
05
Electrical
71.50
06
Civil
71.50
07
Mechanical
71.50
01
Project Engineering
300.00
08
QC&A, Inspection
71.50
02
Process Engineering
280.00
09
Subcontract Admin
78.00
03
Piping Design
240.00
10
Cost Engineering
91.00
04
Instrument Design
240.00
11
Field Engineering
162.80
05
Mechanical Design
240.00
12
210.00
06
Electrical Design
240.00
13
Safety & Medical
71.50
07
Civil Design
240.00
14
Field Accounting
91.00
08
Piping Drafting
165.00
15
Materials Control
135.00
09
Instrument Drafting
165.00
16
General Drafting
110.00
10
Mechanical Drafting
165.00
17
Support, Clerical
68.30
11
Electrical Drafting
165.00
(Home):
12
Civil Drafting
165.00
01
Project Management
360.00
13
General Drafting
165.00
02
Cost Accounting
91.00
14
210.00
03
Construction Dept.
84.50
15
Cost Estimating
210.00
04
Subcon. Admin.
(Field)
78.00
16
Support, Clerical
100.00
05
Construction Manager 360.00
17
Model Building
120.00
06
Area Managers
75.40
07
Subcon. Coordinator
78.00
No.
Design* Discipline
SAR/
MH
Procurement:
No. Construction**
Discipline
SAR/
MH
08
Field Inspector
71.50
01
Procurement
250.00
09
Cost Engineering
91.00
02
Support, Clerical
100.00
10
Field Engineering
162.80
11
210.00
12
Safety & Medical
71.50
13
Support, Clerical
68.30
Eng'g Management:
01
Project Engineering
420.00
System base values.
01
Commissioning Staff
162.80
02
Start-up Staff
162.80
03
Performance Testing
162.80
2012) System base values.
Index = 1870
31-11
Engineering Expenses and
Indirects (Aspen Capital Cost
Estimator and Aspen Process
Economic Analyzer )
US Country Base
Phase
% Eng'ng Manpower
Expense Rate ($/
MH)*
Payroll
Business
Cost Indirects
Basic Engineering
5.40
25
75
Detail Engineering
4.20
25
75
Procurement
9.60
25
75
Engineering
Management
0.00
25
75
($/MH)**
Home Office
Construction Services
3.90
25
75
Field Office Supervision
0.00
25
75
Construction
Management
0.00
25
75
Start-up,
Commissioning
0.00
25
75
UK Country Base
Phase
% Eng'ng Manpower
Expense Rate (PS/
MH)*
Payroll
Business
Cost Indirects
Basic Engineering
4.30
40
90
Detail Engineering
3.60
40
90
Procurement
7.70
40
90
Engineering
Management
0.00
40
90
40
90
(PS/MH)**
31-12
Home Office
3.10
0.00
40
90
Construction
Management
0.00
40
90
Start-up,
Commissioning
0.00
40
90
Engineering Expenses and Indirects - continued
Japan Country Base
% Eng'ng Manpower
Phase
Expense Rate (KY/
MH)*
Payroll Business Cost Indirects
Basic Engineering
0.49
25
75
Detail Engineering
0.38
25
75
Procurement
0.87
25
75
Engineering
Management
0.00
25
75
(KY/MH)**
Home Office
0.36
25
75
0.00
25
75
Construction
Management
0.00
25
75
Start-up,
Commissioning
0.00
25
75
31-13
EU Country Base
Phase
% Eng'ng Manpower
Expense Rate (EUR/
MH)*
Payroll Business Cost Indirects
Basic Engineering
6.20
40
90
Detail Engineering
5.20
40
90
Procurement
11.10
40
90
Engineering
Management
0.00
40
90
(EUR/MH)**
Home Office
4.50
40
90
0.00
40
90
Construction
Management
0.00
40
90
Start-up,
Commissioning
0.00
40
90
*These rates are the current (1Q 2012) System base values, which are escalated by the
Design Engineering Index specified by the user in the Indexing/Escalation data.
**These rates are the current (1Q 2012) System base values, which are escalated by
the Construction Management Index specified by the user in the Indexing/Escalation
data.
31-14
ME Country Base
Phase
% Eng'ng Manpower
Expense Rate (SAR/
MH)*
Payroll
Business
Cost Indirects
Basic Engineering
24.50
25
75
Detail Engineering
19.00
25
75
Procurement
44.20
25
75
Engineering
Management
0.00
25
75
17.80
25
75
0.00
25
75
Construction
Management
0.00
25
75
Start-up,
Commissioning
0.00
25
75
(SAR/MH)**
Home Office
*These rates are the current (1Q 2012) System base values, which are escalated by the
Design Engineering Index specified by the user in the Indexing/Escalation data.
**These rates are the current (1Q 2012) System base values, which are escalated by
the Construction Management Index specified by the user in the Indexing/Escalation
data.
Base Design Engineering Index = 1530 (US), 4750 (UK), 2060 (JP), 1850
(EU), 1620 (ME)
Base Construction Management Index = 1800 (US), 4860 (UK), 1940 (JP),
1720 (EU), 1870 (ME)
Note:
$ indicates U.S. Dollars
PS indicates Pounds Sterling
KY indicates thousand YEN
EUR indicates Euros
SAR indicates Saudi Arabian Riyals
Explanation of Expense Rate
The Expense rate is used to calculate the Basic Engineering Report's
"Overhead Items," which consist of the following:
•
Reproduction
•
Communications
•
Travel
•
Computation
31-15
These four line items collectively comprise engineering expenses. They result
from a fixed percentage split of this expense by phase. Multiply the Total Manhours for the phase by this rate to calculate the total expenses. The system
then allocates these to various categories by percentage as follows:
Basic
Detail
Procure
Home
Reproduction
23%
30%
14%
42%
Communications
3%
4%
12%
8%
Travel
17%
12%
50%
50%
Computation
57%
54%
24%
0%
The amount of the expense is user-adjusted, but how it is split into these
categories is not.
Both the Payroll Burdens/Fringes and Indirects are Percentages of the Total
Engineering Cost in the Basic Engineering Report.
The relationship among the wage rates, expense rate, and cost indirect are as
follows:
31-16
•
Wage rates are the wages paid to a specific disciplines (see page 31-3).
•
The Expense rate is used to calculate the Overhead items in the Basic
Engineering Report.
•
Indirects are typically office expenses. Indirect office expenses include
rent, heat, electricity and other operating expenses not specifically covered
in other engineering accounts.
Standard Engineering Drawing
Types (Aspen Capital Cost
Estimator and Aspen Process
Economic Analyzer)
Basic
Engin eering
Detailed
Engineering
Drawin Description
g No.
Drawing No. Description
1
Process Flow Diagrams
1
2
Piping & Instrument Diagrams 2
Piping Isometrics
3
Interconnecting Piping
Diagrams
3
Special Hanger/Support
Drawings
4
Utility Flow Diagrams
4
Steam Tracing Drawings
5
Utility Piping & Instrument
Dgs
6
Electrical One Line Diagrams
7
Instrument Location Drawings
7
Elec. System Distribution
8
Control Cable Schedules
8
General Equipment
Arrangements
9
Control Room/Console
Drawings
9
Other (Plot Plants, Etc.)
10
Control Systems Schematics
11
Instrument Loop Diagrams
12
Connection Diagrams/Junction
Box Drwgs
13
Electrical One Line Diagrams
14
Substation Layout Drawings
15
Electrical Schematics
16
Power Distribution Drawings
17
Circuit Scheds, Connection
Diagrams
18
Cable Tray Drawings
19
Lighting Drawings
User-specified Drawings
20
Up to nine user-specified drawings (or 21
other tasks, such as models) may be
added to the system drawings by using
a drawing number from the range 91- 23
99.
Note: Only the drawing numbers
24
shown in this table and 91-99 are
accepted.
25
26
31-17
Piping Arrangements (Plans &
Elevns.)
Grounding Drawings
Electrical Tracing Drawings
Equipment Foundation
Drawings
Steelwork Foundation
Drawings
Area Paving Drawings
Misc. Concrete, Supports, Etc.
Basic
Engin eering
31-18
Detailed
Engineering
27
Underground Piping Drawings
28
Structural Steel (Plans &
Elevns.)
29
Ladders & Platforms, Misc.
Steel
30
Grating Drawings
32
Building Arrangement Plans,
Elevns.
33
Architectural Details
34
Facilities Plot Plans
35
Area Equipment Layouts
36
Site Development
38
Other Detail Drawings, Lists
31-19
31-20
32 Construction Equipment
(G4)
Introduction to Construction Equipment Rental
Construction Equipment
32 Construction Equipment(G4)
32-1
Introduction to Construction
Equipment Rental
An Equipment Rental Report is prepared for project estimates when the
Construction Equipment Rental report option is selected. The report identifies
both user and system-selected rental items, durations and rental rates. This
report is deleted upon specific user entry of equipment/plant rental either as a
total cost or as a percentage of field manpower.
The user can revise the system’s evaluation of equipment rental requirements
on an item-by-item basis, and by contractor, by defining Equipment Rental
Data. Options are available for specifying the applicable contractor, adding
days or additional construction equipment to the account, changing days and
rental rates or deleting construction equipment from the account This chapter
includes an indexed list of several hundred rental equipment items contained
within the system base and directly related to work items for equipment and
bulk installation.
For Prime Contractor reporting, equipment rental applies to the project in its
entirety. For contract reporting, equipment rental applies to the responsible
contract and must be provided for each contract if required.
(Aspen Capital Cost Estimator, Aspen Process Economic Analyzer , Aspen InPlant Cost Estimator) Rental days and monthly rates may be adjusted for
construction equipment items.
Equip
No.
Equipment Class Description
21
32-2
AUTOMOTIVE
Size
Metric Units
I-P Units
AMBULANCE
26
AUTOMOTIVE
CAR 2-DOOR
SUBCOMPACT
1.3 LITER
27
AUTOMOTIVE
CAR 4-DOOR
COMPACT
1.6 LITER
28
AUTOMOTIVE
CAR 4-DOOR
STANDARD
2.0 LITER
31
AUTOMOTIVE
MINIBUS
BUS
10 PASSENGER
32
AUTOMOTIVE
BUS
25 PASSENGER
25 PASSENGER
33
AUTOMOTIVE
BUS
40 PASSENGER
40 PASSENGER
41
TRUCK
PICKUP
.5 TONS - 4 X 2
.50 TON - 4 X 2
42
TRUCK
PICKUP
.75 TONS - 4 X 2
75 TON - 4 X 2
43
TRUCK
PICKUP
.75 TONS - 4 X 4
.75 TON - 4 X 4
44
TRUCK
PICKUP - CREW CAB
.75 TONS - 4 X 4
.75 TON - 4 X 4
45
TRUCK
PICKUP
1.0 TONS - 4 X 4
1 TON - 4 X 4
46
TRUCK
HIGHWAY FLATBED
2 TONS - 4 X 2
2 TON - 4 X 2
47
TRUCK
HIGHWAY FLATBED
2 TONS - 4 X 2
6 TON - 4 X 2
Equip
No.
Size
Metric Units
I-P Units
48
TRUCK
HIGHWAY FLATBED
2 TONS - 4 X 2
14 TON - 4 X 2
49
TRUCK
HIGHWAY FLATBED
30 TONS - 6 X 4
27 TON - 6 X 4
51
TRUCK
OFF-ROAD FLATBED
6 TONS - 6 X 6
6 TON - 6 X 6
56
TRUCK
A-FRAME
4X4
4X4
57
TRUCK
LUBE/GREASE
58
TRUCK
FUEL/WATER
5000 GALLONS
18 M3
61
TRUCK
POWERLINE, BUCKET
INSULATED
INSULATED
62
TRUCK
CHERRY PICKER
NON-INSULATED
NONINSULATED
66
TRUCK
DUMP TRUCK
6 CY
5 M3
67
TRUCK
DUMP TRUCK
12 CY
9 M3
68
TRUCK
DUMP TRUCK
20 CY
15 M3
69
TRUCK
DUMP TRUCK
30 CY
23 M3
71
TRUCK
FORKLIFT
2 TONS
72
TRUCK
FORKLIFT
10 TONS
9 TON
76
EARTHMOVING
WHEEL LDR. W/
BACKHOE
0.75 CY
0.6 M3
77
EARTHMOVING
WHEEL LOADER
CAT930 1.75 CY
CAT930 1.3 M3
78
EARTHMOVING
WHEEL LOADER
CAT950 3.0 CY
CAT950 2.3 M3
81
EARTHMOVING
CRAWLER LOADER
1.0 CY
0.75 M3
82
EARTHMOVING
CRAWLER LOADER
CAT955 1.75 CY
CAT955
2 TON
83
EARTHMOVING
CRAWLER LOADER
CAT977 2.75 CY
CAT977
84
EARTHMOVING
CRAWLER LOADER
4.50 CY
3.4 M3
86
EARTHMOVING
WHEEL ARTICUL
LOADER
CAT966 3.50 CY
CAT966 2.5 M3
87
EARTHMOVING
WHEEL ARTICUL
LOADER
CAT988 6.00 CY
CAT988 4.5 M3
88
EARTHMOVING
WHEEL ARTICUL
LOADER
CAT980 PIPELOAD CAT980
PIPELOAD
91
EARTHMOVING
MOTOR GRADER
CAT 12
CAT 12
92
EARTHMOVING
MOTOR GRADER
CAT 14
CAT 42
95
EARTHMOVING
TRENCHER,
DITCHWITCH
12 IN X 3 FT
300 MM X 1.0 M
32-3
Equip
No.
32-4
Size
Metric Units
I-P Units
96
EARTHMOVING
TRENCHER, WHEEL
16 IN X 7 FT 6 IN 400 MM X 2.0 M
97
EARTHMOVING
TRENCHER, WHEEL
28 IN X 8 FT 6 IN 700 MM X 2.5 M
98
EARTHMOVING
TRENCHER, WHEEL
48 IN
99
EARTHMOVING
SCRAPER-ELEVATING
CAT613
11 CY
CAT613 8 M3
100
EARTHMOVING
SCRAPER-ELEVATING
CAT621J
21 CY
CAT621J 16 M3
101
EARTHMOVING
SCRAPER-ELEVATING
CAT633C
32 CY CAT633C 24 M3
102
EARTHMOVING
SCRAPER,WHEEL
TRACTR
TWIN627 14-20
CY
TWIN627 11-15
M3
103
EARTHMOVING
SCRAPER,WHEEL
TRACTR
CAT631C 21-30
CY
CAT631C 16-23
M3
104
EARTHMOVING
SCRAPER,WHEEL
TRACTR
CAT651B 32-44
CY
CAT651B 24-33
M3
105
EARTHMOVING
SCRAPER, TOWED
CAT435F 14-18
CY
CAT435F 11-14
M3
106
EARTHMOVING
SCRAPER, TOWED
CAT D4 68 HP
CAT D4
107
EARTHMOVING
CRAWLER TRACT.
DOZER
CAT D6 120 HP
CAT D6
108
EARTHMOVING
CRAWLER TRACT.
DOZER
CAT D7 180 HP
CAT D7
109
EARTHMOVING
CRAWLER TRACT.
DOZER
CAT D8 270 HP
CAT D8
110
EARTHMOVING
CRAWLER TRACT.
DOZER
CAT D9 385 HP
CAT D9
111
EARTHMOVING
BACKHOE CRAWLER
HYDR
.50 CY
.40 M3
112
EARTHMOVING
BACKHOE CRAWLER
HYDR
.75 CY
.60 M3
113
EARTHMOVING
BACKHOE CRAWLER
HYDR
1.0 CY
75 M3
114
EARTHMOVING
BACKHOE CRAWLER
HYDR
1.5 CY
1.1 M3
115
EARTHMOVING
BACKHOE CRAWLER
HYDR
2.5 CY
1.9 M3
116
EARTHMOVING
TRUCK-MTD GRADALL 5/8 CY G660
G660
117
EARTHMOVING
BACKHOE, SELF-PROP .50 CY
0.4 M3
118
EARTHMOVING
BACKHOE, WHEEL
.75 CY W/
BREAKER
0.6 M3 W/
BREAKER
121
DRILLING
ROTARY ROCK DRILL
CRAWLER MTD 12 CRAWLER MTD
IN
122
DRILLING
TRACK DRILL,SWG
BOOM
4.5 INCHES
115 MM
123
DRILLING
TWIN ROCK DRILL
SUSP. VERTICAL
SUSP.
VERTICAL
124
DRILLING
AUGER,FLATBEDMOUNTD
2.5
TONS,OFFROAD
2 TON,
OFFROAD
1200 MM
Equip
No.
Size
Metric Units
I-P Units
125
DRILLING
DRILL QUAD,SWG
BOOM
4.5 INCHES
115 MM
126
COMPACTION
ROLLER SELFPROPELLD
VIBR DRUM 7
TONS
VIB DRUM 6.5
TON
127
COMPACTION
ROLLER SELFPROPELLD
9 WHEEL 15 TONS 9 WHEEL
TON
128
COMPACTION
ROLLER SELFPROPELLD
SMOOTH
TONS
131
COMPACTION
ROLLER,TOWED, 1
DRUM
SHEEPSFT 40X60 SHEEPSFT 1
IN
X1.5 M
132
COMPACTION
ROLLER,TOWED, 1
DRUM
VIBRATNG 30X54 VIBRG.8 X1.4 M
IN
133
COMPACTION
ROLLER, MANUAL
GUIDE
VIB DRUM 1.0
TONS
134
COMPACTION
RAMMER, HANDHELD
350-700SPM, 130 350-700SPM,
60 KG
136
TRACTOR
TRUCK TRACTOR
20 TONS 4X2
18 TON 4X2
137
TRACTOR
TRUCK TRACTOR
30 TONS 4X2
27 TON 6X4
138
TRACTOR
TRUCK TRACTOR
60 TONS 4X2
54 TON 6X4
139
TRACTOR
OFF-ROAD TRACTOR
20 TONS 4X4
18 TON 4X4
140
TRACTOR
OFF-ROAD TRACTOR
40 TONS 6X6
36 TON 6X6
141
TRACTOR
WHEEL, W/TOW
HITCH
50 HP
40 KW
142
TRACTOR
WHEEL, W/TOW
HITCH
105 HP
80 KW
146
TRAILER
LOWBOY, PLATFORM
147
TRAILER
LOWBOY, PLATFORM
25 TONs
25 TON
148
TRAILER
LOWBOY, PLATFORM
40TONs
35 TON
149
TRAILER
LOWBOY, PLATFORM
50 TONs
45 TON
150
TRAILER
LOWBOY, PLATFORM
60 TONs
55 TON
151
TRAILER
LOWBOY, PLATFORM
75 TONs
70 TON
152
TRAILER
LOWBOY, PLATFORM
100 TONs
90 TON
155
TRAILER
FLATBED - 4 WHEEL
6 TONS
5 TON
156
TRAILER
FLATBED
15 TONS
15 TON
157
TRAILER
FLATBED
30 TONS
25 TON
158
TRAILER
FLOAT, OFFROAD
30 TONS
35 TON
159
TRAILER
FLOAT, OFFROAD
60 TONS
55 TON
161
TRAILER
DIESEL BOWSER
600 GALLONS
2.25 M3
162
TRAILER
FUEL/WATER
2000 GALLONS
7.50 M3
10
15 TONS
14
SMOOTH
TON
9
VIB DRUM 1
TON
15 TON
32-5
Equip
No.
Size
Metric Units
I-P Units
163
TRAILER
FUEL/WATER
5000 GALLONS
18.00 M3
164
TRAILER
FUEL/WATER
8000 GALLONS
30.00 M3
166
TRAILER
MOBILE OFFICE
8 X 35 FEET
2.5 X 10 M
168
TRAILER
X-RAY DARKROOM
169
TRAILER
STORAGE VAN
8 X 28 FEET
2.5 X 8.5 M
171
TRAILER
PIPE POLE
30 TONS
27 TON
172
TRAILER
PIPE DOLLY/5TH
WHEEL
2 AXLE
2 AXLE
173
TRAILER
CABLE REEL
176
CRANE
TELESCOPIC JIB, SELF PROP. 5 TONS
PROP 5 TON
177
CRANE
PROP 9 TON
178
CRANE
PROP 14 TON
181
CRANE
TELESCOPIC JIB
TRUCK - 15 TONS TRUCK - 14
TON
182
CRANE
TELESCOPIC JIB
TON
183
CRANE
TELESCOPIC JIB
TON
184
CRANE
TELESCOPIC JIB
TON
185
CRANE
TELESCOPIC JIB
TON
186
CRANE
TELESCOPIC JIB
TON
187
CRANE
TELESCOPIC JIB
TON
188
CRANE
TELESCOPIC JIB
TON
189
CRANE
TELESCOPIC JIB
TRUCK - 110
TONS
TRUCK - 100
TON
190
CRANE
TELESCOPIC JIB
TRUCK - 200
TONS
TRUCK - 180
TON
191
CRANE
FIXED JIB
TON
192
CRANE
FIXED JIB
TON
193
CRANE
FIXED JIB
TON
16
32-6
Equip
No.
Size
Metric Units
I-P Units
194
CRANE
FIXED JIB
TON
195
CRANE
FIXED JIB
TON
196
CRANE
FIXED JIB
TON
197
CRANE
FIXED JIB
TON
198
CRANE
FIXED JIB
TRUCK - 120
TONS
201
CRANE
FIXED JIB, CRAWLER
15 TONS
202
CRANE
FIXED JIB, CRAWLER
20 TONS
203
CRANE
FIXED JIB, CRAWLER
30 TONS
204
CRANE
FIXED JIB, CRAWLER
40 TONS
205
CRANE
FIXED JIB, CRAWLER
50 TONS
206
CRANE
FIXED JIB, CRAWLER
60 TONS
207
CRANE
FIXED JIB, CRAWLER
90 TONS
208
CRANE
FIXED JIB, CRAWLER
120 TONS
209
CRANE
FIXED JIB, CRAWLER
165 TONS
210
CRANE
FIXED JIB, CRAWLER
200 TONS
211
CRANE
FIXED JIB, CRAWLER
400 TONS
212
CRANE
TOWER-HORIZ. JIB
10T
MAX
4190LB@164FT
MAX 1900KG @
50M
213
CRANE
TOWER-HORIZ. JIB
20T
MAX
9260LB@213FT
MAX 4200KG @
65M
214
CRANE
TOWER-HORIZ. JIB
40T
MAX
6500LB@247FT
MAX 2950KG @
75M
216
CRANE
ATTACHMENT
CLAMSHELL GRAB
1 CY
0.75 M3
217
CRANE
ATTACHMENT
CLAMSHELL GRAB
2 CY
1.50 M3
218
CRANE
ATTACHMENT
CLAMSHELL GRAB
4 CY
3.00 M3
219
CRANE
ATTACHMENT
DRAGLINE BUCKET
1 CY
0.75 M3
220
CRANE
ATTACHMENT
DRAGLINE BUCKET
2 CY
1.50 M3
221
CRANE
ATTACHMENT
DRAGLINE BUCKET
4 CY
3.00 M3
222
CRANE
ATTACHMENT
DRAGLINE BUCKET
6 CY
4.50 M3
223
CRANE
ATTACHMENT
CONCRETE BUCKET
BTM DUMP 1 CY
BTM DUMP 0.75
M3
TRUCK - 110
TON
32-7
Equip
No.
32-8
Size
Metric Units
I-P Units
224
CRANE
ATTACHMENT
CONCRETE BUCKET
BTM DUMP 3 CY
BTM DUMP 2.50
M3
226
GIN POLE
W/HOIST
50 TONS
45 TON
227
GIN POLE
W/HOIST
100 TONS
90 TON
228
GIN POLE
W/HOIST
150 TONS
135 TON
229
GIN POLE
W/HOIST
2250 TONS
200 TON
230
GIN POLE
W/HOIST
600 TONS
540 TON
231
DERRICK
GUY DERRICK
250 TONS
225 TON
233
DERRICK
CRAWLER GUY
DERRICK
225 TONS
200 TON
234
DERRICK
CRAWLER GUY
DERRICK
400 TONS
360 TON
235
PILING
PILE DRIVING
HAMMER
20 KFTLB DIESEL 27 KNM DIESEL
236
PILING
PILE DRIVING
HAMMER
40 KFTLB DIESEL 55 KNM DIESEL
237
PILING
PILE DRIVING
HAMMER
75 KFTLB DIESEL 100 KNM
DIESEL
238
PILING
DRIVER/EXTRACTOR
70 HP VIBRO
239
PILING
PILING FRAME, LEADS 30 FEET
10 M
240
PILING
DRILLING FRAME
AUGER
AUGER
241
COMPRESSOR
DIESEL(SLIDING
VANE)
125 CFM
210 M3/H
242
COMPRESSOR
DIESEL(SLIDING
VANE)
250 CFM
420 M3/H
243
COMPRESSOR
DIESEL(SLIDING
VANE)
315 CFM
540 M3/H
246
COMPRESSOR
DIESEL(ROTARY
SCREW)
250 CFM
420 M3/H
247
COMPRESSOR
DIESEL(ROTARY
SCREW)
365 CFM
620 M3/H
248
COMPRESSOR
DIESEL(ROTARY
SCREW)
600 CFM
1000 M3/H
249
COMPRESSOR
DIESEL(ROTARY
SCREW)
750 CFM
1250 M3/H
250
COMPRESSOR
DIESEL(ROTARY
SCREW)
900 CFM
1500 M3/H
251
COMPRESSOR
DIESEL(ROTARY
SCREW)
1200 CFM
2000 M3/H
VIBRO 50 KW
Equip
No.
Size
Metric Units
I-P Units
256
CONCRETE
BATCHPLANT,
DEMOUNT.
20 CY/H
15 M3/H
257
CONCRETE
CONCRETE MIXER
6 SACK
.25 M3
258
CONCRETE
CONCRETE MIXER
16 SACK (1 CY)
.75 M3
261
CONCRETE
VIBRATOR GASOLINE
2.4 HP, 2 IN HEAD 1.8 KW, 50MM
HEAD
261
CONCRETE
VIBRATOR, AIR
2.5 IN HEAD
65 MM HEAD
263
CONCRETE
CURB BUILDR,
SLIPFORM
75 HP, DIESEL
55 KW, DIESEL
264
CONCRETE
POWER TROWEL, 4
BLADE
36 IN DIA
1 M DIA
266
CONCRETE
MIXER TRUCK
6 CY
5 M3
267
CONCRETE
SITE DUMPER
.75 CY, DIESEL
0.5 M3, DIESEL
268
CONCRETE
STATIC PUMP
269
CONCRETE
TRUCK-MTD
PUMP&BOOM
60 CY/H, 4IN LINE 45 M3/H, 100
MM
270
CONCRETE
CONVEYOR
16 IN X 40 FEET
400 MM X 12 M
271
CONCRETE
REBAR BENDER
HYDRAULIC
HYDRAULIC
272
CONCRETE
REBAR SHEAR
HYDRAULIC
HYDRAULIC
274
CONCRETE
SLIPFORM PAVER
10-24 FEET
3-7 M WIDE
276
WELDING
EQUIPMENT
PORTABLE GASOLINE
200 AMPERES
200 AMPERES
277
WELDING
EQUIPMENT
PORTABLE GASOLINE
300 AMPERES
300 AMPERES
278
WELDING
EQUIPMENT
PORTABLE GASOLINE
400 AMPERES
400 AMPERES
281
WELDING
EQUIPMEN
PORTABLE DIESEL
200 AMPERES
200 AMPERES
282
WELDING
EQUIPMEN
PORTABLE DIESEL
300 AMPERES
200 AMPERES
283
WELDING
EQUIPMEN
PORTABLE DIESEL
400 AMPERES
200 AMPERES
284
WELDING
EQUIPMEN
PORTABLE DIESEL
650 A, TWIN ARC 650 A, TWIN
ARC
286
WELDING
EQUIPMENT
STATIC RECTIFIER
200 AMPERES
200 AMPERES
287
WELDING
EQUIPMENT
STATIC RECTIFIER
300 AMPERES
300 AMPERES
32-9
Equip
No.
32-10
Size
Metric Units
I-P Units
288
WELDING
EQUIPMENT
STATIC RECTIFIER
400 AMPERES
400 AMPERES
289
WELDING
EQUIPMENT
STATIC RECTIFIER
500 AMPERES
500 AMPERES
290
WELDING
EQUIPMENT
STATIC RECTIFIER
600 AMPERES
600 AMPERES
291
WELDING
EQUIPMENT
STATIC RECTIFIER
650 AMPERES
650 AMPERES
293
WELDING
EQUIPMENT
PIPE SEMI-AUTO. CO2
294
WELDING
EQUIPMENT
PIPE AUTOMATIC
296
WELDING
EQUIPMENT
AUTO. SUB-ARC TANK BASE PLATE
BASE PLATE
297
WELDING
EQUIPMENT
AUTO. SUB-ARC TANK WALL
HORIZONTAL
WALL
HORIZONTAL
298
WELDING
EQUIPMENT
AUTO. SUB-ARC TANK WALL VERTICAL
WALL VERTICAL
301
WELDING
EQUIPMENT
OXY./ACT. WELD &
CUT.
COMB. UNIT
COMB. UNIT
302
WELDING
EQUIPMENT
PROPANE GAS SE T &
TRCH
PROPANE GAS SE
T & TRCH
306
WELDING
EQUIPMENT
ELECTRODE DRYING
OVN
311
PIPING
EQUIPMENT
SIDEBOOM
(CAT 571)
(CAT 571)
312
PIPING
EQUIPMENT
SIDEBOOM
(CAT 572)
(CAT 572)
313
PIPING
EQUIPMENT
SIDEBOOM
(CAT 583)
(CAT 583)
314
PIPING
EQUIPMENT
SIDEBOOM
(CAT 594)
(CAT 594)
316
PIPING
EQUIPMENT
CRAWLER TACK
TRACTOR
QUAD ARCS
QUAD ARCS
318
PIPING
EQUIPMENT
BENDING MACHINE
6 - 20 INCHES
150 - 500 MM
319
PIPING
EQUIPMENT
BENDING MACHINE
22 - 36 INCHES
550 - 900 MM
SUBMERGED ARC SUBMERGED
ARC
Equip
No.
Size
Metric Units
I-P Units
320
PIPING
EQUIPMENT
BENDING MACHINE
38 - 48 INCHES
950 - 1250 MM
321
PIPING
EQUIPMENT
TAPESTER, HAND
WRAP
2 - 12 INCHES
50 - 300 MM
322
PIPING
EQUIPMENT
CLEAN PRM TAPE
MACH.
8 - 16 INCHES
200 - 400 MM
323
PIPING
EQUIPMENT
CLEAN PRM TAPE
MACH.
16 - 26 INCHES
400 - 650 MM
324
PIPING
EQUIPMENT
CLEAN PRM TAPE
MACH.
26 - 36 INCHES
650 - 900 MM
325
PIPING
EQUIPMENT
CLEAN PRM TAPE
MACH.
36 - 42 INCHES
900 - 1050 MM
326
PIPING
EQUIPMENT
CLEAN PRM TAPE
MACH.
42-52 INCHES
1050 - 1300
MM
328
PIPING
EQUIPMENT
INTRNL LINE-UP
CLAMP
16 - 18 INCHES
400 - 450MM
329
PIPING
EQUIPMENT
INTRNL LINE-UP
CLAMP
20 - 22 INCHES
500 - 550MM
330
PIPING
EQUIPMENT
INTRNL LINE-UP
CLAMP
24 - 26 INCHES
600 - 650MM
331
PIPING
EQUIPMENT
INTRNL LINE-UP
CLAMP
30 - 32 INCHES
750 - 800MM
332
PIPING
EQUIPMENT
INTRNL LINE-UP
CLAMP
34 - 36 INCHES
850 - 900MM
333
PIPING
EQUIPMENT
INTRNL LINE-UP
CLAMP
40 - 42 INCHES
1000 - 1050MM
334
PIPING
EQUIPMENT
INTRNL LINE-UP
CLAMP
44 - 46 INCHES
1100 - 1150MM
335
PIPING
EQUIPMENT
INTRNL LINE-UP
CLAMP
OVER 48 INCHES
OVER 1200MM
336
PIPING
EQUIPMENT
EXTRNL LINE-UP
CLAMP
8 - 14 INCHES
400 - 450MM
337
PIPING
EQUIPMENT
EXTRNL LINE-UP
CLAMP
16 - 26 INCHES
400 - 650MM
338
PIPING
EQUIPMENT
EXTRNL LINE-UP
CLAMP
28 - 36 INCHES
700 - 900MM
339
PIPING
EQUIPMENT
EXTRNL LINE-UP
CLAMP
36 - 44 INCHES
900 - 1100 MM
340
PIPING
EQUIPMENT
EXTRNL LINE-UP
CLAMP
OVER 42 INCHES
OVER 1100 MM
341
PIPING
EQUIPMENT
CUTTING &
BEVELLING
1 - 4 INCHES
25 - 100 MM
342
PIPING
EQUIPMENT
CUTTING &
BEVELLING
6 - 20 INCHES
150 - 500 MM
343
PIPING
EQUIPMENT
CUTTING &
BEVELLING
22 - 30 INCHES
550 - 750 MM
32-11
Equip
No.
32-12
Size
Metric Units
I-P Units
344
PIPING
EQUIPMENT
CUT & BEVEL, TORCH
10 - 48 INCHES
250 - 1200 MM
346
PIPING
EQUIPMENT
PIPE/CONDUIT
BENDER
0.5-2IN RATCHET UP TO 6
INCHES
347
PIPING
EQUIPMENT
HYDRAUL PIPE
BENDER
1.25-4 INCHES
30 - 100 MM
348
PIPING
EQUIPMENT
BENDER
(MECHANICAL)
2.5-6 IN DIA
65 - 150 MM
349
PIPING
EQUIPMENT
CUT & THREAD
MACHINE
UP TO 6 INCHES
UP TO 150 MM
351
PIPING
EQUIPMENT
DOUBLE JOINTING
YARD
C/W RACK
CONVYRS
C/W RACK
CONVYRS
352
PIPING
EQUIPMENT
X-RAY EQUIPMENT
354
PIPING
EQUIPMENT
INDUCTION HEATER
355
PIPING
EQUIPMENT
HOLIDAY DETECTOR
356
PIPING
EQUIPMENT
ELECTRIC THREADER
UP TO 2 INCHES
UP TO 50 MM
358
PIPING
EQUIPMENT
BORING MACHINE
ROAD BORER
ROAD BORER
361
MISCELLANEOUS
EQUIP.
POTENTIOMETER12
POINT
12 POINT
362
MISCELLANEOUS
EQUIP.
STRESS RELIEVER
TRIPLE RELIEVER TRIPLE
RELIEVER
363
MISCELLANEOUS
EQUIP.
POWER DIST. CENTER 10 KVA
10 KVA
364
MISCELLANEOUS
EQUIP.
BENCH SAW
10 - 12 INCHES
250 - 300 MM
364
MISCELLANEOUS
EQUIP.
PAINT PRESSURE
SPRAY
5 GAL. 8CFM
20 LITER, 15
M3/H
367
MISCELLANEOUS
EQUIP.
GUNITE
8 CY/H
6 M3/H
368
MISCELLANEOUS
EQUIP.
CABLE PULLER UNIT
5000 LBF. ELEC. E LEC.
369
MISCELLANEOUS
EQUIP.
AIR RECEIVING TANK
60 CF
2 M3
370
MISCELLANEOUS
EQUIP.
CHAIN SAW
20 INCHES
500 MM
Equip
No.
Size
Metric Units
I-P Units
371
MISCELLANEOUS
EQUIP.
TELEPHONES &
STATION
374
MISCELLANEOUS
EQUIP.
TENSIOMETER WIRE
ROP
200000 LB CAP
90000 KG CAP
375
MISCELLANEOUS
EQUIP.
TENSIOMETER WIRE
ROP
40000 LB CAP
18000 KG CAP
376
PUMP
CENTRIFUGAL
1.5 INCHES
40 MM
377
PUMP
CENTRIFUGAL
2.0 INCHES
50 MM
378
PUMP
INJECTION PUMP
INHIBITOR
INHIBITOR
379
PUMP
SUBMERSIBLE,
DEWATERG
4 INCHES, 9 HP
100 MM, 7 KW
380
PUMP
SUBMERSIBLE,
DEWATERG
6 INCHES, 27 HP
150 MM, 20 KW
381
PUMP
HYDROSTATIC TEST
4000 PSI
27500 KPA
382
PUMP
WATER FILL
4 IN, 110 GPM
100 MM, 7L/S
383
PUMP
WELLPOINTS & HOSE
8 IN, PER 100 FT
200 MM, PER 30
M
384
PUMP
WELLPOINT,
DIAPHRAGM
8 INCHES
SUCTION
200 MM
SUCTION
385
PUMP
DIAPHRAGM
4 INCHES
SUCTION
100 MM
SUCTION
386
PNEUMATIC PORT. AIR WRENCH
TOOL
1.25 IN DRIVE
30 MM DRIVE
387
PNEUMATIC PORT. JACK HAMMER
TOOL
65 LBS
30 KG
388
PNEUMATIC PORT. SAND BLAST MACHINE 600 LBS, 7CF
TOOL
275 KG, 0.2 M3
391
ELECTRIC EQUIP/ LIGHT PLANT
TOOL
3000 WATT
3000 WATT
392
ELECTRIC EQUIP/ DRILL PRESS
TOOL
1.5 INCHES
40 MM
395
ELECTRIC EQUIP/ DRILL
TOOL
1.0 INCH
25 MM
396
ELECTRIC EQUIP/ GENERATOR SET
TOOL
6 KW
6 KW
397
TOOL
10 KW
10 KW
398
TOOL
20 KW
20 KW
399
TOOL
60 KW
60 KW
400
TOOL
100 KW
100 KW
32-13
Equip
No.
32-14
Size
Metric Units
I-P Units
401
TOOL
150 KW
150 KW
402
TOOL
200 KW
200 KW
404
ELECTRIC EQUIP/ SAW, CIRCULAR
TOOL
6 INCHES
150 MM
406
ELECTRIC EQUIP/ ELECTRIC GRINDER
TOOL
6 INCHES
150 MM
407
ELECTRIC EQUIP/ PEDESTAL GRINDER
TOOL
12 INCHES
300 MM
408
ELECTRIC EQUIP/ LATHE
TOOL
9 INCHES
225 MM
411
HOIST
HAND-CHAIN
1.5 TONS
1.5 TON
412
HOIST
HAND-CHAIN
4.5 TONS
4 TON
413
HOIST
HAND-CHAIN
10 TONS
9 TON
414
HOIST
HAND-CHAIN
2.0 TONS
2 TON
416
HOIST
SINGLE DRUM
22 HP
16 KW
417
HOIST
DOUBLE DRUM
32 HP
24 KW
419
HOIST
PORTABLE MATL.
TOWER
1.0 TONS
1 TON
419
HOIST
PORTABLE MATL.
TOWER
1.0 TONS
1.0 TONS
421
ASPHALT
EQUIPMENT
PAVER/FINISHER
10 FEET WIDE
3 M WIDE
422
ASPHALT
EQUIPMENT
SPREADER TRAILER,
GAS
2000 GAL, SPRAY 7.50 M3, SPRAY
424
ASPHALT
EQUIPMENT
BITUMEN TANKER
2000 GALLON
425
ASPHALT
EQUIPMENT
ASPHALT HEATER
426
SITE/OFFICE
EQUIP
TRANSIT THEODOLITE
427
SITE/OFFICE
EQUIP
PORTABLE BUILDINGS PER 1000 SF
PER 100 M2
430
SITE/OFFICE
EQUIP.
SPACE HEATR, OIL,
AUTO
40 KW
150 MBTU
7.50 M3
Equip
No.
Size
Metric Units
I-P Units
435
PIPING
EQUIPMENT
ROLI CRADLE
4 - 12 INCHES
100 - 300MM
436
PIPING
EQUIPMENT
ROLI CRADLE
12 - 24 INCHES
300 - 600MM
437
PIPING
EQUIPMENT
ROLI CRADLE
24 - 36 INCHES
300 - 600MM
438
PIPING
EQUIPMENT
ROLI CRADLE
36 - 42 INCHES
900 - 1050 MM
439
PIPING
EQUIPMENT
ROLI CRADLE
OVER 42 INCHES
OVER 1050 MM
440
PIPING
EQUIPMENT
HOT TAP MACHINE
2 - 4 INCHES
50 - 100 MM
441
PIPING
EQUIPMENT
HOT TAP MACHINE
6 - 12 INCHES
150 - 300 MM
442
PIPING
EQUIPMENT
HOT TAP MACHINE
14 - 20 INCHES
350 - 500 MM
443
PIPING
EQUIPMENT
HOT TAP MACHINE
24 - 48 INCHES
600 - 1200 MM
444
PIPING
EQUIPMENT
BUTT FUSION
MACHINE
2 - 4 INCHES
50 - 100 MM
445
PIPING
EQUIPMENT
BUTT FUSION
MACHINE
6 - 8 INCHES
150 - 200 MM
446
PIPING
EQUIPMENT
BUTT FUSION
MACHINE
10 - 18 INCHES
250 - 450 MM
447
PIPING
EQUIPMENT
BUTT FUSION
MACHINE
20 - 30 INCHES
500 - 750 MM
448
PIPING
EQUIPMENT
BUTT FUSION
MACHINE
36 - 48 INCHES
900 - 1200 MM
32-15
32-16
33 Base Indices
(G13)
Base Indices
33 Base Indices (G13)
33-1
Base Indices
These indices are generated by Icarus after updating the system costs
(engineering disciplines, wage rates, material costs, shop and field labor rates,
construction equipment rental rates, etc.). We run estimates on our
benchmark projects using the updated system and then use the results to
calculate the indices. Since our benchmark projects contain a variety of
component types fabricated from a variety of materials, these indices are a
composite of the individual cost adjustments that are made. These indices do
not derive from public sources and they may not accurately reflect how the
update will affect your typical projects. To evaluate this, you should run
benchmark projects and develop your own adjustments. Note: “1Q”
represents first quarter, “3Q” represents third quarter.
Country Base Data
Base
for System
Costs
US
33-2
Current:1Q2012
Prior:1Q-2011
1Q-2010
1Q-2009
1Q-2008
1Q-2007
1Q-2006
1Q-2005
1Q-2004
1Q-2003
1Q-2002
1Q-2001
1Q-2000
1Q-1999
1Q-1998
1Q-1997
1Q-1996
1Q-1995
1Q-1994
1Q-1993
1Q-1992
1Q-1991
System Base Index by Category
General
Materials
Construction
Labor
Design
Construction
Engineering
Management
Labor
Labor
2330
2030
1530
1800
2250
2120
2040
2200
2060
1900
1840
1630
1540
1510
1520
1520
1510
1525
1500
1485
1460
1390
1370
1360
1350
2000
2000
2010
1960
1890
1820
1750
1690
1630
1590
1550
1510
1460
1430
1400
1365
1340
1320
1310
1290
1270
1560
1590
1620
1620
1540
1490
1480
1460
1480
1470
1450
1440
1450
1450
1450
1460
1480
1460
1450
1420
1390
1800
1620
1660
1630
1540
1490
1480
1480
1460
1480
1470
1450
1440
1450
1450
1450
1460
1480
1460
1450
1420
1390
Country Base Data
Base
for System
Costs
UK
JP
General
Materials
Construction
Labor
Design
Construction
Engineering
Management
Labor
Labor
Current:1Q2012
Prior:1Q-2011
1Q-2010
1Q-2009
1Q-2008
1Q-2007
1Q-2006
1Q-2005
1Q-2004
1Q-2003
1Q-2002
1Q-2001
1Q-2000
1Q-1999
1Q-1998
1Q-1997
1Q-1996
1Q-1995
1Q-1994
1Q-1993
1Q-1992
1Q-1991
3100
4970
4750
4860
3080
2910
2910
2830
2630
2500
2420
2290
2230
2190
2140
2080
2140
2100
2050
1990
1910
1850
1780
1670
4580
4370
4290
4020
3830
3670
3510
3360
3220
3120
2980
2850
2700
2550
2410
2310
2200
2160
2110
2050
1930
4780
4600
4450
4420
4190
3970
3810
3670
3540
3480
3360
3210
2950
2780
2620
2470
2380
2280
2210
2140
2020
4470
4270
4190
4080
3890
3790
3670
3570
3510
3410
3250
3110
3050
2880
2660
2470
2380
2280
2210
2140
2020
Current:1Q2012
Prior:1Q-2011
1Q-2010
1Q-2009
1Q-2008
1Q-2007
1Q-2006
1Q-2005
1Q-2004
1Q-2003
1Q-2002
1Q-2001
1Q-2000
1Q-1999
1Q-1998
1Q-1997
1Q-1996
1Q-1995
1Q-1994
1550
1130
2060
1940
1580
1480
1500
1750
1760
1450
1410
1330
1220
1210
1230
1260
1370
1350
1255
1250
1250
1390
1130
1140
1150
1150
1160
1170
1180
1200
1250
1300
1330
1350
1370
1350
1340
1350
1350
1320
2030
1950
1900
1930
1960
1460
1440
1380
1370
1350
1360
1360
1360
1360
1350
1360
1390
1460
1910
1830
1780
1820
1840
1470
1460
1400
1380
1370
1370
1370
1350
1350
1350
1360
1390
1460
33-3
Country Base Data
Base
for System
Costs
EU
ME
33-4
General
Materials
Construction
Labor
Design
Construction
Engineering
Management
Labor
Labor
Current:1Q2012
Prior:1Q-2011
1Q-2010
1Q-2009
1Q-2008
1Q-2007
1Q-2006
1Q-2005
1Q-2004
1Q-2003
1Q-2002
1Q-2001
2320
1840
1850
1720
2280
2220
2180
2170
2030
1780
1700
1640
1580
1560
1520
1920
1860
1840
1790
1720
1700
1670
1650
1630
1600
1550
1880
1810
1790
1730
1660
1590
1560
1550
1530
1510
1450
1790
1740
1720
1670
1600
1580
1560
1540
1520
1490
1450
Current:1Q2012
Prior:1Q-2011
1Q-2010
1Q-2009
1Q-2008
1Q-2007
2390
2280
1620
1870
2380
2230
2160
2200
2060
2030
1950
1930
1970
1890
1620
1590
1580
1610
1540
1660
1590
1580
1610
1540
34 Code Accounts
(G10)
Introduction to Code Accounts
Indirect Codes and Descriptions
Direct Codes and Descriptions
Equipment and Setting
Piping
Civil
Steel
Instrumentation
Electrical
Insulation
Paint
34 Code Accounts (G10)
34-1
Introduction to Code Accounts
Aspen Icarus systems contain a 3-digit standard code of account set to which
costs and manhours are allocated in developing the project estimate. This is
referred to as the “ICARUS” code of accounts. The code of accounts form can
be used either to modify the ICARUS standard code of accounts or to create a
completely new set of accounts. The resulting user-developed code of
accounts is termed as the “user” code of accounts. In addition, the user may
develop two sets of code of accounts, namely, a “user-reporting” code of
accounts, and an “user-internal” code of accounts, where the reporting code of
accounts represent the level of granularity that user wishes to see in the
output reports, and the internal code of accounts refers to the allocation and
grouping of the standard ICARUS system code of accounts to a level of detail
intended for the user, for the purposes of indexing and contract scope
definition. If new codes of account are defined, account codes must be
supplied and all references to the account codes in subsequent codes must
reference the new codes of account (exceptions to this rule will be discussed
subsequently). If modifications are made to existing code of accounts, the
account code must not be specified, since the account code is implicitly defined
based on the account number that is used.
The Code of Accounts input data is composed of three types. The code of
account “Definitions” are used to define either a name for a new account
number or a new name for a standard ICARUS account. The code of account
“allocations” are used to reassign costs and manhours from one or more
standard system accounts into either another ICARUS account or a newly
defined user code of account. Costs and manhours may be assigned directly
into a current account or into a new account with a supplemental cost item.
The code of account “reporting” is used to further group a very detailed userdeveloped code of accounts into a smaller set of accounts that can be
displayed in output reports. The user’s internal code of accounts must be used
on indexing and contract scope input forms, if the user code of accounts is
developed. However, for the ease of exchange of components between
multiple projects, the user may switch between the user-internal code of
accounts and ICARUS system code of account numbers by using the
appropriate switch between user/ICARUS code of accounts. However, the
user’s reporting code of accounts is never used in the input forms, and
displayed only the output reports. In the absence of reporting code of
accounts, output reports use the user (internal) code of accounts.
Modifying the System Code of Accounts
The ICARUS standard code of accounts may be transformed into a new code of
accounts in one or more of the following ways:
34-2
•
An ICARUS account name can be changed.
•
A new account can be created by defining it. This must be in the range
1-999 and must not already be defined as a standard account.
•
Costs and manhours can be reassigned from one account to another.
The account code for the modified code of accounts must not be specified and
is determined by the system (for example, PIPING account code includes all
accounts from 300 to 399).
Creating a Different Code of Accounts
A new code of accounts may be created that is different from the ICARUS
system standards code of accounts. A new code of accounts is the one in which
one or both of the following conditions are met:
•
Account numbers are created outside the range of the ICARUS system
code of accounts (i.e., outside the range of 1-999, e.g., 1000-99999999).
•
The account type (piping, civil, etc.) must be specified, thus changing the
account number range to which the account type is applied.
To develop a different code of accounts, every required code of account must
be specified, and the account type must be specified to designate its allocation
in various summary reports. This caveat applies to the indirect codes of
account, where all indirect account types P1 through PB must be specified.
Thus, these accounts, as defined, will constitute the entire code of accounts
(direct and indirect) for the estimate.
While modifying the ICARUS code of accounts, or creating a completely new
user code of accounts, the user may specify the currency symbol of
procurement. This currency symbol refers to direct material procurement cost,
and to a limited set of indirect, and allows the user to develop a multi-currency
procurement strategy. The symbols and conversion rates (in terms of a
multiplier to one of the four country basis currencies in the system) ate stored
in a central CURRENCY.DAT file. When a particular, direct material code of
account is defined as being procured in the selected currency, special
procurement output reports display the currency exposure of the given project
in terms of that selected currency, in addition to the project basis currency.
However, all other reports are always in the project currency.
Transfers from the ICARUS system standard code of accounts to the Userinternal code of accounts can be very simple or complex, depending on the
desire of breakdown. Breakdown can be very complex, by material, subtype,
size (for piping), equipment symbol and equipment type. Thus, a single code
of account can be broken into multiple codes. This transfer is performed using
the code of account allocation, together with exceptions. User-internal code of
accounts are referred to, in the user input, in the indexing and contractor
scope input. As already mentioned, the user may choose either the userinternal code of account or the ICARUS system code of accounts on the
component forms, using the user/ICARUS switch.
Example
The allocations are one step transfers from one account to a second account.
They should not be interpreted as sequential transfers. For example, if the
following costs were calculated by the system in the designated codes of
account:
COA
Cost
315
1000
417
10000
591
100000
34-3
From ICARUS
COA
To ICARUS COA
Allocate to
ICARUS User
Matl COA
315
blank
4178325
417
blank
5911234
591
blank
4178325
The following resulting allocations would be reported, if no further reporting
COAs are specified:
COA
Cost
315
0
4178325
1000
5911234
110000
However, allocations have been specified in a different sequence, the same
result will be reported.
Reporting Code of Accounts
Creating complex user code of accounts is important for proper indexing,
contract scope allocation, and procurement strategy. But, it may be necessary
to summarize the results in a simple form for easy understanding of results. In
other cases, the results may be summarized in to ways, one for the use of the
client, and another way for the use of the management. The reporting code of
account layer provides a method of summarizing the user-internal code of
accounts into a simpler set for reporting use. The only place that the reporting
code of accounts is used, is in reporting. The reporting COA form allows the
user to group the user-internal or ICARUS Codes of account to a more
manageable subset, for reporting purposes.
Example
COA
Cost
3154
1000
3191
10000
3300
100000
From ICARUS
COA
To ICARUS COA
Allocate to
ICARUS User
Matl COA
3100
3300
3
The following resulting allocations would be reported:
34-4
COA
Cost
3
111000
There are several useful applications for the Code of Accounts input:
•
Multiple Codes of account files can created for different clients in the code
of accounts library. Each file can represent the client’s COA structure.
Appropriate COA file can be selected at the project level and used.
•
Costs can be moved from one account group to other. For example, the
system reports electrical trenching in the electrical account, and the user
may wish to report trenching as a civil item. The system maintains fidelity
in account groups, in three distinct categories, indirects, bulks and
equipment. Codes can be transferred inside the three categories, but not
between them. This applies to both, reporting and the user-internal code
of accounts.
•
A special supplemental item is to be added to the estimate. The user may
wish to create a new account to maintain visibility of the
supplemental cost.
•
On the contrary, an entirely new set of code of accounts can be created.
This may be useful in clarifying the costs of the project to the
management, in addition to indexing and defining the contractor scope.
•
Use of reporting codes of account allow the separation of reporting
structure from the user-internal COA structure. More importantly, it
simplifies reporting the estimate results to the client.
•
Currency selection at the account definition level allows the user to develop
a procurement strategy for the project.
Output Reports
The Code of Accounts Summary reflects the user-specified account numbers
and names. The Master Summary, Contract Summaries and Area Summaries
allocate the estimated costs according to the account type (piping, civil, and so
on). It is incumbent upon the user when defining an entirely different code of
accounts to specify account types that correspond with the chosen account
number groups. An inconsistency would occur, for example, if, within a series
of account numbers for piping (P), one of the accounts were assigned an
instrumentation account type (I). This account would be grouped numerically
with the piping accounts in the Code of Accounts Summary, but it would be
summarized with instrumentation in the other summaries. This inconsistency
could be avoided by allocating this account into a numbered account in the
Instrumentation group. Then the estimated costs and man-hours for this item
would appear both in a numbered instrumentation account and in the
instrumentation summary.
In the Bulk Detail and Bulk Summary Appendices of the system output report
the user-specified account numbers are reported, but the account names are
the system names and not the user-specified names. The system account
name forms an integral part of the detailed item description. It is necessary,
therefore, to retain the system account name in these appendices for clarity
and for Aspen Icarus to provide technical support.
34-5
34-6
Field Indirects (P1)
Engineering Indirects (PA)
01 -09 Titles not assigned
10 LUMP SUM CONST. INDIRECT
11 FRINGE BENEFITS
12 BURDENS
13 CONSUMABLES, SMALL TOOLS
14 MISC. (INSURANCE, ETC)
15 SCAFFOLDING
16 EQUIPMENT RENTAL
17 VENDOR REPRESENTATIVES
18 FIELD SERVICES
19 TEMP. CONST., UTILITIES
20 MOBILIZATION, DEMOBILIZE
21 CATERING, ACCOMODATION
22 TRAVEL
23 OVERTIME PREMIUM
80 LUMP SUM CONST. MGMT
81 HOME OFFICE CONST. SUPP.
82 CONSTRUCTION MANAGEMENT
83 -84 Titles not assigned
Special Indirects (P2
Contractor Indirects (PB)
24 SPECIAL INDIRECT ITEM 1
26 - 49 Titles not assigned
85 FIELD CONST. SUPERVISION
86 STARTUP, COMISSIONING
Freight (P3)
G & A Overheads (P6)
50
51
52
53
54
55
56
90 G AND A OVERHEADS
LUMP SUM FREIGHT
DOMESTIC FREIGHT
OCEAN FREIGHT
AIR FREIGHT
MODULE FREIGHT
OTHER FRIEGHT
- 59 Tittles not assigned
Taxes (P4)
Contractor Fee (P7)
60
61
62
63
64
65
66
91 CONTRACT FEE
LUMP SUM TAXES, PERMITS
PERMITS
MATERIALS TAXES
CONSTRUCTION TAXES
ENGINEERING TAXES
OTHER TAXES
- 69 Titles not assigned
Engineering (P5)
Escalation (P8)
70
71
72
73
74
75
76 -
97 ESCALATION
LUMP SUM ENGINEERING
BASIC ENGINEERING
DETAIL ENGINEERING
MATERIAL PROCUREMENT
SUBCONTRACT PROCUREMENT
ENGINEERING MANAGEMENT
79 Titles not assigned
Field Indirects (P1)
Engineering Indirects (PA)
Royalty, Miscellaneous Charges (P9)
98 ROYALTY, MISC. CHARGES
Contingencies (P0)
99 CONTINGENCY
34-7
Direct Codes and Descriptions
Equipment and Setting
34-8
100
103
104
105
106
107
109
EQUIPMENT AND SETTING
SPECIAL PLANT ITEM
SPECIAL EQUIPMENT ITEM
MISC. ITEM ALLOWANCE
OTHER EQUIPMENT ITEMS
WAREHOUSE SPARES
EQUIPMENT DEMOLITION
200
201
202
203
204
205
FLUID SEPARATION EQUIP.
DUST COLLECTORS
SCRUBBERS
BAG HOUSES
PRECIPITATORS
SEPARATORS
110
111
112
113
114
115
116
117
PROCESS VESSELS
TRAY TOWERS & TRAYS
PACKED TOWERS & PACKING
VERTICAL VESSELS
HORIZONTAL VESSELS
VACUUM VESSELS
CRYSTALLIZERS
EVAPORATORS
210
211
212
213
214
215
216
217
MATERIALS HANDLING EQUIP
CONVEYORS
FEEDERS
CRANES,HOISTS,ETC
ELEVATORS
SCALES
MAGNETS
CAR DUMPERS & SHAKERS
120
121
122
123
124
125
126
STORAGE VESSELS
ATMOSPHERIC STORAGE TANK
PRESSURIZED STORAGE TANK
SILOS
BINS AND HOPPERS
GAS HOLDERS
STOCK CHESTS
220
221
222
223
224
ELECTRICAL GENERATORS
GAS TURBINE GENERATORS
DIESEL GENERATORS
STEAM TURBINE GENERATORS
PORTABLE GENERATORS
130
131
132
133
134
REACTION,MIXING EQUIP.
REACTORS & AUTOCLAVES
AGITATED VESSELS
BLENDERS
MIXERS
240
241
242
243
244
BOILER PLANT EQUIPMENT
BOILERS
PACKAGE BOILER
ECONOMIZERS
PREHEATERS
150
151
152
153
154
COMPRESSORS & BLOWERS
CENTRIFUGAL COMPRESSORS
RECIPROCATING COMPRESSOR
TURBO-EXPAND. COMPRESSOR
FANS AND BLOWERS
250
251
252
253
254
255
PROCESS HEATERS
FURNACES,HEATERS
WASTE HEAT BOILERS
INCINERATORS
KILNS
STACKS
160
161
162
163
164
165
166
167
PUMPS
CENTRIFUGAL PUMPS
RECIPROCATING PUMPS
VACUUM PUMPS
ROTARY,GEAR PUMPS
VERTICAL PUMPS
SUMP & WELL PUMPS
SLURRY PUMPS
260
261
262
263
264
265
266
HEAT EXCHANGERS
SHELL & TUBE EXCHANGERS
REBOILERS
DOUBLE PIPE EXCHANGERS
AIR COOLERS
COOLING TOWERS
MISC. HEAT EXCHANGERS
170
171
172
173
174
175
DRIVERS & GEAR REDUCERS
ELECTRIC MOTORS
STEAM TURBINES
GAS TURBINES
GAS & DIESEL ENGINES
GEAR REDUCERS
270
271
272
273
274
275
LININGS
REFRACTORY LININGS
ACID BRICK LININGS
CAST LININGS
POND LININGS
OTHER LININGS
180
181
182
183
184
185
SIZE REDUCTION EQUIP
CRUSHERS,BREAKERS
MILLS
PULVERIZERS
CUTTERS,FLAKERS
STOCK TREATMENT
280
281
282
283
284
285
MISC. PACKAGE UNITS
REFRIGERATION UNITS
HVAC EQUIPMENT
WATER TREATING UNITS
INSTRUMENT AIR SYSTEMS
MODULE SETTING
190
191
192
193
194
195
196
197
SOLIDS SEPARATION EQUIP.
SCREENS AND GRIZZLIES
FILTERS
CENTRIFUGES
DRYERS
LIQUID CYCLONES
FLOATATION CELLS
THICKENERS,CLARIFIERS
290
291
292
293
MISCELLANEOUS EQUIPMENT
EJECTORS
PROPRIETARY EQUIPMENT
FLARES
34-9
Piping
300
302
303
304
305
306
307
309
PIPING
SUBCONTRACT PIPING
SPECIAL PLANT PIPING
SPECIAL EQUIP. PIPING
OTHER EQUIPMENT PIPE
PIPING SYSTEM TESTING
PREFAB PIPE REWORK
PIPING DEMOLITION
NON-METAL PIPE/FITTINGS
NON-METAL FIELD MAT’L
NON-METAL FIELD SHOP FAB
NONMETAL REMOTESHOP MATL
NONMETAL REMOTESHOP FAB
NON-METAL VALVES
310 CARBON STL PIPE/FITTINGS
311CS FIELD MAT’L
312CS FIELD SHOP FAB
313CS REMOTE SHOP MAT’L
314CS REMOTE SHOP FAB
315CS VALVES: FLANGED
316CS VALVES: NON-FLANGED
317CS PIPE ERECTION
357 NON-METAL PIPE ERECTION
320 STAINLESS PIPE/FITTINGS
321SS FIELD MAT’L
322SS FIELD SHOP FAB
323SS REMOTE SHOP MAT’L
324SS REMOTE SHOP FAB
325SS VALVES: FLANGED
326SS VALVES: NON-FLANGED
327SS PIPE ERECTION
360
361
362
363
330
331
332
333
334
335
336
337
MISC.METAL PIPE/FITTINGS
MISC. METAL FIELD MAT’L
MISC.METAL FIELDSHOP FAB
MISC.METAL RMT SHOP MATL
MISC. METAL RMT SHOP FAB
MISC.METAL VALVE:FLANGED
MISC.METAL VALVE:NOFLANG
MISC.METAL PIPE ERECTION
365 HAND CONTROLS
366 PIPE HANGERS, SHOES ETC.
340
341
342
343
344
345
LINED
LINED
LINED
LINED
LINED
LINED
368 MECHANICAL CONNECTIONS
369 FLOW DIVERSION PANELS
PIPE/FITTINGS
PIPE FIELD MAT’L
FIELD SHOP FAB
REMOTE SHOP MAT’L
REMOTE SHOP FAB
VALVES
347 LINED PIPE ERECTION
34-10
350
351
352
353
354
355
370
371
372
373
374
376
377
378
PIPING SPECIALTIES
TRAPS & VACUUM BREAKERS
TRACING TUBING & FITTING
JACKET INTERCONNECTIONS
FIREWATER, BURIED PIPE
FIREWATER PIPING
HYDRANTS,HOSE,NOZZLE,ETC
DELUGE SYSTEMS
SHOWER, EYEWASH, ETC.
BURIED PIPE INSTALLATION
PIPE TRENCH & BACKFILL
COAT AND WRAP PIPE
380
381
382
383
DUCTWORK/LAUNDERS
PROCESS DUCTWORK
HVAC DUCTWORK
LAUNDERS
390
391
392
393
394
395
396
397
398
399
PIPELINES
PIPELINE-MAINLINE PIPE
PIPELINE-VALVES,FITTINGS
PIPELINE-FAB. & INSTALL
PIPELINE-SCRAPER L/R
PIPELINE-DBL JOINT/COAT
PIPELINE-SUPPORTS
PIPELINE-RADIOGRAPH TEST
PIPELINE-MARINE WORK
PIPELINE-MISC. PIPING
34-11
Civil
34-12
400
402
403
404
405
409
CIVIL
SUBCONTRACT CIVIL
SPECIAL PLANT CIVIL
SPECIAL EQUIP. CIVIL
SCAFFOLDING
CIVIL DEMOLITION
450
451
452
453
454
455
456
457
458
410
411
412
413
414
415
416
417
418
419
EARTHWORK
CLEAR SITE
BULK EXCAVATION
ROCK EXCAVATION
BLASTING
HAULING & DUMPING
SITE FILL & COMPACT
DEWATERING
STABILIZATION
CONTAINMENT,EMBANKMENTS
460 PRECAST CONCRETE
461 PRECAST PIPERACK
462 PRECAST BEAMS & COLUMNS
420
421
422
423
424
425
ROADS,RAILROADS
GRADE,COMPACT BASE
ROADS
PAVING
RAILROADS
BOARD ROADS
470
471
472
473
474
475
476
430
431
432
433
434
435
436
437
438
439
OTHER SITEWORK
TEST BORINGS
DEMOLITION & RELOCATION
LANDSCAPING
FENCING
RETAINING WALLS
PILING
SHORING
DRILLED WELLS
DRAINAGE
480 MISCELLANEOUS CIVIL
481 LININGS AND COATINGS
485 OFFSHORE CIVIL
440
441
442
443
444
445
446
447
448
449
CONCRETE
AGGREGATE
CEMENT
SAND
POURED CONCRETE
GROUT
CONCRETE POUR AND FINISH
EXCAVATION & BACKFILL
MISCELLANEOUS CONCRETE
OTHER EQUIP. CONCRETE
490
491
492
493
494
499
REBAR, FORMWORK, ETC.
REBAR
FOUNDATION ACCESSORIES
INSTALL REBAR
FORMWORK MATERIALS
FIELD FABRICATE FORMWORK
INSTALL FORMWORK
STRIP & CLEAN FORMWORK
BACKFILL
BUILDINGS
SUBCONTRACT BUILDINGS
BLDG STRUCTURE/FINISHES
BUILDING FURNISHINGS
BUILDING ELECTRICAL
BUILDING PLUMBING
BUILDING HVAC
PIPELINE CIVIL WORK
PIPELINE-ROW & SITE WORK
PIPELINE-ROW CROSSINGS
PIPELINE-DITCHING
PIPELINE-ANCHORS/SUPPORT
PIPELINE-MISC. CIVIL
Steel
500
502
503
504
509
STEEL
SUBCONTRACT STEEL
SPECIAL PLANT STEEL
SPECIAL EQUIP. STEEL
STEEL DEMOLITION
540 TOWERS AND TRUSSES
541 STEEL TOWERS
542 STEEL TRUSSES
510
511
512
513
519
EQUIPMENT STEEL
EQUIPMENT SUPPORT STEEL
LADDERS
PLATFORMS
OTHER EQUIPMENT STEEL
550 STEEL PLATE ITEMS
551 FABRICATED PLATE
520
521
522
523
STRUCTURAL STEEL
STEEL STRUCTURES
PIPERACK STEEL
PIPE SUPPORTS
580 OFFSHORE STEELWORK
530
531
532
533
534
535
OTHER STEEL ITEMS
FLOORING & STAIR TREADS
HANDRAIL AND TOE PLATE
OTHER BLDG/STRUCT STEEL
BUILDING SIDING
MISCELLANEOUS STEEL ITEM
590
591
592
593
OTHER STEELWORK
STEEL UNLOAD & HANDLING
THRUST ANCHORS
DEFLECTION ANCHORS
34-13
Instrumentation
600
602
603
604
609
INSTRUMENTATION
SUBCONTRCT INSTMENTATION
SPECIAL PLANT INSTRUMENT
SPECIAL EQUIP INSTRUMENT
INSTRUMENT DEMOLITION
640
641
642
644
645
646
647
648
649
INSTR. SUPPORT & ENCL.
TRAYS & SUPPORT
CONDUIT & FITTINGS
INSTRUMENT HOUSING
PNEU. JUNCTION BOXES
ELEC. JUNCTION BOXES
T/C JUNCTION BOXES
MULTIPLEX JUNCTION BOXES
OTHER SUPPORTS
610
611
612
613
614
615
616
617
618
619
FIELD INSTRUMENTATION
FLOW INSTRUMENTS
LEVEL INSTRUMENTS
PRESSURE INSTRUMENTS
TEMPERATURE INSTRUMENTS
ANALYZERS
MOTION INSTRUMENTS
BURNER INSTRUMENTS
ORIFICE PLATES
OTHER EQUIPMENT INSTR.
650
651
653
659
INSTRUMENT ELECTRICAL
WIRE/CABLE ETC.
SOLENOIDS
OTHER INSTR. ELECTRICAL
620
621
622
623
624
625
627
628
629
PANELS, PANEL DEVICES
CONTROL CENTER PANELS
CONTROL CTR CONNECTIONS
BACK OF PANEL INSTRUMENT
EMERGENCY SHUT-DOWN BOP
ALARM SWITCH BOP
EQUIP. CONTROL PANEL
EQUIP. PANEL DEVICES
OTHER PANEL DEVICES
660
661
662
663
664
665
666
667
669
COMPUTER CONTROL
CONTROLLER INTERFACES
INDIC./RECORD INTERFACES
T/C INTERFACES
OPERATOR STATIONS
CABLE/DATA HIGHWAYS
BARRIERS & TRANSDUCERS
PROGRAMMABLE CONTROLLERS
OTHER COMPUTER CONTROL
630
631
632
633
634
635
636
637
638
639
INSTRUMENT RUNS
AIR SUPPLY PIPING
INSTRUMENT PIPING
TERMINATIONS
PNEUMATIC TUBING
PNEUMATIC MULTI-TUBE
INSTRUMENT SIGNAL WIRING
MULTI-COND. INSTR. WIRE
T/C EXTENSION WIRING
T/C MULTI-COND. WIRING
670 MISC. INSTRUMENTATION
671 Q.C. EQUIPMENT
680
681
682
683
684
685
686
FINAL CONTROL ELEMENTS
CONTROL VALVES
SAFETY VALVES
RUPTURE DISCS
MOTOR OPERATED VALVES
REGULATING VALVES
DIVERTER VALVES
690 OTHER INSTRUMENT WORK
691 INSTRUMENT TESTING
34-14
Electrical
700
702
703
704
709
ELECTRICAL
SUBCONTRACT ELECTRICAL
SPECIAL PLANT ELECTRICAL
SPECIAL EQUIP ELECTRICAL
ELECTRICAL DEMOLITON
747
748
749
750
751
752
753
754
755
756
757
SUBSTATION STEEL
SWITCHRACK
RECTIFIERS
BLDG/AREA ELECTRICAL
BLDG/AREA LIGHTING
LIGHTING FIXTURES
RECEPTACLES/SWITCHES
HVAC ELECTRICAL
MISC. SMALL TRANSFORMERS
PANELBOARDS
WIRE/CABLE - LIGHTING
710
711
712
713
714
715
716
717
718
719
WIRE, CABLE, ETC.
WIRE/CABLE - LOW VOLTAGE
WIRE/CABLE -HIGH VOLTAGE
PILOT LIGHT
PUSH BUTTON STATION
TERMINATORS/CONNECTORS
JUNCTION BOXES
WIRE/CABLE - MV
WIRE/CABLE - CV
OTHER EQUIPMENT WIRING
758
760
761
762
EQUIPMENT CABINETS
BURIED CABLE
ELECTRICAL TRENCHING
UNDERGROUND CABLE DUCT
720
721
722
723
CONDUIT, TRAYS, ETC.
CONDUIT
CONDUIT FITTINGS
CABLE TRAYS
770 GROUNDING, CATH. PROTEC.
771 GROUNDING SYSTEMS
772 CATHODIC PROTECTION
730
731
732
733
734
735
736
737
738
739
OTHER ELEC. EQUIPMENT
VARIABLE FREQUENCY DRIVE
CAPACITORS
MOTOR CONTROL CENTER - LV
TRANSFORMERS - MV
TRANSFORMERS - LV
SWITCHGEAR - MV
SWITCHGEAR - LV
BUS DUCT - LV
DISCONNECT SWITCH
780
781
782
783
785
786
787
788
740
741
742
743
744
745
746
MAJOR ELEC. EQUIPMENT
790 OTHER ELECTRICAL
TRANSFORMERS - HV
791 ELECTRICAL CIRCUIT TSTNG
SWITCHGEAR - HV
792 ELECTRICAL TRACING
MCC EQUIPPED SPACE
794 SOLAR PANELS
MOTOR CONTROL CENTER - MV 795 BATTERY PACKS
BUS DUCT - MV/HV
796 UPS
TRANSMISSION LINES
797 EMERGENCY GENERATOR
COMMUNICATION,ALARMS,ETC
TELEPHONE
INTERCOM
ANNUNCIATORS
CLOSED CIRCUIT TV
RADIO SYSTEMS
AREA NETWORK SYSTEMS
METEOROLOGICAL SYSTEMS
34-15
Insulation
800
802
803
804
809
INSULATION, FIREPROOFING
SUBCONTRACT INSULATION
SPECIAL PLANT INSULATION
SPECIAL EQUIP INSULATION
INSULATION DEMOLITION
810
811
812
813
814
815
819
INSULATION
PIPE INSULATION
EQUIP INSULATION
MODULE INSULATION SHOP
MODULE INSULATION FIELD
PERSONNEL PROTECTION
OTHER EQUIP. INSULATION
820
821
822
823
FIREPROOFING
STRUCTURAL FIREPROOFING
SKIRT/LEG FIREPROOFING
CABLE TRAY FIREPROOFING
830 SPECIAL COATINGS
831 ACID TILE PAVING
Paint
34-16
900
902
903
904
909
PAINT
SUBCONTRACT PAINT
SPECIAL PLANT PAINT
SPECIAL EQUIP PAINT
PAINT DEMOLITION
910
911
912
913
914
915
916
918
919
PAINTING
PAINT - EQUIPMENT
PAINT - PIPING
PAINT - STRUCTURES
PAINT MODULE EQUIPMENT
PAINT MODULE PIPING
PAINT MODULE STRUCTURES
OTHER COATINGS
OTHER EQUIPMENT PAINT
920
921
922
923
SURFACE
SURFACE
SURFACE
SURFACE
PREPARATION
PREP - EQUIPMENT
PREP - PIPING
PREP - STEEL
34-17
34-18
35 Database Relations
(G10)
Sequence Numbers of Attributes in Relations
Relationship of Database Relations
DETAILS Relation
DESIGN Relation
REMARKS Relation
PROJDATA Relation
NEWCOA Relation
EQRENT Relation
CRWSCH Relation
CSTCTRL Relation
REPGRP Relation
CNTRCT Relation
COMPONENT Relation
INDIRECTS Relation
Aspen Capital Cost Estimator Indirect Codes and Descriptions
QSUM Relations
STORED REPORTS Relation
STORED QUERIES Relation
K (CUSSPC)-TABLE Relation
R-Table Relation
S-Table Relation
T-Table Relation
U-Table Relation
V-Table Relation
W-Table Relation
X-Table Relation
Y-Table Relation
Z-Table Relation
Attribute Descriptions
35 Database Relations (G10)
35-1
CERATE (F)
CRWSCH (G)
EQRENT (H)
CSTCTRL (J)
CUSSPC (K)
REPGRP (L)
CNTRCT (M)
COMPONENT (N)
INDIRECTS (P)
RTABLE (R)
INT
NEWCOA (E)
Width
PROJDATA (D)
ACCOUNT
Type
REMARKS (C)
Name
DESIGN (B)
Attribute
DETAILS (A)
Sequence Numbers of
Attributes in Relations
11
-
-
-
-
-
-
-
-
-
-
-
-
-
-
ACTCOA
INT
-
-
-
-
-
-
5
-
5
-
-
-
-
-
-
ACTSEQ
INT
-
-
-
-
-
-
3
-
3
-
-
-
-
-
-
ACTSRT
INT
-
-
-
-
-
-
4
-
4
-
-
-
-
-
-
ACTTYP
INT
-
-
-
-
-
-
2
-
2
-
-
-
-
-
-
AMOUNT
REAL
-
-
-
5
-
-
-
-
-
-
-
-
-
-
-
APPTYPE
INT
-
-
-
-
-
-
-
-
-
-
-
-
5
-
-
AREA
INT
12
2
2
-
-
-
-
-
-
-
-
-
-
-
-
AREAWBS
TEXT
-
-
-
-
-
-
-
-
-
-
5
-
-
-
-
ATYPE
INT
-
-
-
-
-
-
-
-
-
-
1
-
-
-
-
BTSEQ
INT
-
16
-
-
-
-
-
-
-
-
-
-
-
-
-
CATLNO
TEXT
CCOA
INT
COADES
TEXT
CEAMT
REAL
CEDESC
TEXT
CEFLAG
TEXT
CENUM
CESEQ
2
20
-
-
-
-
-
-
-
-
-
6
-
-
-
-
-
-
-
-
-
1
-
-
-
-
-
-
-
-
-
-
3
-
-
-
-
-
-
-
-
-
-
-
-
2
-
-
-
-
-
-
4
-
-
-
-
-
-
-
-
-
60
-
-
-
-
-
5
-
-
-
-
-
-
-
-
-
2
-
-
-
-
-
1
-
-
-
-
-
-
-
-
-
INT
-
-
-
-
-
2
-
-
-
-
-
-
-
-
-
INT
31
-
-
-
-
-
1
1
1
1
-
-
-
-
1
24
CLASS
INT
20
-
-
-
-
-
-
-
-
-
-
-
-
-
-
CNTRBY
INT
-
-
-
-
-
-
-
-
-
-
-
2
-
-
-
CNTRNM
TEXT
-
-
-
-
-
-
-
-
-
-
-
3
-
-
-
CNTRNO
INT
-
-
-
-
-
-
-
-
-
-
-
1
-
-
-
CNTWKF
INT
-
-
-
-
-
3
-
-
-
-
-
-
-
-
-
COA
INT
1
-
-
1
-
-
-
-
-
-
-
-
-
1
-
CCOAACT
TEXT
2
-
-
-
-
3
-
-
-
-
-
-
-
-
-
-
CCOADES
TEXT
24
-
-
-
-
2
-
-
-
-
-
-
-
-
-
-
COAIND
INT
-
-
-
-
-
-
-
-
-
-
-
-
-
2
COAMOD
INT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
35-2
24
14
DETAILS (A)
DESIGN (B)
REMARKS (C)
PROJDATA (D)
NEWCOA (E)
CERATE (F)
CRWSCH (G)
EQRENT (H)
CSTCTRL (J)
CUSSPC (K)
REPGRP (L)
CNTRCT (M)
COMPONENT (N)
INDIRECTS (P)
RTABLE (R)
COMCOD
TEXT
36
37
-
-
-
-
-
-
-
-
-
-
-
-
-
-
COMPWBS
TEXT
3
35
-
-
-
-
-
-
-
-
-
-
7
-
-
-
CONTRACT
INT
13
-
-
-
-
-
-
-
-
-
-
-
-
3
-
DAYPWK
INT
-
-
-
-
-
-
7
-
-
-
-
-
-
-
-
DESCR
TEXT
-
-
4
-
-
-
-
-
-
-
-
-
-
-
-
DIAM
REAL
24
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Attribute
Name
Type
Width
76
DUPITEMS
INT
-
-
-
-
-
-
-
-
-
-
-
-
4
-
-
DUPQTY
INT
33
-
-
-
-
-
-
-
-
-
-
-
-
-
-
EXTRA1
INT
21
-
-
-
-
-
-
-
-
-
-
-
-
-
-
EXTRA2
REAL
EXTRA3
TEXT
HOURRRAT
22
-
-
-
-
-
-
-
-
-
-
-
-
-
-
23
-
-
-
-
-
-
-
-
-
-
-
-
-
-
FLOAT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
4
HRSPDA
REAL
-
-
-
-
-
-
9
-
-
-
-
-
-
-
-
ICACOA
INT
32
-
-
-
-
-
-
-
-
-
-
-
-
6
-
ICUNIT
INT
36 11
-
-
-
-
-
-
-
-
-
-
-
-
-
INDDES
TEXT
4
-
-
-
-
-
-
-
-
-
-
-
-
-
9
-
INDAMOUNT INT
32
-
-
-
-
-
-
-
-
-
-
-
-
-
5
-
INDHOURS
INT
-
-
-
-
-
-
-
-
-
-
-
-
-
4
-
ITEM
TEXT
24
-
-
-
2
-
-
-
-
-
-
-
-
-
-
-
ITEMDES
TEXT
28
4
-
-
-
-
-
-
-
-
-
-
-
-
-
-
ITEMCOD
INT
-
1
1
-
-
-
-
-
-
-
-
-
-
-
-
INTREF
INT
34
-
-
-
-
-
-
-
-
-
-
-
6
-
-
IUMVAL
REAL
-
12
-
-
-
-
-
-
-
-
-
-
-
-
-
LCODE
INT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
LDESC
TEXT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
LCOST
REAL
9
-
-
-
-
-
-
-
-
-
-
-
-
-
5
24
LCOSTRAT
FLOAT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
LHOURS
REAL
8
-
-
-
-
-
-
-
-
-
-
-
-
-
LINELOOP
INT
25
-
-
-
-
-
-
-
-
-
-
-
-
-
LOCID
TEXT
16
-
-
-
-
-
-
-
-
-
-
-
-
-
8
35-3
RTABLE (R)
INDIRECTS (P)
COMPONENT (N)
CNTRCT (M)
REPGRP (L)
CUSSPC (K)
CSTCTRL (J)
EQRENT (H)
CRWSCH (G)
CERATE (F)
NEWCOA (E)
PROJDATA (D)
REMARKS (C)
Name
DESIGN (B)
Attribute
DETAILS (A)
Sequence Numbers of Attributes in Relations - continued
Type
Width
MATL
TEXT
5
10
-
-
-
-
-
-
-
-
-
-
-
-
-
-
MCODE
INT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
MCOST
REAL
7
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3
MCOSTRAT FLOAT
MDESC
TEXT
-
-
-
-
-
-
-
-
-
-
-
-
-
NOITEM
INT
-
-
-
-
-
-
10
2
6
-
-
-
-
-
-
NPCT01
INT
-
-
-
-
-
-
11
3
7
-
-
-
-
-
-
NPCT02
INT
-
-
-
-
-
-
12
4
-
-
-
-
-
-
-
NPCT03
INT
-
-
-
-
-
-
13
5
-
-
-
-
-
-
-
NPCT04
INT
-
-
-
-
-
-
14
6
-
-
-
-
-
-
-
NPCT05
INT
-
-
-
-
-
-
15
7
-
-
-
-
-
-
-
NPCT06
INT
-
-
-
-
-
-
16
8
-
-
-
-
-
-
-
NPCT07
INT
-
-
-
-
-
-
17
9
-
-
-
-
-
-
-
NPCT08
INT
-
-
-
-
-
-
18 10
-
-
-
-
-
-
-
NPCT09
INT
-
-
-
-
-
-
19 11
-
-
-
-
-
-
-
NPCT010
INT
-
-
-
-
-
-
20 12
-
-
-
-
-
-
-
NPCT011
INT
-
-
-
-
-
-
21 13
-
-
-
-
-
-
-
NPCT012
INT
-
-
-
-
-
-
22 14
-
-
-
-
-
-
-
NPCT013
INT
-
-
-
-
-
-
-
15
-
-
-
-
-
-
-
NPCT014
INT
-
-
-
-
-
-
-
16
-
-
-
-
-
-
-
NPCT015
INT
-
-
-
-
-
-
-
17
-
-
-
-
-
-
-
ORIGIN
TEXT
6
2
3
3
-
-
-
-
-
-
-
-
-
-
-
-
PARAM
TEXT
32
-
4
-
-
-
-
-
-
-
-
-
-
-
-
-
PCLASS
TEXT
4
-
-
-
-
-
-
-
-
-
4
-
-
-
-
-
PCTOF
INT
-
-
-
4
-
-
-
-
-
-
-
-
-
8
-
PERCENT
REAL
-
-
-
3
-
-
-
-
-
-
-
-
-
7
-
PIPSPC
TEXT
-
-
-
-
-
-
-
-
-
2
-
-
-
-
-
PIPTYP
INT
15
-
-
-
-
-
-
-
-
-
-
-
-
-
-
PRCURC
TEXT
38
-
-
-
-
-
-
-
-
-
-
-
-
-
-
PROPNAM
TEXT
-
13
-
-
-
-
-
-
-
-
-
-
-
-
-
PROPNUM
INT
-
10
-
-
-
-
-
-
-
-
-
-
-
-
-
35-4
8
36
NEWCOA (E)
CERATE (F)
CRWSCH (G)
EQRENT (H)
CSTCTRL (J)
CUSSPC (K)
REPGRP (L)
CNTRCT (M)
COMPONENT (N)
INDIRECTS (P)
RTABLE (R)
REAL
PROJDATA (D)
QUANT
Width
REMARKS (C)
Type
DESIGN (B)
Name
DETAILS (A)
Attribute
5
-
-
-
-
-
-
-
-
-
-
-
-
-
-
REFID
INT
28 14
5
-
-
-
-
-
-
-
-
-
1
-
-
REPGRP
INT
-
-
-
-
-
-
-
-
-
-
2
-
-
-
-
RESULT
REAL
-
-
-
6
-
-
-
-
-
-
-
-
-
-
-
RPGSEQ
INT
-
-
-
-
-
-
-
-
-
-
3
-
-
-
-
SCHAREA
INT
-
-
-
-
-
-
6
-
-
-
-
-
-
-
-
SCHED
TEXT
-
-
-
-
-
-
-
-
-
3
-
-
-
-
-
SHIFTS
INT
-
-
-
-
-
-
8
-
-
-
-
-
-
-
-
SOURCE
TEXT
17
-
-
-
-
-
-
-
-
-
-
-
-
-
-
SUBAREA
INT
30
-
-
-
-
-
-
-
-
-
-
-
-
-
-
SUBTYPE
INT
29
-
-
-
-
-
-
-
-
-
-
-
-
-
-
SUMCODE
INT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
4
-
-
-
-
-
-
-
-
-
-
-
-
-
5
-
-
-
-
-
4
2
TITLE
TEXT
TYPSCT
INT
32
UNIT
TEXT
8
-
7
-
-
-
-
-
-
-
-
-
-
-
-
-
UNITIN
TEXT
8
-
9
-
-
-
-
-
-
-
-
-
-
-
-
-
UNITS
TEXT
8
6
-
-
-
-
-
-
-
-
-
-
-
-
-
-
USERDES
TEXT
25
26
-
-
-
-
-
-
-
-
-
-
-
2
-
-
USERTAG
TEXT
12
27
-
-
-
-
-
-
-
-
-
-
-
3
-
-
VALUER
REAL
-
6
-
-
-
-
-
-
-
-
-
-
-
-
-
VALUET
TEXT
12
-
5
-
-
-
-
-
-
-
-
-
-
-
-
-
VALUEU
TEXT
12
-
8
-
-
-
-
-
-
-
-
-
-
-
-
-
WGT
REAL
18
-
-
-
-
-
-
-
-
-
-
-
-
-
-
WUNIT
TEXT
19
-
-
-
-
-
-
-
-
-
-
-
-
-
-
4
35-5
Relationship of Database
Relations
35-6
DETAILS Relation
No.
Column Name
Type of Data
Description of Data Stored under
each Column
1
COA
integer
Code of Account (COA)
2
ORIGIN
text 6
3 characters each of Item Type + Item
Ref No. (HE 101)
3
COADES
text 24
Title of cost element which is assigned
to account code
4
ITEMDES
text 28
Detailed description of cost element,
material or labor
5
QUANT
real
Quantity
6
UNITS
text 8
Unit of measure associated with
quantity
7
MCOST
real
Material cost for total quantity
8
LHOURS
real
Man-hours of field labor for total
quantity
9
LCOST
real
Cost of field labor for total quantity
10
MATL
text 5
Material symbol (five character string)
11
ACCOUNT
integer
Major account for this item.
12
AREA
integer
Area ID/report group, assigned an
integer value of unity
13
CONTRACT
integer
Contract ID
14
COAMOD
integer
Code of account (COA) modifier
15
PIPTYP
integer
Class of material for piping
16
LOCID
text 8
Sub-description related to ORIGIN (LINE
03, LOOP 02)
17
SOURCE
text 2
Symbol used to characterize direct,
subcontract or remote shop costs
18
WGT
real
Weight
19
WUNIT
text 4
Unit of measure associated with weight
20
CLASS
integer
Class
21
EXTRA1
integer
Your use, for integer values, filled with 0
22
EXTRA2
real
Your use, for decimal values, filled with
0.00
23
EXTRA3
text 4
Your use, for text, filled with blanks
24
DIAM
real
Pipe diameter, decimal (e.g., 2.0)
25
LINELOOP
integer
For piping - the line number (01-40)
For instrumentation - the loop number
(01-50)
35-7
35-8
No.
Column Name
Type of Data
each Column
26
USERDES
text 25
(01-50)
For components - Item description
For Mat’l/Man-hour Additions - Item
description
For Pipe Bulk - Item Details - Item
description
For Instrument Bulk Items - Item
description
27
USERTAG
text 12
User Tag Number or Pipe Specs if
custom pipe specs are used
28
REFID
integer
The 4-digit Item reference number for
the component
29
SUBTYPE
integer
For Equipment - cost basis
For Piping - type of valve or fitting
For Civil - type of foundation
For Instrumentation - type of loop main
component
For Insulation - type of insulation or
fireproofing
30
SUBAREA
integer
Subsidiary area number, within AREA
31
CESEQ
integer
Sequence number for records in Details
relation
32
ICACOA
integer
Icarus code of account for item
33
DUPQTY
integer
Duplicate quantity flag
34
INTREF
integer
Internal reference identification
35
COMPWBS
text 3
Component Work Breakdown Structure
identifier
36
ICUNIT
integer
Internal Unit of Measure unit
37
COMCOD
text 36
Commodity code for materials (Future
use)
38
PRCURC
text 33
Procurement Currency
DESIGN Relation
No.
Column Name
Type of Data
each Column
1
ITMCOD
integer
Item code.
2
AREA
integer
Area ID, assigned integer value of unity.
3
ORIGIN
text 6
3-characters: Item Type + Item
Reference No. (HE 101).
4
PARAM
text 25
Description of design element.
5
VALUET
text 12
Value of design parameter, as text.
6
VALUER
real
Value of design parameter, decimal
value.
7
UNIT
text 8
Unit of measure associated with numeric
design value
8
VALUEU
text 12
Value of design parameters specified by
user as text. (For Aspen Capital Cost
Estimator and Aspen In-Plant Cost
Estimator only.)
9
UNITIN
text 8
Unit of measure associated with VALUEU
10
PROPNUM
integer
Reserved for future use
11
ICUNIT
integer
Internal Unit of Measure identifier
12
IUMVAL
real
System value in internal units of
measure
13
PROPNAM
text 36
System property name
14
REFID
integer
Integer value of 3-digit component
number
15
INDLVL
integer
Indicates indent level for reports
16
BTSEQ
integer
Sequence number for DESIGN table
REMARKS Relation
No.
Column Name
Type of Data
each Column
1
ITMCOD
integer
Item code. (Two digits.)
2
AREA
integer
Area reference number defined by user.
(Two digits, default is 01.)
3
ORIGIN
text 6
Responsible item for the data in the
record (e.g., "HE 101").
4
DESCR
text 76
Description of ITEM as specified by user
(for example, “PROPANE STORAGE
TANK").
5
REFID
integer
number
35-9
PROJDATA Relation
No.
Column Name
Type of Data
each Column
1
COA
integer
System code of account or user's
account code as revised (3 digits).
2
ITEM
text 24
System-generated or user-defined
description for this item (e.g.,
"CONSUMABLES/SMALL TOOLS").
3
PERCENT
real
System-generated or user-defined
description for this item (e.g.,
"CONSUMABLES/SMALL TOOLS").
4
PCTOF
integer
System-calculated code representing
the portion of the project estimate to be
precentaged (1 digit)
5
AMOUNT
real
Lump sum value specified by user.
RESULT
real
The value calculated when PERCENT is
applied to PCTOF, where appropriate.
NEWCOA Relation
No.
Column Name
Type of Data
each Column
1
CCOA
integer
User-changed code of account
2
CCOADES
text 24
User-changed code of account
description (e.g.,”SPECIAL COMPANY
ITEMS").
3
CCOAACT
text 2
COA category (EQ, P, C, ST, I, E, IN, PT)
EQRENT Relation
Aspen In-Plant Cost Estimator only
35-10
No.
Column Name
Type of Data
each Column
1
CESEQ
integer
Key - relates to DETAILS relation
2
NOITEM
integer
Number of items in list
3
NPCT1
integer
List item 1
4
NPCT2
integer
List item 2
5
NPCT3
integer
List item 3
6
NPCT4
integer
List item 4
7
NPCT5
integer
List item 5
8
NPCT6
integer
List item 6
9
NPCT7
integer
List item 7
10
NPCT8
integer
List item 8
No.
Column Name
Type of Data
each Column
11
NPCT9
integer
List item 9
12
NPCT10
integer
List item 10
13
NPCT11
integer
List item 11
14
NPCT12
integer
List item 12
15
NPCT13
integer
List item 13
16
NPCT14
integer
List item 14
17
NPCT15
integer
List item 15
CRWSCH Relation
No.
Column Name
Type of Data
each Column
1
CESEQ
integer
2
ACTTYP
integer
Activity level (area, project, proc.)
3
ACTSEQ
integer
Activity ID at component level
4
ACTSRT
integer
Activity ID at area level
5
ACTCOA
integer
Scheduling code of account
6
SCHAREA
integer
Display flag
7
DAYPWK
integer
Working days per week
8
SHIFTS
integer
Number of shifts per day
9
HRSPDA
real
Working hours per day
10
NOITEM
integer
11
NPCT01
integer
List item 1
12
NPCT02
integer
List item 2
13
NPCT03
integer
List item 3
14
NPCT04
integer
List item4
15
NPCT05
integer
List item 5
16
NPCT06
integer
List item 6
17
NPCT07
integer
List item 7
18
NPCT08
integer
List item 8
19
NPCT09
integer
List item 9
20
NPCT10
integer
List item 10
21
NPCT11
integer
List item 11
22
NPCT12
integer
List item 12
CSTCTRL Relation
35-11
No.
Column Name
Type of Data
each Column
1
CESEQ
integer
2
ACTTYP
integer
Activity level (area, project, proc.)
3
ACTSEQ
integer
Activity ID at component level
4
ACTSRT
integer
Activity ID at area level
5
ACTCOA
integer
Scheduling code of accounts
6
NOITEM
integer
7
NPCT01
integer
List item 1
REPGRP Relation
No.
Column Name
Type of Data
each Column
1
ATYPE
integer
Report group designation (1 = report
group, 2 = sub-group)
2
REPGRP
integer
Report group number
3
RPGSEQ
integer
Report group sequence (sub-group)
4
TITLE
text 32
Report group title
5
AREAWBS
text 2
Area Work Breakdown Structure
identifier
6
SCHAREA
integer
Scheduling Area for this report group
CNTRCT Relation
Aspen Capital Cost Estimator only
No.
Column Name
Type of Data
each Column
1
CNTRNO
integer
Contractor number
2
CNTRBY
integer
Contracted by (parent contractor)
3
CNTRNM
text 24
Contractor name
COMPONENT Relation
Aspen Capital Cost Estimator and Aspen In-Plant Cost Estimator only
35-12
No.
Column Name
Type of Data
each Column
1
REFID
integer
The integer value of the 4-digit internal
reference number
2
USERDES
text 25
Item description
3
USERTAG
text 12
User Tag Number
No.
Column Name
Type of Data
each Column
4
DUPITEMS
integer
Number of duplicate items
5
APPTYPE
integer
Component type
6
INTREF
integer
7
COMPWBS
text 3
identifier
8
STRUCTAG
text 12
User Tag of Structure where component
is mounted
INDIRECTS Relation
Aspen Capital Cost Estimator only
No.
Column Name
Type of Data
each Column
1
COA
integer
Code of Account (COA) (See list on
following page).
2
COADES
text 24
to account code (See list on following
page).
3
CONTRACT
integer
Contract ID
4
INDHOURS
integer
Indirect hours for this account
5
INDAMOUNT
integer
Indirect cost for this account
6
ICACOA
integer
Icarus code of account for item
7
PERCENT
real
Percent value entered by user or
calculated by system
8
PCTOF
integer
System-calculated code representing
the portion of the project estimate to be
percentaged (1 digit)
9
INDDES
text 32
User indirect description or “SYSTEM
GENERATED”
35-13
K (CUSSPC)-TABLE Relation
No.
Column Name
Type of Data
each Column
1
CESEQ
integer
2
PIPSPC
text 8
Custom piping spec
3
SCHED
text 4
Pipe schedule
4
PCLASS
text 4
Flange class
5
TYPSCT
text 4
Type of data (1 = class, 2 = schedule,
3= thickness
6
CATLNO
text 20
Item designation
7
CONTYP
text 2
Type of Fitting Connection (one of the
following: (SW SC SB WW WF VC PF VS)
8
PIPTYP
text 1
Pipe Type (“S” or “W” or “ “)
9
XRAYS
real
Weld X-Rays
10
PDEGF
real
Pipe Temperature in Deg Fahrenheit
11
PPSIG
real
Pipe Pressure in psi
12
TRACEM
text4
Tracing Type
13
NPRIMR
text4
Number of Primary Paint Coats
14
NFINAL
text4
Number of Final Paint Coats
15
INSMTL
text5
Insulation Material
16
INSTHK
text5
Insulation Thickness
R-TABLE Relation
35-14
No.
Column Name
Type of Data
each Column
1
CESEQ
integer
Key- relates (links) to the DETAILS
relation (A table or AprojID)
2
COAIND
integer
to account code (See list on following
page)
3
MCOSTRAT
float
Ratio of MCOST output to MCOST
system
4
HOURRRAT
float
Ratio of HOURS output to HOURS
system
5
LCOSTRAT
float
Ratio of LCOST output to LCOST system
QSUM Relations
No.
Column Name
Type of Data
each Column
1
ACCOUNT
integer
Major account for this item. A.ACCOUNT
2
CODEGROUP
integer
Sub-Group of Icarus cod of account for
item. Evaluated from
Xref_ICACOA.ICACOA_Group
3
ICACOA
integer
Icarus code of account for item.
Evaluated from P.ICACOA and A.ICACOA
4
ICACOADES
text 25
Icarus Title of cost element which is
assigned to account code.
Evaluated from
Xref_ICACOA.ICACOA_Det_Desc_USA1
5
FULLDES
text 50
Major account title for this item. (10)
Indirects.
Evaluated from Xref_Account.[Full
Description]
6
COA
integer
Code of Account (COA). P.COA, A.COA
7
COADES
text 25
to account code.
Evaluated from
Xref_ICACOA.ICACOA_Det_Desc_USA1,
E.CCOADES,
8
QSUMCOA
integer
Icarus sub-account for this item.
Evaluated from
Xref_ICACOAInd.ICACOA_Group,
Xref_QSUMCOA_Criteria.QSUMCOA
9
QSUMCOADES
text 255
Title of sub-account which assigned to
sub-account code. Evaluated from
Xref_QSumCOA.QSUMCOADES
10
ITEMDES
text 30
Detailed description of cost element,
material or labor.
Evaluated from A.ITEMDES
11
COMPONENT
text 40
Item Description.
Evaluated from A.ORIGIN, A.SUBAREA
12
QUANT
real
Quantity.
Evaluated from A.QUANT
13
UNITS
text 10
Unit of measure associated with
quantity. Evaluated from A.UNITS
14
ICUNIT
integer
Internal Unit of Measure unit.
Evaluated from A.ICUNIT
15
KEYQUANT
real
Key Quantity – Characteristic quantity
for group of items
16
KEYUNITS
text 255
Key Quantity – Characteristic quantity
for group of items
35-15
No.
Column Name
Type of Data
each Column
17
HOURS
real
Unit of measure associated with key
quantity
18
LCOST
real
Man-hours of field labor or total
quantity. Evaluated from Sum of
P.INDHOURS
19
MCOST
real
Cost of field labor for total quanity.
Evaluated from A.LCOST
20
TOTCOST
real
Material cost for total quantity.
Evaluated from A.MCOST
21
CLASS
integer
Class.
Evaluated from A.CLASS
22
WGT
real
Weight.
Evaluated from A.WGT
23
WUNIT
text 255
Unit of measure associated with weight.
Evaluated from A.WUNIT
24
DIAM
integer
Pipe diameter, decimal (e.g., 2.0).
Evaluated from A.DIAM
25
USERDES
text 30
(01-50)
description
description
Description
Evaluated from A.USERDES
26
MATL
text 10
Material Symbol (five character string).
Evaluated from A.MATL
27
PIPTYP
integer
Class of material for piping. A.PIPTYP
28
LOCID
text 10
Sub-description related to ORIGIN (LINE
03, LOOP 02).
Evaluated from A.LOCID
29
LINELOOP
integer
For piping – the line number (01-40)
For instrumentation – the looop number
(01-50).
Evaluated from A.LINELOOP
35-16
30
COAMOD
integer
Code of account (COA) modifier.
Evaluated from A.COAMOD
31
LOCATION
text 255
Location Description – Above Ground/
Under Ground.
Evaluated from
Xref_QSUMCOA_Criteria.LOCATION
No.
Column Name
Type of Data
each Column
32
SUBTYPE
integer
For Equipment - cost basis
For Piping - type of valve or fitting
For Civil - type of foundation
For Instrumentation - type of loop main
component
For Insulation - type of insulation or
Fireproofing
Evaluated from A.SUBTYPE
33
SOURCE
text 5
Symbol used to characterize direct, subcontract or remote shop costs.
Evaluated from A.SOURCE
34
REFID
integer
the component.
Evaluated from A.REFID
35
ORIGIN
text 10
3 characters each of Item Type + Tem
Ref No. (HE 101).
Evaluated from A.ORIGIN
36
AREA
integer
Area ID/report group, assigned an integer value of unity.
Evaluated from A.AREA
37
SUBAREA
integer
Subsidiary area number, within AREA.
Evaluated from A.SUBAREA
38
COMPWBS
text 5
Identifier.
Evaluated from A.COMPWBS
39
CONTRACT
integer
Contract ID.
Evaluated from Table P, A.CONTRACT
40
CONTRACTOR
text 30
Contractor Name.
Evaluated from M.CNTRNM
41
DUPQTY
integer
Duplicate quantity flag.
Evaluated from A.DUPQTY
42
CESEQ
integer
Relation.
Evaluated from A.CESEQ
43
INTREF
integer
Internal reference identification.
Evaluated from A.INTREF
35-17
STORED REPORTS Relation
No.
Column Name
Type of Data
each Column
1
ID
integer
Unique ID for Query – Constant cross
releases
2
Name
Text 100
Unique Text Name
3
TreeView1
text 255
Composite Tree (See Name - Lev below)
4
Prompt
text 255
Text Description for Display
5
KbaseFlag
text 50
List of Products for the Report
3 – Capital Cost Report
E – Process Economic Analyzer
M – In-Plant Cost Estimator
6
UserGroupNo
text 50
User Group Number
0: All Reports / All Disciplines
1: Process
2: Equipment / Insul / Paint
3: Piping / Insul / Paint
4: Civil / Structural / Arch / Insul / Paint
5: Management / Project Level
6: Electrical / Instrumentation / Insul /
Paint
7: Quantity Info Only
8: Unit Cost Info Only
7
ImportType
text 50
Type of the Import. Use Full if you
creating a custom report inside reporter.
8
LicMgrGroupNo
text 50
Reserved. Not used
9
BaseRT
text 50
Reserved. Not used
10
Type
text 50
Type of Report, Excel or Crystal
11
TemplName
text 50
Type of Report, Excel or Crystal
12
SheetName
text 50
Name of the template
13
SubQueries
text 50
Sub queries to be used in the Excel
Worksheet (Excel Only)
14
PostProcedure
text 50
MacroSet to be used.
MacroSet_1
MacroSet_2
MacroSet_3
MacroSet_4
35-18
15
Executable
text 50
Reserved. Not used
16
Name-Lev1
text 100
Report List Tree Text – Level 1
17
Name-Lev2
text 100
18
Name-Lev3
text 100
19
Name-Lev4
text 100
35-19
No.
Column Name
Type of Data
each Column
20
Name-Lev5
text 100
21
AutoFilter
Yes/No
Auto Filter Turn ON/OFF (Excel Only)
22
MultiSheetID
text 128
Used for new feature where number of
reports and sheet names are determined by number of contractors/identifiers in the project.
For example, for report Project
Summary by Contractor, the value in
this column is QSUM.CONTRACTOR
(TableName.Column name)
STORED QUERIES Relation
No.
Column Name
Type of Data
each Column
1
ID
text 10
Unique ID for Query – Constant cross
releases
2
Name
text 255
Unique Text Name
3
Generate
Yes/No
Create MS Access Query from Row
4
TreeView1
text 255
Composite Tree (See Lev below)
5
Prompt
text 255
Text Description for Display
(Management and UOD reports only)
6
KbaseFlag
text 255
List of Products for the Report
3 – Capital Cost Report
E – Process Economic Analyzer
M – In-Plant Cost Estimator
7
UserGroupNo
text 255
User Group Number
0: All Reports / All Disciplines
1: Process
2: Equipment / Insul / Paint
3: Piping / Insul / Paint
4: Civil / Structural / Arch / Insul / Paint
5: Management / Project Level
6: Electrical / Instrumentation / Insul /
Paint
7: Quantity Info Only
8: Unit Cost Info Only
8
ImportType
text 50
Type of the Import. Use Full if you are
creating a custom report inside reporter.
9
LicMgrGroupNo
text 255
Reserved. Not used
10
BaseRT
text 255
Reserved. Not used
11
SQLStr
Memo
Query stored as text
12
fStr
text 255
Format String (Management and UOD
reports only)
13
Lev_1
text 255
14
Lev_2
text 255
15
Lev_3
text 255
16
Lev_4
text 255
17
Lev_5
text 255
35-20
CERATE Relation (F-Table)
No.
Column Name
Type of Data
each Column
1
CEFLAG
text 2
Record type (CR = craft, ER = equipment rental)
2
CENUM
integer
Item number (CR = 51 - 99, ER = 1 450)
3
CNTWKF
integer
Contract or work force
4
CEAMT
real
Rate (CR = CUR/HR, ER = CUR/Month)
5
CEDESC
text 60
Description of item
6
CEDUR
integer
T'otal Hours for Item for Contractor
Total Hours for Craft for Contractor
(HOURS) OR
Total Rental Duration Days for
Equipment Item for Contractor (DAYS)
7
CEAMOUNT
integer
Total Indirect Cost for Item for Contractor Total Labor Cost for Craft for Contractor
OR
Total Equipment Rental Cost for
Equipment Item for Contractor
8
CEALLOC
integer
Allocated Rental Days for Equipment
Item for Contractor (DAYS) – Only for
Equipment Rental
S-Table Relation
35-21
No.
Column Name
Type of Data
each Column
1
CESEQ
integer
relation
2
INTREF
integer
3
LINELOOP
integer
For piping – the line number (01-40)
For instrumentation – the loop number
(01-50)
4
LTYPE
c
To differentiate between branch and
main line
No.
Column Name
Type of Data
each Column
5
USERDES
text 30
(01-50)
description
description
Description
6
LINETAG
text 36
For Piping Bulk – User Tag
For Pipe Bulk - Item Details – Pipe Line
Tag
7
LNDESEQ
integer
Item reference number of the connected
equipment.
8
DIRECT
text 3
Pipe Bulk - Item Details – Pipe Line Flow
Direction
9
LNDESLN
integer
Pipe Bulk - Item Details – Connected
Equipment Line Number
10
STREAM
text 30
Pipe Bulk - Item Details - Stream
properties to be used for this line
11
MATL
text 5
Material symbol (five character string)
12
DIAM
integer
Pipe diameter, decimal (e.g., 2.0)
13
LINLEN
integer
Pipe Length, decimal (e.g. 2.0)
14
PIPSPC
text 10
Custom Pipe Spec
35-22
T-Table Relation
No.
Column Name
Type of Data
each Column
1
DUMMYCOL
text 2
Dummy only
2
STREAM
text 36
Stream Name
3
TEMP
integer
Temperature
4
PRESS
integer
Pressure
5
MWGT
integer
Molecular Weight
6
TOTMFLOW
integer
Total Mass Flow
7
LIQMFLOW
integer
Liquid Mass Flow
8
LIQMDEN
integer
Liquid Mass Density
9
LIQVISC
integer
Liquid Viscosity
10
LIQSTEN
integer
Liquid Surface Tension
11
VAPMFLOW
integer
Vapor Mass Flow
12
VAPMDEN
integer
Vapor Mass Density
13
VAPVISC
integer
Vapor Viscosity
14
SOLMFLOW
integer
Solid Mass Flow
15
SOLMDEN
integer
Solid Mass Density
U-Table Relation
35-23
No.
Column Name
Type of Data
each Column
1
ITMCOD
integer
Item code (Two digits)
2
AREA
nteger
Area ID, assigned integer value of unity.
3
ORIGIN
text 10
3-characters: Item Type + Item Reference No. (HE 101).
4
PARAM
text 35
Description of design element.
5
VALUET
text 80
Value of design parameter, as text.
6
VALUER
real
Value of design parameter, decimal
value.
7
UNIT
text 10
Unit of measure associated with numeric
design value
8
VALUEU
text 15
Value of design parameters specified by
user as text. (For Aspen Capital Cost
Estimator and Aspen In-Plant Cost Estimator only.)
9
UNITIN
text 10
Unit of measure associated with VALUEU
10
PROPNUM
integer
Reserved for future use. It should be
more than 900000
11
ICUNIT
integer
Internal Unit of Measure unit.
12
VALUES
real
Same as VALUER
No.
Column Name
Type of Data
each Column
13
PROPNAM
text 40
System property name
14
REFID
integer
number
15
INDLVL
integer
Indicates indent level for reports
35-24
V-Table Relation
No.
Column Name
Type of Data
each Column
1
Index
integer
Sequence Number
2
Field1
text 80
Constains Aspen Process Economic
Analyzer related useful information.
Project Name, Capacity, Plant Location,
Brief Description, Schedule, Investment,
Project Information, Simulator
information etc.
3
Field2
text 80
Contains the data value for field1
4
Field3
text 30
Reserved.
W-Table Relation
No.
Column Name
Type of Data
each Column
1
Index
integer
Sequence Number
2
Item
text 60
Item (Sales, Expenses, Operating Costs
etc.)
3
Units
text 20
Units
4
Year1-Year20
real
Contains cost spread over 20 years
X-Table Relation
35-25
No.
Column Name
Type of Data
each Column
1
Field1
integer
Sequence Number
2
Field2
text 30
Area Name
3
Field3
text 30
Component Name
4
Field4
text 30
Component Type
5
Field5
text 30
Total Direct Cost
Y-Table Relation
No.
Column Name
Type of Data
each Column
1
2
SeqNo
Field2
integer
text 60
Sequence Number
ITEM. Contains useful information
about Project, Capital Cost Evaluation
Basis, Time Period, Schedule, Capital
Costs Parameters, Operating Costs
Parameters, General Investment
Parameters, Escalation, Project
Results Summary, Project Capital
Summary, Engineering Summary,
Raw Materials Costs and Product
Sales, Operating Labor and
Maintenance Costs etc.
3
Field3
text 30
4
5
Field4
Field5
text 255
text 30
Measure of Unit for the Field2
Value stored for Field2.
6
Field6
text 30
7
Field7
text 30
8
Field8
text 30
9
Field9
text 30
10
Field10
text 30
Field11-Field 21 text 10
11
Design, Eng, Procurement Cost for
Project Capital Summary Manhours
for Engineering Summary
Construction Material (Applicable to
Project to Project Cost Summary
only)
Construction Manhours (Applicable
to Project to Project Cost Summary
only)
Construction Manpower Manhours
(Applicable to Project to Project Cost
Summary only)
Construction Indirects Manhours
(Applicable to Project to Project Cost
Summary only)
Reserved
Reserved
35-26
Z-Table Relation
No.
Column Name
Type of Data
each Column
1
REFID
integer
the component
2
COMPTYPE
text 10
Character Component Type
3
ORIGIN
text 10
3 characters each of Item Type + Item
Ref No. (HE 101)
4
FULLNAME
text 60
Object name in the Object database
5
DISPNAME
text 74
User specified name in GUI along with
model name
Aspen Capital Cost Estimator
35-27
Field Indirects
Engineering
01
10
11
12
13
14
15
16
17
18
19
20
21
22
23
70
71
72
73
74
75
76
-09 Titles not assigned
LUMP SUM CONST. INDIRECT
FRINGE BENEFITS
BURDENS
CONSUMABLES, SMALL TOOLS
MISC. (INSURANCE, ETC.)
SCAFFOLDING
EQUIPMENT RENTAL
VENDOR REPRESENTATIVES
FIELD SERVICES
TEMP. CONST., UTILITIES
MOBILIZATION, DEMOBILIZE
CATERING, ACCOMODATION
TRAVEL
OVERTIME PREMIUM
LUMP SUM ENGINEERING
BASIC ENGINEERING
DETAIL ENGINEERING
MATERIAL PROCUREMENT
SUBCONTRACT PROCUREMENT
ENGINEERING MANAGEMENT
Special Indirects
Engineering Indirects
80
81
82
83
Freight
Contractor Indirects
50
51
52
53
54
55
56
85 FIELD CONST. SUPERVISION
86 STARTUP, COMISSIONING
LUMP SUM FREIGHT
DOMESTIC FREIGHT
OCEAN FREIGHT
AIR FREIGHT
MODULE FREIGHT
OTHER FRIEGHT
- 59 Tittles not assigned
LUMP SUM CONST. MGMT
HOME OFFICE CONST. SUPP.
CONSTRUCTION MANAGEMENT
-84 Titles not assigned
Taxes
G & A Overheads
60
61
62
63
64
65
66
90 G AND A OVERHEADS
LUMP SUM TAXES, PERMITS
PERMITS
MATERIALS TAXES
CONSTRUCTION TAXES
ENGINEERING TAXES
OTHER TAXES
Contractor Fee
91 CONTRACT FEE
Escalation
97 ESCALATION
Royalty, Miscellaneous Charges
98 ROYALTY, MISC. CHARGES
Contingencies
99 CONTINGENCY
35-28
Attribute Descriptions
Attribute
Description
ACCOUNT
Major account for this item, leading digit taken from system code of accounts to
characterize the account class:
Account
Description
0
Other, indirects
1
Equipment, Code of Account (COA) 100 - 199
2
Equipment, Code of Account (COA) 200 - 299
3
Piping
4
Civil
5
Steel
6
Instrumentation
7
Electrical
8
Insulation
9
Paint
ACTCOA
Scheduling code of account. For Aspen In-Plant Cost Estimator only.
ACTSEQ
Activity ID at component level. For Aspen In-Plant Cost Estimator only.
ACTSRT
Activity ID at area level. For Aspen In-Plant Cost Estimator only.
ACTTYP
Activity level (area, project, proc.). For Aspen Capital Cost Estimator and Icarus
Project
Manager only.
AMOUNT
Lump sum value specified by user for indirect costs.
APPTYPE
Equipment
Equipment
0 Not applicable
58
TDS
Tray drying systems
1 AC
Air compressors
60
TW
Towers
3 AD
Air dryers
62
VP
Vacuum pumps
4 AT
Agitated tanks
63
VS
Vibrating screens
6 BL
Blenders
64
VT
Vertical tanks
7C
Condensers
65
WFE
Wiped film evaporators
8 CTW Cooling towers
66
WTS
9 CE
Cranes
68
MOT
Motors
10 CO
Conveyors
69
RB
Reboilers
11 CP
Centrifugal pumps
70
FU
Furnaces
12 CR
Crushers
Component Type
Component Type
71 TUR
Turbines
13 CRY Crystallizers
72
Agitators
14 CT
73 LIN
Centrifuges
15 DDT Double diameter towers 74
16 D
35-29
AG
PAK
Linings
Packings
Dryers
Attribute Descriptions - continued
Attribute
Description
APPTYPE
17 DC
Dust collectors
Known Cost
18 DD
Drum dryers
76 Cost known equipment
19 E
Evaluators
77 Cost known bulks
20 EG
Electrical generators
21 EJ
Ejectors
Plant Bulks and Buildings
22 EL
Elevators
80
Buildings
24 F
Filters
81
PIP Piping
26 FE
Feeders
82 CIV Civil
27 FL
Flakers
83 STL Steelwork
28 FLR Flares
84 INS
29 FN
85 ELC
Fans
Instrumentation
Electrical general
32 GC Gas compressors
86 INL
34 GP Gear pumps
87 PNT Paint
Insulation
36 HE Heat exchangers
88
ELC Electrical substation
37 HO Hoists
38 HT Horizontal tanks
Site Development
39 HU Heating units
91 DEMOL Demolition
42 K
Kneaders
92 DRAINS Drainage
43 M
Mills
93 EARTH
Earthwork general
44 MX Mixers
94 FENCE
Fencing
45 P
Pumps
95 LANDSP Landscaping
48 R
Reactors
96 PAVING Paving
49 RD Rotary dryers
97 PILING Piling
50 RU
Refrigeration units
98 RAILRD Railroads
52 S
Scales
99 EARTH Earthwork excavation
53 ST
Stock treatment
54 SE
Separation equipment
Library Items
55 STK Stacks
100 Library items
56 STB Steam boiler
101 Equipment model library
57 T
Thickeners
AREA
Area reference number defined by user. Default is 01. Reference
number 00 refers to project data in the C relation.
ATYPE
Report group designation (1 = report group, 2 = sub group).
AREAWBS
Area level Work Breakdown Structure -- 2 characters.
BTSEQ
Unique sequence number to define the order of records in the DESIGN
table for design reports.
CATLNO
Item designation. For Aspen Capital Cost Estimator and Aspen In-Plant
Cost Estimator only.
CATLNO
Item designation. For Aspen Capital Cost Estimator and Aspen In-Plant
CCOA
User-changed code of account.
35-30
Attribute
Description
CCOAACT
COA category (EQ, P, C, ST, I, E, IN, PT).
CCOADES
User-changed code of account description (text, 24 characters).
Attribute Description
35-31
CEAMT
Rate (CR = CUR/HR, ER = CUR/Month). For Aspen In-Plant Cost Estimator
only.
CEDESC
Description of item.
CEFLAG
Record type (CR = craft, ER = equipment rental). For Aspen In-Plant Cost
Estimator only.
CENUM
Item number (CR = 51 - 99, ER = 1 - 450). For Aspen In-Plant Cost
Estimator only.
CESEQ
Sequence number for records in Details relation. For Aspen Capital Cost
Estimator and
Aspen In-Plant Cost Estimator only.
CLASS
Class as defined below:
Class
Description
0
Other
01
Site Development
10
Process Equipment
20
Bulk Items
30
Area components, testing
31
Buildings
40
Area Site Development
50
Unit Substation
60
Main Substations
70
Control (CTL) Centers
80
OPS Centers
90
Project Items (rotating equipment, spare parts,
transmission lines, testing).
CNTRBY
Contracted by (parent contractor). For Aspen Capital Cost Estimator only.
CNTRNM
Contractor name. For Aspen Capital Cost Estimator only.
CNTRNO
Contractor number. For Aspen Capital Cost Estimator only.
CNTWKF
Contract or work force. For Aspen In-Plant Cost Estimator only.
COA
System code of account or user’s account code as revised. For Aspen InPlant Cost Estimator, COA is 3-digits. For Aspen Capital Cost Estimator,
COA is 4-digits.
COADES
System code of account description or user's description as revised (text,
24 characters).
Attribute
Description
COAMOD
Code of account (COA) modifier
COAMOD
COA Range
Description
0
1 - 999
Default if not shown below
Equipment
0
100 - 299
1
100 - 299
Direct Hire
Subcontract Equipment
Piping
0
300 - 399
Above Ground Piping
1
300 - 399
Underground Piping
2
300 - 399
Chemical Sewer
Civil - Site Development
1
422 - 423
Site Development Paving (Roads)
2
422 - 423
Site Development Paving (Other)
1
400 - 459
Small blocks: <3 CY[< 2.3 M3]
2
400 - 459
Medium blocks:3-10 CY[2.3-7.65 M3]
3
400 - 459
Large blocks:10-25 CY[7.65-19.1 M3]
4
400 - 459
Mass pours: 25-50CY[19.2-38.2 M3]
5
400 - 459
Mass pours:50-100 CY[38.2-76.5 M3]
6
400 - 459
Mass pours: >100CY[>76.5 M3]
7
400 - 459
Piling
8
400 - 459
Conduit Envelopes
9
400 - 459
Elevated slabs
Civil - Concrete
Steel
1
500 - 599
Extra light:<12 LB/FT[< 18 KG/M]
2
500 - 599
Light:12-< 20 LB/FT[ 18-< 30 KG/M]
3
500 - 599
Medium20-< 40 LB/FT[ 30-< 60 KG/M]
4
500 - 599
Heavy40-80 LB/FT[ 60-122 KG/M]
5
500 - 599
Extra Heavy> 80 LB/FT[>122 KG/M]
6
500 - 599
Stairs and Ladders
7
500 - 599
Ladders
9
500 - 599
Misc. (Fab. Plate)
Instrumentation
1
641
Pneumatic Instrument Cable Tray
2
641
Electronic Instrument Cable Tray
Electrical
0
700 - 799
Above Ground Electrical.
1
700 - 799
Underground Electrical.
35-32
Attribute
Description
0
811
Pipe Insulation
1
811
Duct Insulation
0
912
Paint Pipe
1
912
Paint Duct
0
922
Surface Prep Pipe
1
922
Surface Prep Duct
Attribute
Description
COAIND
Title of cost element which is assigned to account code.
COMCOD
Commodity code to uniquely identify materials used in the Icarus
Evaluation Engine (IEE). The Commodity Code COMCOD is a 30
Character code. Each major bulk type has an individual a coding
sequence. Currently only piping has a coding sequence defined.
For Piping:
To decode use the following column breakdown:
Column:
1
2
3
123456789012345678901234567890
AMMMMMUDDDDPEECFFFFFGWRSSS####
COMPWBS
35-33
Column
Position
Description
A
1
Account Code Indicator - 3=Piping
M
2-6
Pipe material code
U
7
Units of measure Indicator - I/P(I) or Metric(M)
D
8-11
Diameter in units indicated
P
12
Material Type indicator - Pipe (P), Valve (V) or
Fitting (F)
E
13-14
Subtype extension (e.g. Trim on Valve, Flange
type, etc) (Currently Not Used)
C
15
Class/Schedule Indicator - Schedule (S), Flange
Class (F), Din designation (D) or Thickness (T)
F
16-20
Class/Schedule designation as indicated in above
units
G
21
Location - Above Ground (A)/Underground
Code(U)
W
22
Pipe Fabrication - Welded(W)/Seamless(S)
R
23
Fabrication Type - Remote Shop(R)/Field Shop(F)
S
24-26
ICARUS Subtype(See Subtype attribute)
#
27-30
Reserved for future use
Component level Work Breakdown Structure -- 3 characters.
Attribute
Description
CONTRACT Reference number of contractor assigned to purchase/install this item. For
Aspen Capital Cost Estimator, the default is one. For all other systems, the
default
is zero.
DAYPWK
Working days per week. For Aspen In-Plant Cost Estimator only.
DESCR
Description of item as specified by user (text, 76 characters).
DIAM
Pipe diameter, decimal (for example, 2.0).
DUPITEMS
Number of duplicate items.
DUPQTY
Duplicate quantity flag. For Aspen Capital Cost Estimator and Aspen InPlant Cost Estimator only.
0 = standard (unique quantity field)
1 = QUANT field of this record duplicated elsewhere.
EXTRA1
Integer. Not assigned. This is a spare attribute for the user to allocate
values asnecessary. The system will initialize to integer zero. The attribute
name can be changed and values calculated as a function of other numeric
data.
EXTRA2
Real. Not assigned but initialized to a real number of the value 0.0.
EXTRA3
Text. Not assigned but initialized to a value of four blank characters (“
").
HOURRAT
Ratio of HOURS output to HOURS system.
HRSPDA
Working hours per day. For Aspen In-Plant Cost Estimator only.
ICACOA
Icarus code of account for item. For Aspen Capital Cost Estimator and
ICUNIT
Icarus Internal Units of Measure identifier.
Unit
No.
I/P
Conversion
Description I/P Metric
Metric
Notes
Description
1
INCHES
2.5400E+01
MM
2
FEET
3.0480E-01
M
3
MILES
1.6093E+00
KM
4
MESH
1.0000E+00
MESH
5
FT
3.0480E-01
M
6
SF
9.2903E-02
M2
7
SY
8.3613E-01
M2
8
SQ IN
6.4516E+02
MM2
9
IN THK
2.5400E+01
MM THK
10
IN DIAM
2.5400E+01
MM DIAM
11
CF
2.8317E-02
M3
12
CY
7.6455E-01
M3
13
GALLONS
3.7854E-03
M3
14
BARRELS
1.5899E-01
M3
15
BD FT
2.3597E-03
M3
Piping Diameters
35-34
ICUNIT
35-35
Icarus Internal Units of Measure identifier. (Continued)
16
BAGS
8.5275E-01
17
cur/CY
cur/M3
Currency Units/Unit
Volume
18
cur
cur
Currency Units
19
cur/LB
cur/KG
Currency/Unit Weight
20
LB
21
LBS
4.5359E-01
KG
22
TONS
9.0718E-01
TONNE
23
LB/FT
1.4882E+00
KG/M
25
LB/YD
4.9605E-01
KG/M
4.5359E-01
BAG-50KG
KG
26
cur/SF
27
LB/BATCH
4.5359E-01
cur/M2
KG/BATCH
Currency/Unit Area
28
LB/MMBTU
7.5066E+00
KG/MW-HR
29
PCF
1.6018E+01
KG/M3
30
W/SF
1.0753E+01
W/M2
31
PSIG
6.8948E+00
KPA
32
PSI
6.8947E-03
PA
33
IN H2O
2.4908E+02
PA
35
IN HG
3.3864E+00
KPA
36
MM HG
1.3332E+02
PA
37
PSF
4.7880E-02
KN/M2
38
LBF
4.4482E+00
N
39
FT-LB
1.3558E+00
N-M
40
IN/S
2.5400E+00
CM/S
41
FPM
1.8288E+01
M/H
42
RPM
1.0000E+00
RPM
43
MPH
1.6093E+00
KM/H
44
HERTZ
1.0000E+00
HERTZ
45
RPM
1.0000E+00
RPM
46
CFH
2.8317E-02
M3/H
47
CFM
1.6990E+00
M3/H
48
MINUTE
1.0000E+00
MINUTE
49
TPD/SF
4.0689E-01
TPH/M2
50
GPM
6.3090E-02
L/S
51
GPH
3.7854E-03
M3/H
52
LB/H
4.5359E-01
KG/H
53
TPH
9.0718E-01
TONNE/H
54
TPD
3.7799E-02
TONNE/H
55
CFM/SF
1.8288E+01
M3/H/M2
56
V
1.0000E+00
V
Vessel pressure
Motor RPM
Country Based
ICUNIT
57
W
1.0000E+00
W
58
A
1.0000E+00
A
59
KV
1.0000E+00
KV
60
KW
1.0000E+00
KW
61
KA
1.0000E+00
KA
62
KVA
1.0000E+00
KVA
63
HP
7.4570E-01
HP
64
MVA
1.0000E+00
MVA
65
OHM-IN
2.5400E+00
OHM-CM
66
DEG F
1.0000E+00
DEG C
Temperature
67
DEG F
5.5556E-01
DEG C
Temperature
Difference
68
FC
1.0764E+01
LUX
Lighting
69
TONS-REF
3.5169E+00
KW
Tons of Refrigeration
70
GPM/SF
6.7909E-01
L/S/M2
71
BTU/H/SF
3.1546E+00
W/M2
72
BTU/H
2.9307E-01
W
73
BTU/LB
2.3260E+00
KJ/KG
74
MMBTU/H
2.9307E-01
MEGAW
75
BTU/CF
3.7250E+01
KJ/M3
76
CPOISE
1.0000E+00
MPA-S
77
CSTOKE
1.0000E+00
MM2/S
Motor Power
78
BTU/LB/F
4.1868E+00
KJ/KG/K
79
DEGREE
1.0000E+00
DEGREE
80
PERCENT
1.0000E+00
PERCENT
81
GAUGE
1.0000E+00
GAUGE
82
PAIR
1.0000E+00
PAIR
Instrumentation
83
BWG
1.0000E+00
BWG
HEX tubing
84
LOOP(S)
1.0000E+00
LOOP(S)
Instrumentation
85
COATS
1.0000E+00
COATS
Paint
Slope
Duct, HEX tubing
86
wire size
wire size
Electrical
87
MCM
1.0000E+00
MCM
Electrical
88
AWG
1.0000E+00
AWG
Electrical
89
CUTS
1.0000E+00
CUTS
Piping
90
SECTION
1.0000E+00
SECTION
91
CLASS
1.0000E+00
CLASS
Electrical
92
SPACES
1.0000E+00
SPACES
Electrical
93
CIRCUITS
1.0000E+00
CIRCUITS
Electrical
94
CIRCUITS
1.0000E+00
CIRCUITS
Compressors
95
STAGES
1.0000E+00
STAGES
35-36
ICUNIT
96
FLOORS
1.0000E+00
FLOORS
97
EACH
1.0000E+00
EACH
98
BAYS
1.0000E+00
BAYS
99
Buildings, Air Coolers
1.0000E+00
Blank Units
101
IN
2.5400E+01
MM
102
IN DIA
2.5400E+01
MM DIA
103
IN LG
2.5400E+01
MM LG
104
IN THK
2.5400E+01
MM THK
105
IN DP
2.5400E+01
MM DP
106
IN WD
2.5400E+01
MM WD
107
IN SZ
2.5400E+01
MM SZ
108
IN HT
2.5400E+01
MM HT
109
IN WL
2.5400E+01
MM WL
111
FT
3.0480E-01
M
112
FT DIA
3.0480E-01
M DIA
113
FT LG
3.0480E-01
M LG
114
FT DP
3.0480E-01
M DP
115
FT WD
3.0480E-01
M WD
116
FT HT
3.0480E-01
M HT
117
FT MHOLE
3.0480E-01
M MHOLE
118
HOURS
1.0000E+00
HOURS
119
WEEKS
1.0000E+00
HOURS
Attribute
Description
INDAMOUNT Indirect cost for this account.
INDDES
Indirects description. Either user-supplied or “SYSTEM GENERATED”.
INDHOURS
Indirect hours for this account.
INTREF
Internal reference identification.
ITEM
System-generated or user-defined description for this item
(text, 24 characters)
ITEMDES
System-generated or user-defined description for this item
(text, 28 characters).
ITMCOD
Item code:
ITMCOD
Description
DESIGN
35-37
0
Other
10
For equipment design data — brief
ITMCOD
Item code:
11*
For equipment design data — full (10 is a subset of 11 with
the provision that it must be a design item)
19
For driver power only (where applicable).
20
For brief plant bulk, area bulk and area site development
items
21*
For plant bulk items — full
30*
For project site development items
40
For library items
96
Custom pipe specs
97
Project or area data sheets
98
For design and project estimate basis
REMARKS
Equipment Items:
10
For user's description
11
For equipment symbol
12
For first 2 lines of remarks
13
For user's tag number
Plant Bulk Items:
20
21
23
For first 2 lines of remarks
Project Site Development:
35-38
30
31
Attribute
Description
IUMVAL
System value in internal Units of Measure. Does not apply when
ICUNIT is 0 or 99 and may be incorrect for items containing costs.
LCOST
Field manpower cost for this item.
LCOSTRAT
Ratio of LCOST output to LCOST system.
LHOURS
Field man-hours associated with this item.
LINELOOP
Piping line number (01 - 40) or instrument loop number (01 - 50).
O if not applicable.
LCODE
Not assigned. Used in cost tracking programs to identify a category of
labor costs.
LDESC
Not assigned. Used in cost tracking programs to describe a category of
labor costs
Attribute
Description
LOCID
Identifier to help qualify the part associated with this item (text, 8
characters).
Examples:
Piping
Line 1 PLT AIR
DRAINS
Instrumentation
LOOP 1 UNIV
AIR SUP LOCAL
Civil
TYPE 15
Electrical
MOTOR PUSHB
FEEDER
MATL
System material symbol characteristic of the material of construction
for this item (text, 5 characters; e.g., "SS304").
MCODE
Not assigned. Used in cost tracking programs to identify a category of
material costs
MCOST
Material cost for this item.
MCOSTRAT
Ratio of MCOST output to MCOST system.
MDESC
Not assigned. Used in cost tracking programs to describe a category of
material costs.
NOITEM
Number of items in list.
NPCTnn
List item for number nn. For Aspen In-Plant Cost Estimator only.
The CRWSCH relation includes nn for 1 to 12.
The EQRENT relation incudes nn for 1 to 15.
The CSTCTRL relation includes nn for 1.
ORIGIN
Responsible item for the data in this record (text, 6 characters).
Example:
CP 100 GRADE PIP001 USS110 (unit substation)
DDT222 PAD
CIV001 MSS001(main)
BLD001 OPEN
STL001 CTL 60
AREA
EXOPEN INS001 SUBSTN (project testing - all substations)
UT HDR MILBLD ELC001 UT STN
INL001
PNT001
PARAM
Parameter description (text, 32 characters).
PCLASS
Flange class. For Aspen Capital Cost Estimator and Aspen In-Plant Cost
Estimator only.
PCTOF
A system-allocated code representing the portion of the project
estimate to be percentaged, as follows. For IPM only. (In other
systems, PCTOF is reserved for future use.
35-39
35-40
Attribute
Description
PCTOF
Description
1 Direct materials plus direct field labor costs
2 Direct material costs
3 Direct field labor cost
4 Direct material plus labor, and construction indirect costs
5 All project costs
6 Unit Cost Library Item(s) Booked to COA 1-48
7 Unit Cost Library Item(s) Booked to COA 49-98
8 Unit Cost Library Item(s) Booked to COA 99
PERCENT
Percentage value specified by the user.
PIPSPC
Custom piping spec. For Aspen Capital Cost Estimator and Aspen InPlant Cost Estimator only.
PIPTYP
Class of material for piping.
PIPTYP Piping Material
0 Pipe labor
1 Carbon steel
2 Stainless steel
3 Titanium
5 Aluminum
6 Monel/Inconel
7 Copper
8 Hastelloy
9 Lined pipe, miscellaneous pipe
PRCURC
Procurement Currency symbol for alternate material sources.
PROPNAM
System Property Name
PROPNUM
Property number used to describe the field description
QUANT
Quantity, used in conjunction with "UNITS" attribute.
REFID
For Aspen In-Plant Cost Estimator and COST® —3-digit component
number.
For Aspen Capital Cost Estimator —4-digit internal reference number.
REPGRP
Report group number.
RESULT
The value calculated when PERCENT is applied to the values,
represented by PCTOF, where appropriate.
RPGSEQ
Report group sequence (sub-group).
SCHAREA
In Aspen In-Plant Cost Estimator: Display flag
In Aspen Capital Cost Estimator: For concurrent scheduling within the
project used for reporting and schedule tracking.
SCHED
Pipe schedule. For Aspen Capital Cost Estimator and Aspen In-Plant
SHIFTS
Number of shifts per day. For Aspen In-Plant Cost Estimator only.
Attribute
Description
SOURCE
Symbol used to characterize direct, subcontract or remote shop costs
(text, 2 characters):
SOURCE Description
RS
Remote shop
IT
User input — total direct cost
lM
User input — direct material costs
lL
User input — direct manpower cost
IS
User input — total subcontract cost
SS
User input — direct costs, system-prepared subcontract cost
ST
User input — subcontract total cost
SM User input — subcontract material cost
SL
User input — subcontract manpower cost.
STRUCTAG
Indicates structure to which the component is assigned.
SUBAREA
Subsidiary area number, within AREA. For Aspen Capital Cost Estimator and
Attribute
Description
SUBTYPE
For Equipment — cost basis
0 System calculated
1 User specified
2 Remote shop paint
For Piping — type of valve or fitting
0
2
80
98
99
101
102
103
104
105
106
107
108
109
110
111
112
113
120
121
122
Other
Remote shop paint
Steam tracing
Tubing
Pipe
90 DEG elbow
Flange
Reducer (to next lower size)
Tee
Blind
Union (also Couplings)
Spectacle blind
Strainer
Threadolet
Expansion joint
Transition joint
WYE for HDPE only
Steam trap
Clamp
45 DEG elbow
Ferrule
35-41
35-42
Attribute
Description
SUBTYPE continued
For Piping — type of valve or fitting - continued
123
Cross
124
Eccentric reducer
125
Hose adapter
126
Pipe adapter
127
Swivel joint
128
Caps
129
Screwable Plugs
130
Weldolet
131
Sockolet
201
Globe valve
202
Ball valve
203
Butterfly valve
204
Gate valve
205
Knife gate valve
206
Plug valve
207
Angle valve
208
Check valve
311
Rotameter
314
Meterrun
332
Vortex flow meter
333
Mag meter
334
Mass flow meter
390
Orifice flange-union
391
Orifice plate
401
Control valve GLO
402
On/off ball valve
403
Control valve BUO
411
Control valve GLP
412
Control valve BAP
413
Control valve BUP
421
Control valve ANO
422
Control valve ANP
423
Control valve DVS
424
Control valve TKS
431
Control valve (no reducers)
432
Control valve
433
3-way valve
434
Regulating valve
481
Slide gate on/off
482
Slide gate positioning
483
Diverter valve
501
TSV
502
Relief valve
503
Rupture disk
801
Victaulic coupl.
Attribute
Description
SUBTYPE continued
For Piping — type of valve or fitting - continued
802
Insul. flange
899
Vent/drain
900
Gaskets
950
Bolts
951
Pre-fab pipe supports
952
Tubing elbow
953
Tubing reducer
954
Tubing tee
955
Tubing union
956
Tubing ball valve
Attribute
Description
SUBTYPE continued
For Piping - Field Labor Subtype
STRESS RELIEF
FIELD ERECTION
MISC FIELD FABRICATION
CUT PIPE
BEVEL PIPE
WELD PIPE
PIPE TESTING
ERECT VALVES
BOLT-UP CONNECTIONS
FIELD X-RAY
Bend Pipe
threadolets
weldolets
JUMPER CONNECTIONS
SWAGE AND WELD JACKET
Shop Handling Small Pipe
Cut & Thread Pipe
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
35-43
Attribute
Description
SUBTYPE continued
For Ducting — type of fittings and/or Duct type
701
Round Duct
702
Round duct and stiffeners
703
Elbows
704
Tees
706
Dampers
707
Access doors
708
Flexible connections
709
Duct hangers
711
Spiral duct
712
Spiral duct and stiffeners
713
Elbows
714
Tees
715
Reducers
716
Dampers
717
Access doors
718
719
Duct Hangers
721
Square duct
722
Square duct and stiffeners
723
Elbows
724
Tees
725
Reducers
726
Dampers
727
Access doors
728
729
Duct Hangers
Attribute
Description
SUBTYPE continued
For Ducting - Field Labor Handle and Erect Duct
Round Duct
Spiral Duct
Square Duct
35-44
31
32
33
Attribute
Description
SUBTYPE - For Civil — type of foundation
Continued
0 Other
1 OCT+PROJ
2 OCTAGONL
3 PAVING
4 MASSPOUR
5S M BLOCK
6 LG BLOCK
7 PILECAP
8 CONDUIT
9 RING
10 BASIN
11 EL SLAB
12 COLM/BM
13 WALL
14 GRAD BM
15 PIER
16 FOOTING
17 BOX
18 SLAB GRD
30 Rectangular - Above grade and below grade concrete tanks, and tile
chests
31 Cylindrical - Above grade and below grade concrete tanks, and tile
chests
50 User defined excavation in Bulk Adjustment Civil entry
71 SHEET PILING
72 HPILE
80 User defined piles in Bulk Adjustment Civil entry or in Site Design.
81 RAYMOND
82 WOOD
83 PIPE
84 PRECAST
85 POURED
86 STEEL-H
87 CAISSON
35-45
Attribute
Description
SUBTYPE - For Civil — type of foundation
Continued
• For Civil — Miscellaneous
30 Rectangular - Above grade and below grade concrete tanks, and tile
chests
31 Cylindrical - Above grade and below grade concrete tanks, and tile
chests
50 User defined excavation in Bulk Adjustment Civil entry
Subtype Piling
88 FRANKI
89 AUGUR
90 Rigging and dismantling pile driving/drilling equipment
• For Steel
2 Remote shop paint
11 Remote shop CONC Fireproof
12 Remote shop MAGN Fireproof
13 Remote shop Pyrocrete FPR
For Electrical
•
Type of wire/cable and cable termination
– Where xx = position of the wire size in the Wire Sizes table. For
example:
Wire size 14 AWG is in Position 1 on the Wire Sizes table for US Country
Base; therefore, a low voltage (LV) 14 AWG wire would be expressed as
101.
– Wire size 35 MM2 is in Position 8 on the Wire Sizes table for UK, JP,
and EU Country Bases; therefore, a medium voltage (MV) 35MM2 wire
would be expressed as 208. Note that the position of the wire size on
the table is determined by counting down, not across.1xx Low voltage
(LV) cable/wire2xx Medium voltage (MV) cable/wire3xx High
voltage (HV) cable/wire4xx Control voltage (CV) cable/wire5xx
Lighting (LT) cable/wire
• Type of wire/cable and cable termination
100 LV conduit
200 MV conduit
300 HV conduit
400 CV conduit
500 LT conduit
551 Low Voltage Feeder Cable - Lighting
552 Low Voltage Feeder Cable - Electrical Tracing
35-46
Attribute
Description
SUBTYPE - For Electrical (continued)
Continued
• Type of termination
611 LV termination
612 MV termination
613 HV termination
614 CV termination
615 LT termination
• Communication and Alarm Systems
651 CCTV System Cabinets
652 Telephone System Cabinets
653 Area Network System Cabinets
654 Radio System Cabinets
655 Access Control System Cabinets
656 Intrusion Detection System Cabinets
657 Meteorological Monitoring System Cabinets
658 7C 16 AWG cable/12 pair 7C 1.25 mm2 cable
659 4 pair phone cable
660 12 pair 18 AWG cable/12 pair .8 mm2 cable
661 3C 14 AWG cable/3C 1.5 mm2 cable
662 24 fiber armor cable
663 24 fiber armor terminations
664 25 pr OSP CAT5 armor cable
665 25 pr OSP CAT5 armor terminations
• Cathode Protection
701 Bonding Station
702 Pipeline Cathodic Protection
703 Install Anode
704 Coke Breeze Backfill
705 Anode Bed Watering Pipe
706 Galvanic Anodes
707 Install Surface Casing
708 Anode Support Pipe
709 Termin Junction Box
710 Transformer/Rectifier
711 Solar Panels
712 Solar Panel Connection
713 Underground Cable
714 Potential Measure Test Station
• Tracing
800 Electrical tracing
801 Self-Regulating Heating Cable
811 Mineral Insulated Alloy
821 Tracing Panelboard
825 Heating Cable
831 Tracing Controller
35-47
Attribute
Description
SUBTYPE - For Instrumentation — type of main loop component construction Continued
continued
110
111
112
120
121
130
140
160
170
171
190
200
210
211
230
231
232
233
234
250
270
310
311
312
313
314
330
331
332
333
334
335
PI Gauge
PI Gauge
PI Draft
PIT
PT W/ Seal
PIC Local
PS Switch
DPI Gauge
DPIT
DPT W/ Seal
DPS Switch
Testwell
TE/TC
TI Dial
TT/TC
TIT/FILL
TT/RTD
TT Wet Bulb
TT Surface
TIC Local
TS Switch
FI Gauge
FI ROT
FI DP Cell
FQI
FI Meterrun
FIT DP Cell
FIT W/O SEN
FIT Vortex
FIT Magnet.
FIT Mass FL
FIT Ultras
336
350
360
361
390
391
410
411
412
430
FIT Turbine
FIC Local
FS Switch
FQIS
Orifice Flange
Orifice Plate
LI Gauge
LI Gauge
LI Bubbler
LIT DP
35-48
Attribute
Description
continued
431
432
433
434
435
450
460
461
462
463
464
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
600
620
621
622
640
650
660
661
LIT Tape FL.
LIT DISP
LIT Ultras.
LIT Nuclear
LIT Radar
LC DISP
LS Wet
LS Dry
LS Vibrating
LS Cond.
LS CAP.
AT (PH)
AT (ORP)
AT (O2)
AET BTU
Density Inst.
Consistency
AT%LEL
AT H2S DET.
AT CO2
AT VIST.
AT Color
AT Flame
AT Cloud
AT Smoke
AT Flash
AT Gravity
AT Heating
AT GC.
AT H2&HC
AT H2S PHY.
AT HC
AT H2S/SO2
AT Sulphur
CT Conduct.
W LD 4 Cell
W LD 3 Cell
W LD 6 Cell
SIT
SS
XE Axial
XE Radial
35-49
Attribute
Description
continued
670
680
681
690
691
700
701
710
720
740
999
XS VIB
PNT Variable
PNT ON/OFF
PNS
EL Position
HIC Local
HIC
HSW
BS Infrared
Solenoid
CV CNTRL VLV
For Insulation — type of insulation or fireproofing
0 Other
1 CASIL (Hot insulation)
2 MWOOL
3 FOAM (Hot insulation)
4 FOAM (Cold insulation)
5 CWOOL
6 PURIF (Cold insulation)
7 PURIF (Hot insulation)
8 CASIL (Cold insulation)
11 CONC Fireproof
12 MAGN Fireproof
13 Pyrocrete FPR
For Piping: Pipeline
Note: For Cathodic Protection Subtypes, see Electrical
601 Haul pipe to R-O-W
602 Stringing pipe on R-O-W
603 Launcher
604 Receiver
605 Main road/RR crossing
606 Minor/Dirt road crossing
607 Clearing and Grading
608 Clean up R-O-W
609 R-O-W blasting
610 Build BERM through marsh
611 Build BERM on trench
613 Concrete Anchor, Weld Plate
614 Haul Concrete Pipe Support
615 String, Set Pipe Support
616 Ditch Blasting
35-50
Attribute
Description
SUBTYPE - For Piping: Pipeline
Continued
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
643
644
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
Ditch, Sand & Softsoil
Ditch, Rocky Soil
Ditch, Weathered Shale
Ditch, Weathered Rock
Ditch, Hard Rock
Rework after Blasting
Rock Ditch By Hand
Ditch Trimming
Haul, Place Sand
Haul Piles
String Piles
Drive Support Piles
Drive Thrust Anchor
Drive Deflection Anchor
Drilled Piles
Concrete Fill, Drilled Piles
Cut Off Piles
Anode Trench
Surface Bed Vertical Anode
Anode Surface Casing
Drill Cased Anode Well
Drill Uncased Anode Well
Cement Plug
Access Roads to R-O-W
Concrete Valve Boxes
Double Joint
FBE External Coat
Internal Coating
Coating Inspection
Line Up & Connect Pipe
Tie-in Connection
Line Up & Weld
Tie-in Welds
X-Ray Field Inspection
Epxoy Shrink Sleeves
Hydrotest
Aerial KM Markers
KM Markers
Warning Signs
Pipeline Vents
Pipeline Drains
Place Pipe in Support
Lower In, Backfill, Clean
Haul Ring Girder
String Ring Girder
35-51
Attribute
Description
SUBTYPE - For Piping: Pipeline
Continued
671
672
673
674
675
676
677
678
679
680
681
690
691
692
699
35-52
Dress & Grind Pile Head
Weld Pipe Pile Cap Plate
Weld Tee
Weld Ring Girder
Place Pipe In Support
Install Insulation & Bolt Down
Guide Bars for Tee
Welding
Miscellaneous Drains
Relief Line
Steel Support Shoes
Steelwork Thrust Anchor
Steelwork Deflection Anchor
Solar Panel Steel
Pipeline Instruments
Attribute
Description
SUMCODE
Not assigned. Used in cost tracking programs to group costs into cost
centers.
TITLE
Report group title.
TYPSCT
Type of data (1 = schedule, 2 = class). For Aspen Capital Cost
Estimator and Aspen In-Plant Cost Estimator only.
UNIT
Unit of measure associated with numeric design value.
UNITIN
Unit of measure associated with user specified design value.
UNITS
Units of measure associated with QUANT (ity) (text, 8 characters; for
example, “FEET”, “CY”, “M3”).
USERDES
User specified description for component, installation material/manhour additions, installation pipe or installation instrumentation.
USERTAG
Equipment component user tag or pipe specs if custom pipe specs are
used.
VALUER
The value of the design parameter (PARAM) as a real number (useful in
calculations). For parameter (PARAM) "ITEM TYPE", VALUER contains
the number of items.
VALUET
Value of design parameters, as text.
VALUEU
Value of design parameter specified by user as text.
WGT
Weight of this item.
WUNIT
Unit of measure associated with item weight (WGT) attribute (text, 4
characters; for example, "LBS ", "KG ").
35-53
35-54
35-55
35-56
36 Icarus Technology
(G10)
Introduction to Areas
Area Specifications
Report Groups
Icarus Systems are Based on Craft Labor
Project Schedule
Equipment Fabricate/Ship Items
Barchart Report Format
Equipment Procurement Schematic
Process Control
Overview of System Input Specifications for Power Distribution
Power Distribution
Mode of Supply and Distribution
Power Distribution Components
Redundancy
Usage Instructions
Reporting of Results
Project Definition
Workforce
Construction Overhead - Prime Contractor Basis
Contracts: Description/Scope
36 Icarus Technology (G10)
36-1
Introduction to Areas
In Aspen Capital Cost Estimator and Aspen Process Economic Analyzer, areas
can be defined as a way to describe the construction methodology that prevails
for that section of the project. Specifications are defined for each area. These
specifications include mechanical design specifications for each of the major
accounts along with dimensions and indexing.
Reasons for Areas
Areas are defined for the following reasons:
36-2
•
Cost accounting: Project components arranged into areas are easier to
review. Many of the cost reports are arranged by area.
•
Site conditions: Different sections of the plant site may contain different
site conditions. The user can define these site conditions, such as soil type,
instrumentation type, electrical class and division, or area type (on-grade,
in-steel, and so on.), in the area specifications. As a result, the site
conditions will impact the area bulk quantities, costs, and man-hours
developed for an area.
•
Contractor assignments: As contractors and contractors’ scope of work
(CONSETs) are defined, areas are then assigned to the defined scope of
work. Areas can affect the flexibility of assigning work to contractors. For
example, if different contractors are responsible for above grade and below
grade piping, each of these can be defined in separate areas and assigned
to the appropriate contractors. Without these being defined in separate
areas, it would be impossible to assign above grade and below grade pipe
to different contractors.
•
Process control and power distribution: Once the user defines the major
process control and power distribution elements in the estimate, the user
must assign areas to defined control centers and unit substations. For
example, the total instrumentation developed for an area would be used
to size that area’s Control Center. Details of process control and power
distribution are developed and reported in the last area sections of the
Detailed Bulk report and Area Bulk section of the Equipment List report for
the last area. It is suggested that users define one last area as an
OFFSITES/PROCESS & POWER area to separate the numerous details
developed for Process Control and Power Distribution from all other detail.
•
Importing: When defining areas, keep in mind that whole areas and their
components can be imported into other projects with matching country
base, currency and units of measure. “Checklist” areas can be created as a
way to prevent from forgetting typical project components in a new project
estimate. An example of this would be a steelwork Checklist Area that
would include all typical sitework items. Once imported into a project,
sitework items that are not needed in a project would be deleted and
design specifications for the different sitework components would be
revised.
Area Types
There are several different area types to select from. Each area type has its
own set of default area bulks that will be developed. The different area types
that may be defined are:
•
•
On-Grade (with or without concrete pad). This is the default area type. By
default the system develops the following bulks for an on-grade area:
°
Perimeter lights every 50 feet.
°
Lights are supplied from 1 or more area panelboards, supplied from a
disconnect switch in the MCC for this area.
°
A ground grid the length of the perimeter.
°
A concrete pad will be developed based on the dimensions of the area if
the PAD option is selected.
Open-Steel (OPEN)
The following area bulks will be developed for an OPEN type area:
•
°
A multi-level, open-steel structure developed based on the dimensions
of the area.
°
One in-steel level for every 15 feet [4.5 M] of height.
°
75% of each level is floor grating for steel structure and concrete slab
for concrete structure, with perimeter toe-plate and handrail.
°
Pendant lights supplied from a local panelboard developed just to
supply the lights in the structure.
°
Structural members are sized for both dead and live loads based on the
weight of equipment “hung” in the structure. See section below for
information on “hanging” equipment. Note: Equipment items that are
“hung” lose their foundations and support steel is provided to tie the
item into the structure.
°
Bracing is provided according to wind and seismic requirements.
°
Open-Structure (OPEN)
Open structure type can be steel, pre-cast concrete, or cast-in-place
concrete. Steel is the default structure type.
The following area bulks will be developed for an OPEN type area:
°
A multi-level, open-steel structure developed based on the dimensions
of the area.
°
One in-steel level for every 15 feet [4.5 M] of height.
°
75% of each level is floor grating for steel structure and concrete slab
for concrete structure, with perimeter toe-plate and handrail.
°
Pendant lights supplied from a local panelboard developed just to
supply the lights in the structure.
°
Structural members are sized for both dead and live loads based on the
weight of equipment “hung” in the structure. See section below for
information on “hanging” equipment. Note: Equipment items that are
36-3
“hung” lose their foundations and support steel is provided to tie the
item into the structure.
•
°
Bracing is provided according to wind and seismic requirements.
°
Existing Open-Steel (EX-OPEN)
The following area bulks are developed for an EX-OPEN type area:
°
All bulks that were developed for the OPEN type area will be developed
except for the OPEN STEEL STRUCTURE as it is assumed to exist.
°
Support steel is provided.
Logic for Hanging Equipment
Equipment
Loaded Automatically
Shell & Tube Heat
Exchanger
Yes
Horizontal Tank
Yes
Thermosiphon reboiler
Yes
Other reboilers
No
Loaded when Skirt/
Leg is set to 0
Agitated Tank
Yes
Double-Diam. Tower
Yes
Packed Tower
Yes
Trayed Tower
Yes
Vertical Tank
Yes
All Others (pumps, and so
on)
No or N/A
No or N/A
See also: Chapter 20: Steel - Logic for Hanging Equipment in Steel Structures
•
Module
These area bulks are developed for a MODULE type area:
°
A SKID (flat base structural model) module is developed by default or
the user can select from the following module types:
- Cylindrical 1-bay cold box
- Rectangular, 1-bay cold box fully enclosed
- Rectangular, 1-bay cold box 3 sides enclosed
- Truckable* (See details below.)
- Bargeable* (See details below)
- Module lighting
°
•
36-4
Ground grid
* Truckable Module - TRMD
The truckable module is designed as a one bay braced frame structure and
the user can specify the number of levels. The user can add up to four
truckable modules within the area and up to two modules can be stacked.
Use the Structure Tag TRMD-1 to TRMD-4 for specifying the module to
which the equipment is loaded. If no Structure Tag is specified, equipment
weight is distributed among the modules. One dimension can be up to 80ft
(24m) [Length, Width, or Height] and the other two dimensions up to 25ft
(7.6m).
You can specify an allowance for temporary bracing used during shipping.
The default is 10% of the steel weight.
•
* Bargeable Module - Bargeable Module - BRGM
Bargeable process module is designed as a braced frame structure.
Dimensions can be up to 200ft(60.8m) [Length] x 200ft(60.8m)[Width] x
100ft(30.4m) [Height]. You can add up to four modules within an area and
up to two modules can be stacked similar to Truckable. Use structure tag
BRGM-1 to BRGM-4 for specifying the module to which the equipment is
loaded. If no structure tag is specified, equipment weight is distributed
among the modules. The transportation cost varies significantly from one
project to another, so you should enter the transportation cost from
module shop to site.
You can specify:
°
the shipping season (Default: Summer)
°
the shipping route
°
transverse, longitudinal and vertical acceleration values
°
an allowance for temporary bracing used during shipping. The default is
5% of the steel weight
These specifications work in conjunction with each other:
When a BRGM module type is selected, the selected season, route, and module
height (the tallest module of the four governs) enable calculation of the
shipping acceleration fields. Thus, based on these selections, acceleration
values are automatically calculated.
Note: The shipping accelerations determined by the system are good for
initial estimates when no information or data is available. To fine tune the
estimate using more accurate acceleration coefficients, it is recommended that
36-5
a naval architect be consulted to determine the particular barge type, season,
shipping route, and module height. You can input the shipping accelerations
provided by the naval architect into the acceleration fields to override the
defaults provided by Aspen Capital Cost Estimator.
•
* Piperack (see details) - Piperack Module - PRMD
A plant bulk piperack is required to specify the piperack module dimensions
and details. Specify only one piperack in one piperack module area.
Equipments, Structures, and Buildings are not allowed on the piperack
module except Air cooler.
•
Floor
The following area bulks are developed for a FLOOR type area:
°
Pendant lights
Figure A.1: How Aspen Capital Cost
Estimator Hangs Equipment in an OPEN or
EX-OPEN Area
Equipment
Automatic Set
Shell & Tube Exchanger
Yes
Horizontal Tank
Yes
Thermosiphon Reboiler
Yes
Other Reboilers
No
Skirt/Leg = 0
Agitated Tank
Yes
Double-Diameter Tower
Yes
Packed Tower
Yes
Trayed Tower
Yes
Vertical Tank
Yes
All others (pumps, etc.) No or N/A
No or N/A
Default Area Bulks
There are area bulks that are automatically generated for an area. These area
bulks are developed to meet the requirements of the area and can be
suppressed in the Area Specifications for that area. If you execute a project
level estimate, you can review these area bulks in the Area Bulks section of
the Equipment List report.
36-6
Figure A.2: Summary of Area Bulks
Automatically Developed for Each Area
Area Bulks
On-grade Pad
Area Types
Open
Area Lighting & Grounding
X
Equipment Grounding
X
Concrete Pad
Open Steel Structure
Ex-open Module Floor
X
X
X
X
X
X
X
X
X
X
X
X
Module Structure
Area Specifications
For each defined area, the user may enter specifications that will affect designs
and quantities of bulks in an area. While most of the area specifications are
design specifications that will override design specifications entered at the
project level, the most significant area specifications are those that will affect
lengths of pipe, electrical cable, and instrument signal wiring or tubing. These
length specifications include:
•
Area Dimensions
Defined in Area Type Definition, Area Dimensions are used as a default to
develop lengths for all of the following system developed items:
- Piping.
- Electrical cable/wiring.
- Instrument signal wiring /tubing.
Note: Area dimensions do not have any effect on user-added bulks, such as
yard pipe, cable runs, signal wire runs, and so on.
The user can enter area length (L), width (W), and height (H). Only area types
OPEN or EX-OPEN will recognize and use the height dimension.
One example of how the system uses Area Dimension is the determination of
pipe lengths. If an area dimension of 30 X 30 is entered, the system will take
½ (L+W) of the area to determine the default final cut-off lengths of pipe, so in
the above example, ½(L+W)= ½ (30+30) = ½ (60) = 30. The default final
cut-off length of pipe in this area would be 30’. Any line of pipe that had an
original length of less than 30’ would be unaffected by this 30’ x 30’
area dimension.
Area Dimensions are used in a similar way to determine cable and signal
wiring lengths in an area unless the user overrides this calculation with
specific entries.
The area dimensions are also used to size and/or quantify area pads, modules,
open steel structures, grounding, area lighting, concrete pads, etc.
•
Pipe Envelope
Defined in Area Pipe Specifications, Pipe Envelope takes precedence over
Area Dimensions in calculating pipe lengths in an area. Just as Area
Dimensions did in the above example, Pipe Envelope defines the final cutoff length of pipe for all system developed piping in an area. The user
36-7
can make entries for Pipe Envelope length, width, and height as well as%
Adjustment and Maximum Pipe Length.
The following is an example of how the system will use this information to
calculate pipe length:
1
The “standard length” is calculated using the line length equation.
2
The “standard length” is multiplied by area pipe spec for% adjustment.
3
The final cutoff length is calculated:
a) EQPIPELEN + 0.5 * HT
- EQPIPELEN=0.5*(Area Pipe Envelope L+W+H)
- if not set, then EQPIPELEN=0.5*(Area L+W+H)
b)Then area spec for Maximum Pipe Length is applied.
•
Electrical cable run lengths
Defined in Area Electrical Specifications, there are distance specifications
available that will be used to calculate lengths for all system developed
electrical cable in an area. These specifications include Distance to MCC
and Distance to Panel.
•
Instrument signal wiring or tubing lengths
Defined in Area Instrumentation Specifications, there are distance
specifications available that will be used to calculate lengths for all system
developed signal wiring or tubing lengths in an area. These include
Distance from Junction Box (JB) to Control Center (CC).
Report Groups
All defined areas are assigned to defined Report Groups in the Area Tree
diagram. Report groups are a way to group areas together for reporting in
various Report Group summary reports. For example, if you had a process
area where some components were on-grade and some were in-steel, you
could define two separate areas: an ON-GRADE area and an OPEN-STEEL area.
These two areas are separate to ensure that the appropriate bulks are
developed, but can be assigned to the same REPORT GROUP so costs and
man-hours can be summarized together in REPORT GROUP summary reports.
Icarus Systems are Based on Craft Labor
All country base locations are based on a division of labor along craft lines.
Each craft performs only those work items assigned to it — pipefitters only
perform pipefitting operations; welders only perform welding operations; etc.
In Icarus systems, work items can be reassigned to a craft to reflect
site conditions.
This strict default division of labor is a necessary starting point if you are to be
able to change the work rules. It is only because hours are initially “booked” to
the correct crafts that you can subsequently book them to different crafts and
thereby change the division of labor appropriate for any contractor. This is
done by creating a new workforce and then reassigning the labor hours away
from the default crafts to the new workforce crafts.
For example, a skid fabrication shop might be represented as follows:
36-8
1
Create a new workforce to be used by the skid fabricator. This workforce is
initially an exact copy of the system’s default workforce. Change (or add)
the craft names in the new workforce to reflect those present in the skid
fabrication workforce. For example, change “laborer” to “day-laborer,” add
a new craft called “mechanical,” etc.
2
Change the division of labor. Reassign labor hours booked to the default
crafts in the workforce to the newly-defined crafts. For example, reassign
100% of the labor hours booked to riggers and pipefitters to the new
“mechanical” craft.
3
Enter the wage rate and productivity for each craft in the new workforce.
4
Link (assign) the new workforce to the skid contractor. Any work assigned
to this contractor is performed using the new workforce.
Using this method, up to nine distinct construction workforces for each
project can be created. This permits the simulation of an extremely
complicated mix of contractors having diverse work rules.
Project Schedule
A project schedule is developed based on the estimate scope of work for a
project estimate. This schedule includes dates and durations for design
engineering, procurement, delivery of material and equipment, site
development and construction. The construction schedule is integrated with
the cost estimate to provide the basis for estimation of schedule-dependent
costs such as equipment rental requirements, field supervision and
construction management.
The schedule information may be reported in three different ways:
1
The total construction duration will be shown on the Project Data Sheet,
and, if applicable, the construction durations for each contract will also be
shown on the Contract Data Sheet.
2
If the Schedule report option is specified, the system generates two
histogram reports, the Project Cash Flow Summary and Project Manpower
Schedule (which displays the manpower resources required for each week
of the construction schedule). Manpower should also be provided for any
contracts refined.
3
The Project Schedule Data may be used to develop barchart reports in
addition to the histograms for greater schedule detail.
The Project Schedule Data, with an entry for the date to start engineering, is
required to generate the barchart reports. These standard barcharts
are produced:
•
General Schedule - Provides a balanced view of all phases of the project
schedule.
36-9
•
Engineering Schedule - Focuses on details of the design phase, such as the
production of piping isometrics, and on specific procurement items,
showing only a single bar for all construction.
•
Construction Schedule - Shows only a single bar for the design and
procurement phases but focuses on major construction elements such as
piperack erection and piping installation.
Each barchart may also show additional bars created by the user. Also, if
contracts are used, another barchart is provided for the Contracts Schedule.
The barcharts appear within the body of the project estimate report and a
duplicate is appended to the report.
The project schedule is affected by adjustments to engineering man-hours,
field man-hours and productivity and construction workweek specified
elsewhere and any schedule modifications requested in the Project Schedule
Data. The techniques of the scheduling system are utilized in the logical
sequencing of the adjusted design and construction tasks to produce a
summary schedule. Simulation of delayed or accelerated schedules is possible
through the various adjustments available. However, the user interested in
developing a detailed schedule for rush projects, or projects using offset
prefabrication, is advised to use the scheduling system, where control of
activity logic is possible.
Regardless of whether the barchart reports are to be produced, the Project
Schedule Data may be used to adjust the schedule and therefore adjust the
cost estimate. The data provides percentage adjustment fields for design/
procurement duration, for delivery times and for construction duration.
Changes to the system default equipment fabricate/ship times, which may
increase or decrease the total construction duration, can be made in various
ways. A specific value for total construction weeks may be specified.
Equipment Fabricate/Ship
Items
In the absence of user input, the system will use the fabricate/ship times (in
weeks) shown in Table PS-2. If a percentage adjustment is specified for
deliveries, these defaults will all be adjusted accordingly. An entry for a
particular class will be used exactly as entered. A fabricate/ship time entry for
a particular piece of equipment will also be used as entered; all other
equipment of the same class will be assigned the system default value as
adjusted, or the value of the class if specified.
Equip.
Equipment Class
Class No.
36-10
1
2
3
Receive Receive
Fabricate
Quotes Vendor Data and Ship
(weeks) (weeks)
(weeks)
01
Process Vessels
3
4
14
02
Towers
4
4
26
03
Storage Vessels
3
4
33
04
Pumps
3
0
18
05
Compressors
6
8
24
Equip.
Equipment Class
Class No.
06
Turbines
1
2
3
Receive Receive
Fabricate
Quotes Vendor Data and Ship
(weeks) (weeks)
(weeks)
4
8
32
07
Heat Exchangers
3
4
20
08
Boilers
6
8
32
09
Furnaces
4
6
26
10
Air Coolers
4
4
18
11
Package Refrigeration
4
6
30
12
Electric Generators
4
6
22
13
Air Dryers
3
3
16
14
Conveyors
3
4
20
15
Mills; Crushers
6
6
30
16
Fans, blowers
3
2
12
17
Elevators
4
4
16
18
Motors
3
4
10
19
Dust Collectors
3
4
14
20
Filters
2
3
12
21
Centrifuges
4
6
28
22
Agitators, Mixers
3
4
12
22
Cooling Towers
4
3
26
24
Miscellaneous Equipment
4
4
16
25
Pre-Engineered Package
4
4
24
26
Packings, Linings
3
4
12
Note: For field erected equipment, the schedule will be sequenced with the
field erection period included in the fabricate and ship deliver time.
1
No user adjustments available
2
User may specify a % adjustment with Project Schedule Data.
3
A % adjustment or weeks may be specified with Project Schedule Data.
The user intending to substantially reduce the default fabricate/ship times is
cautioned to specify a value for all classes or use a percentage adjustment to
deliveries, to avoid overlooking a longer delivery time for a minor piece of
equipment.
Barchart Report Format
For the user interested in restricting each barchart report to a single page to
improve the appearance of the report, the following table shows the maximum
36-11
number of summary bars on each barchart (that is, report length) developed
by the system:
System Summary Bars
With Basic
Without
Engineering
Basic
General Schedule
24
20
Engineering Schedule
16
14
Construction Schedule
19
18
The user may highlight up to five classes of equipment and up to five specific
items of equipment which appears on all reports except the Contracts
Schedule. Up to five user-defined bars may be added, which appear on the
Engineering and Construction Schedules.
User Additions
Bars
Equipment
General Schedule
N/A
10
Engineering Schedule
5
10
Construction Schedule
5
10
Since a single page report can contain only 24 summary bars, a combination of
system summary bars and user additions that exceeds 24 is printed on a
second page.
The horizontal time scale is adjusted automatically by the system to show
either six years, three years or one and a half years on one page-width
as required.
Fabricate and Ship Weeks
When defining the equipment fabricate and ship time per class, you are
specifying the number of weeks for equipment fabrication and shipping of
vendor data. These times should be entered for any equipment classes whose
anticipated fabricate and ship time differs from the system default. Refer to
“Equipment Procurement Schematic” for the procurement/delivery sequence.
Impacting the Project Schedule
To produce a project schedule when using Aspen Capital Cost Estimator or
COST®, an engineering start date must be specified. (Specifying a construction
start date is optional.) The system then develops a critical path method (CPM)
planning schedule based on the estimate scope of work. The estimate scope of
work is tied to the engineering and construction work items in the project.
Included in this schedule are:
TM
36-12
•
Dates and durations for design engineering
•
Procurement
•
Delivery of materials and equipment
•
Site development
•
Construction.
The following items have an impact on the project schedule:
•
Percentage adjustments for design/procurement duration, delivery times
and construction duration
•
Project scope
•
Field labor shifts, productivities, etc.
•
Index man-hours
•
Percentage adjustments to man-hours through material/man-hours
adjustments
•
Supplemental man-hours added through material/man-hour additions
•
Overrides to the system’s fabrication and ship times to increase or
decrease the total construction duration by equipment class (for example,
HE - 20 weeks) or by equipment item (for example, DDT 101 - 10 weeks).
Remember that the project schedule is based on project scope. The project
schedule is more realistic if components are specified correctly and accurately.
Most importantly, keep in mind that the schedule is a preliminary conceptual
schedule. The schedule is not for execution.
Process Control
The Process Control Data may be used to specify the desired configuration and
type of control scheme:
36-13
•
Analog
•
Digital
•
Combinations of analog and digital control.
Overview
Two types of process control systems are discussed here:
•
Analog
•
Distributed digital control.
The user may select either type, or combinations of each type, to represent
the desired control scheme.
The process control scheme may be defined by two types of data. Control
Center data defines a group of analog or digital devices of similar types,
assigned by the user via a Control Center Reference Number, to provide
control system functions to one or more Areas for Sub-units.
Operator Center data defines a distributed digital control Operator Center; that
is, a staffed center consisting of video display and computer-controlled
indicating, recording, controlling, processing, and transmitting devices.
Operator Centers are used in conjunction with Control Centers only for digital
control schemes.
Groups of analog devices are defined only by analog types of Control Centers.
If Process Control Data is not defined by the user, the system develops one
digital Control Center and one Operator Center for the project to be estimated.
Note: The costs of Operator and Control Centers will be reported in project
estimates only, against the Instrumentation account for the last Area in the
project. Accordingly, control room specifications and other instrumentationrelated items to be reported with project process control items should be
included as part of the last Area.
Introduction
The system is designed to develop a list of quantities of materials, material
costs, and field manpower needed to install items relating to the
instrumentation and control of process equipment.
The user’s equipment list, as organized into Areas, is used to develop
individual items of instrumentation in the following major categories.
36-14
•
Sensors and transmitters
•
Panels and panel mounted devices - analog; front/back of panel, ESD
(emergency shut-down), annunciators, switches, etc.
•
Supply and signal tubing, wiring, bundles
•
Supports, racks, enclosures, junction boxes
•
High voltage instrumentation (switches, switch wire, solenoids)
•
Computer-controlled instruments: controllers, process interface units (high
and low entry level signals), operator stations, co-axial data cable,
redundancy, transducers, barriers, etc.
•
Final control elements.
The user guides the system in developing instrumentation by defining the
desired control scheme at four discrete levels which are listed here and
discussed below:
•
Equipment: Instrumentation Volumetric Model
•
Area considerations (Area, Sub-unit)
•
Control Center: one or more, each serving a group of areas, containing
panels, mounted instruments (if analog) or computer-controlled
instruments (if digital)
•
Operator Center: one or more, if required, each serving one or more
Control Centers, containing computer console operator stations for
purposes of processing:
- process information
- alarm conditions
- control signals
- records for display and printing.
Equipment-Instrumentation Volumetric
Model
Each item of equipment selected by the user is assigned a model for
instrumentation. Specific Volumetric Model drawings in the Piping and
Instrumentation Drawings illustrate piping (by line number) and
instrumentation (by loop number).
Volumetric Models for instrumentation of process equipment are assigned
based upon equipment item and type, function to be performed, and special
user requirement identified by applicable type or installation bulks.
For example, a tower would be instrumented as a distillation tower (default
application type) unless it was redefined to function as an absorber, thereby
receiving piping and instrumentation for use as an absorber.
A tank, horizontal or vertical, will be instrumented for normal process
conditions. However, the user may designate knock-out or storage application
requirements thereby revising the nature of piping and instrumentation to be
provided to the vessel.
An installation bulk feature permits the user to create an entire
instrumentation scheme for any item of equipment, or for the user to modify
the system’s instrumentation Volumetric Model on a loop by loop basis adding a new loop, deleting a system defined loop, or appending loops to a
loop thereby providing for extremely flexible instrumentation schemes.
For each loop, you can specify a sensor, two control valves and their costs with
currency.
There is a field for Hookup option at the Project, Area and bulk level to
specify the hookup option to be used. The default is Primary hookup option.
For creating custom assemblies and choosing your own hookup parts, use
Customer External Files.
36-15
In each case, instrumentation materials, quantities, material costs, and field
man-hours to install equipment instrumentation would be reported against the
item of equipment. Material items include:
•
All local instrumentation, sensors, transmitters, air supplies, tubing, wiring,
control, and relief valves
•
Equipment panel and instrument costs for those items of equipment
designated by the system (turbine, gas compressor) or by the user to bear
local panel mounted instruments.
Area Considerations
The concept of an Area and Sub-unit are discussed in the Area section. The
Area or Sub-unit may be viewed, for present purposes, as an area or section of
the project, and includes all equipment and bulk items so contained.
For instrumentation, an Area or Sub-unit grouping of equipment items would
be characterized by a unique set of the following:
•
Designated Control Center
•
Design level - standard or full. (See Piping and Instrumentation Drawings.)
•
Type of instrumentation - pneumatic or electronic
•
Type of transmission, thermocouple extension cabling, and nature
of support
•
Average length of transmission line from equipment item to Control Center
•
Cable tray dimensions
•
Electrical classification to establish cabling and barrier requirements.
It is important that these area criteria affect the installed cost of each
equipment item requiring instrumentation; the design level and type of
instrumentation are most important influences on instrument selection,
quantities and costs. The remaining area criteria heavily influence the lengths
and type of signal wire cable and tubing and are not insignificant.
Instrument materials, quantities, costs and field man-hours to install and test
will be developed by the system and assigned and reported against the area.
These include field junction boxes and wire, cable and tubing runs, conduit,
cable trays serving the area and communicating with the designated
Control Center.
Control Centers
The system surveys the various items of equipment within an Area for Control
Center instrumentation requirements. More than one Area may be delegated
to a Control Center; several Control Centers may be designated by the user. If
of the digital type, such Control Centers would normally be unstaffed electronic
centers that may be grouped together for operator control using the Operator
Center concept described in the next section.
Two classes of Control Centers are defined by the following characteristics:
1
36-16
Analog Control Centers -
•
Electrical, panel mounted instruments based upon pneumatic, electronic,
high voltage switching.
•
Instruments to record or indicate the value of a variable, or develop and
transmit a control signal (pneumatic, electronic, high voltage switch signal)
to field mounted control elements.
•
Four types, depending upon desired extent of graphic panels:
- NONEtotally devoid of instruments, panels, etc.
- CONVconventional panel board (4.75 instruments per linear foot
[15.6 per meter])
- SEMI semi-graphics panel (3.75 instruments per linear foot [12.3 per
meter])
- FULL full graphic display (2.5 instruments per linear foot [8.2 per
meter]).
•
Staffed by Control Center operators.
2
Digital Control Centers -
•
Devices, that is, process interface units, for conversion of analog signals
(pneumatic, electronic, high voltage switching) into digital computer
signals to be utilized at the designated Operator Center.
•
Reconversion of computer developed digital control signals into analog
signals (pneumatic, electronic, high voltage switch signals) for
transmission to field mounted control elements.
•
Limited pretreatment of digital signals (arithmetic, logical, combinatorial).
•
Display devices appropriate to testing, maintenance functions.
•
Not generally staffed by operator personnel except for maintenance
and testing.
Designation of Control Center Requirements
The user may designate the desired control scheme, first at the Unit Area level
for purposes of designating area requirements and then at the Control Center
level to establish the nature of the Control Center. Areas and Control Centers
are linked together by a user assigned Control Center Reference Number; the
reference number is defined for each Control Center and referenced for each
Unit Area assigned to transmit/receive signals to/from the defined
Control Center.
Absence of User Control Center Designation
Should the user not define or refer to a Control Center for one or more Areas,
the system develops a digital Control Center for those units. This systemdeveloped Control Center is referred to as Control Center Reference Number
“0” in SCAN and PROJect Estimate reports. Quantities, costs, and man-hours
for instrumentation items required to support those Unit Areas unreferenced
by the user will be developed and listed by the system for Control Center “0”.
36-17
Operator Centers
The system is designed to evaluate, size, and develop installed costs of digital
control and data processing equipment, cabling and furnishings for
Operator Centers.
The major cost items considered are:
•
CRT’s - though termed CRT’s (cathode ray tubes) these are
microprocessors that provide supervisory, control, and data processing
functions in addition to multi-color display and keyboard entry functions.
•
History module - hardware and software devices for displaying or recording
the history of a variable (important for large or complex process, less so
for small process facilities).
•
Printers - to permit printed output of selected current or historical values of
variables; to log the operations of the center.
•
Engineers keyboard - for building and changing configurations or displays.
•
Local Control Network (LCN) - principally fiber-optic cable (redundant) and
associated microelectronics to direct data “moving” along the data path to
and from:
- devices in one Operator Center
- one Operator Center and another
- the Operator Center and each of its subordinate Control Centers.
•
Other data processing peripherals and furniture.
The user may designate the type (local or universal) and size of an Operator
Center, or alternatively permit the system to determine Operator Center
requirements.
Sizing an Operator Center is accomplished by the system by matching the list
of items with process equipment requirements. The principal sizing parameters
are the number of digital control loops and control points to be serviced by the
Operator Center. These parameters are obtained at the Operator Center level
according to the following hierarchy:
•
Operator Center
•
Control Center
•
Area
•
Equipment and piping control instrumentation.
Thus, control instrumentation requirements at the equipment level are used
first to size individual Control Centers and then to size each Operator Center
upon grouping relevant Control Center requirements.
Example
In the sketch below, a proposed project is to be provided with a combined
analog/digital control system for five areas, that is, Area 100, 200, 300, 400,
500. One section of Area 100 and all of Area 500 is to be provided with a
conventional analog control system. Further, suppose that Area 100 and 400
36-18
require individual process interface unit locations, that is, different
Control Centers.
Because Area 100 requires both digital and analog control, it is convenient to
split it into two Areas, one a Sub-unit of the other, and thereby enable the
description of one portion as digitally controlled and the other as analog
controlled.
Reference numbers need be assigned to the Unit Areas and centers. Suppose:
MAIN-100:
Area No. = 01
SUB-UNIT 100:
Area No. = 01
AREA-200:
Area No. = 02
AREA-300:
Area No. = 03
AREA-400:
Area No. = 04
AREA-500:
Area No. = 05
and for the Control Centers:
Digital, for MAIN 100:
Center No. 10
Analog, for SUB-UNIT-100:
Center No. 11
Digital for AREA-200:
Center No. 20
Center No. 20
Center No. 40
Analog for AREA-500:
Center No. 11
and for the Area, a reference number of 90.
The Project Control Data
The Project Control Data would be prepared as follows:
Project Control
36-19
Center No.
Type
90
Operator Center
10
Digital Control Center
20
40
11
Analog Control Center
Note that additional Project Control Data may be appended to this list to
expand the control system for other yet undefined process areas. Up to five
independent Operator centers may be defined along with their subordinate
Control Centers to a combined maximum total of 20.
The Area Data for this Example
In the text below, the Unit Area Data is illustrated; the term “etc.” denotes all
remaining area information, that is, the complete set of area data and the
component descriptions. Area 100 is split into two sub-units, named MAIN-100
and SUB-UNIT-100:
Area Title
Area Number
Control Center Number
etc.
MAIN-100
01
10
Area Title
Area Number
etc.
SUB-UNIT-100
01
11
Note: The Control Center Number is 10 for the Main Section and 11 for the
Sub-unit.
Then for the remaining units:
36-20
Area Title
Area Number
etc.
MAIN-200
02
20
Area Title
Area Number
etc.
MAIN-300
03
20
Area Title
Area Number
etc.
MAIN-400
04
40
Area Title
Area Number
etc.
MAIN-500
05
11
Note: AREA-200 and AREA-300 share Control Center Number 20; SUB-UNIT100 and AREA-500 share analog Control Center Number 11.
Reporting of Results for this Example
PROJect estimate reports would be prepared for this example as follows:
•
Equipment: instrumentation local to the item would be reported in the
detailed listing of field materials and manpower for the item of equipment.
•
Area: junction boxes, bundle runs (and associated tray and conduit) would
be developed as an Unit Area cost for each Sub-unit; instrument testing
would be developed for each area.
•
Project costs: all instrumentation costs for the project would be developed
and reported against the last Unit Area in the project. Analog Control
Centers would be sized and reported independently of digital centers.
Digital Control Center Number 10 would be sized based upon the
requirements of equipment in MAIN-100. Center Number 20 would be sized
from requirements of both AREA-200 and 300; and Center Number 40
from AREA-400 requirements. The Operator Center would be developed
from group requirements, that is, those of Control Centers 10, 20, and 40.
Notes for Defining the Operator Center
The following entry field notes are helpful when defining the type of Operator
Center to serve the instrumentation requirements of subordinate digital
Control Centers. A maximum of five sets of PC OPS Data may be used.
An Operator Center is not provided in support of analog Control Centers.
Entry field
Note
Operator center no. The Operator Center Reference Number is a unique
number assigned by the user to identify each digital
Operator Center. The reference number, from 01 to 99,
is used to identify the Operator Center in detailed
system reports.
Conset
The contract set number (CONSET) identifies which
group of contractors is performing work in this
Operator Center. The CONSET number must have been
previously defined with Contract Scope Data.
CONSET must be specified for multiple contractor type
estimates. CONSET is not applicable to prime
contractor type estimates.
36-21
Entry field
Note
Configuration
The configuration consists of items affecting the design
of a Universal Operator Center.
No. of operator CRT Specifies the total number of Operator CRT’s (cathode
ray tube terminals) required for the Operator Center;
includes touch screen console and operator keyboard. Microelectronics associated with the CRT’s provide supervisory and
control functions.
No. of indicating
CRT
Specifies the total number of Indicating CRT’s required
for the Operator Center. Upper tier units for indicating only.
The number specified must be less than or equal to the
number of Operator CRT’s and the sum of the Operator CRT’s
and Indicating CRT’s must be 10 or less.
History module
Indicates inclusion or exclusion of the history module
for trend analysis.
Engineer’s
keyboard:
Indicates inclusion or exclusion of an engineering
keyboard for configuration and display building.
LCN Cable
Indicates inclusion or exclusion of the Local Control
Network Cable. The Cable is a pair of fiber-optic cables
connecting up to 10 Universal Operator Centers with
their associated Control Centers.
Power supply data
The Power Supply to Operator Center specifies the feeder
type and source of power for this Digital Operator Center.
Unit Substation ID
A value must be specified if Power Distribution Data is
present in the project or an ERROR condition will prevail.
If Power Distribution Data is not provided, the system will
generate a MAIN and UNIT substation to serve power at the
voltage(s) required by loads in this Operator Center. The
system generated UNIT substation(s) will be assigned ID=0.
The Reference Number consists of two parts:
• ID- The ID portion of the Reference Number of the standalone UNIT or principle UNIT substations in the family of
UNIT substations serving power to this Operator Center.
• No. - The “NO.” portion of the Reference Number of the
subordinate Unit substation in the family of UNIT
substations serving power to this Operator Center.
Please see Power Distribution Data for further information.
Cable type
Denotes the type of power cable to be used for this
Operator Center.
Cable placement
Indicates the desired method of cable placement for
this Operator Center.
Valid entries include:
•
•
Distance to MCC
36-22
ABOVE - Cable run above ground.
BELOW - Cable run below grade (not available for wire-/
cable in trays); includes trenching, sandbed and backfill;
one trench allocated for four equipment item cable runs;
cable protection type is defined by the user by General
Project Data Electrical.
Specifies the distance to the motor control center
serving power to this Operator Center.
Notes for Defining the Standard
Control Center
The following entry field notes are helpful when defining the standard
control center.
Entry field
Note
Control center no.
The Control Center Reference Number is a unique number,
from 01 to 99, assigned by the user to identify each Control
Center to serve the instrumentation requirements of the
various Area or Sub-units. This is the same reference number
used in the Area Description to identify the relationship
between the Area and Control Center.
Conset
The contract set number (CONSET) identifies which group of
contractors is performing work in this Control Center. The
CONSET number must have been previously defined in
Contract Scope Data.
A Control Center Reference Number must be specified for
multiple contractor estimates. This field is not applicable for
prime contractor type estimates.
Control center type Specifies a symbol representing the types of Control Center,
devices, and general configuration.
Valid entries are:
Analog Control Center
• CONV - Conventional display.
• SEMI - Semi-graphics display.
• FULL - Full graphics display.
• NONE - Existing Control Center; costs and manpower
pertaining to all instruments, panels, and peripheral
equipment will be excluded from the estimate.
• DDCTL - Distributed digital Control Center.
Distance to OPS ctr
For distributed digital Control Centers only. Specifies the
distance between this Control Center and the supervisory
Operator Center. The range is 0 to 5000 FEET [0 to 1525 M]. A
redundant data digital path or “highway” will be developed
using this distance.
36-23
Notes for Defining the Standard Control Center - continued
Entry field
Note
Design data
Design allowance, as a percentage (0 to 100%) of the
number of instrumentation points, loops, devices, etc., that
are developed by the system from Volumetric Models or
from user-defined loops of instrumentation.
Note: 1.If this PC CTL Data is for an analog Control Center
(type symbol = CONV, SEMI, FULL, NONE), the only
functional design allowance is that for Spares.
If for a digital Control Center, allowances apply to each of
the five categories.
Note: 2.The design allowance will be applied on a
percentage basis, that is 100% indicates a one for one basis
(exception, 100% for recorders is a one per ten basis).
Spares(%)
If an analog Control Center, allowance for spares will be
delegated the sizing and selection of field junction boxes,
and pneumatic and cable bundle runs from the field junction
box to the Control Center.
If a digital Control Center, the spares allowance will be
delegated to junction box and tube and cable bundle
sizing and selection, as above, and additionally to
spare boards in either multifunction controllers or
process interface units for (a) controllers, (b)
recorders, and indicators, and (c) thermocouples.
Analog indicators(%) For digital Control Centers only. The design allowance for
analog indicator type instrumentation to be installed in the
Operator Center for this Control Center. The allowance will
be applied to develop additional analog indicators (TI, FI,
etc.) in Operator Center cabinetry based upon the number of
indicating loops serviced by the Control Center.
Analog recorders(%) For digital Control Centers only. The design allowance for
analog recorder type instrumentation to be installed in the
Operator Center for this Control Center. The allowance will
be applied to develop additional analog recorders in
Operator Center cabinetry based upon the number or
recording instruments serviced by the Control Center.
36-24
Redundant
control(%)
For digital Control Centers only. Indicate the percent of the
controllers determined by process specifications that require
redundancy. Multifunction - UAC units will be substituted for
the requested percentage of controllers.
Battery back-up(%)
For digital Control Centers only. The design allowance for
battery operated back-up supply. The design allowance
provides battery backup for multifunction controller
cabinets only.
Notes for Defining the Standard Control Center - continued
Entry field
Note
Power supply data Specifies the feeder type and source of power for this
Control Center.
Unit substation
Specifies the Reference Number of the UNIT substation serving
power to this Control Center. The Reference Number consists of
two parts, as defined by the user with Power Distribution Data.
ID-The ID portion of the Reference Number of the stand-alone
UNIT or principle UNIT substations in the family of UNIT
substations serving power to this Control Center.
No. -The “No.” portion of the Reference Number of the
subordinate UNIT substation in the family of UNIT substations
serving power to this Control Center.
Cable type
Denotes the type of power cable to be used for this Control
Center.
Cable placement
Indicates the desired method of cable placement for this Control
Center.
•
•
ABOVE-Cable run above ground.
BELOW-Cable run below grade (not available for wire/cable
in trays); including trenching, sandbed and backfill, one
trench allocated for four equipment item cable runs; cable
protection type is defined by the user in the General Project
Data - Electrical.
Distance to MCC
Specifies the distance to the motor control center serving power
to this Control Center
36-25
Notes for Defining the PLC
Control Center
The following entry field notes are helpful when defining the PLC
control center.
Entry field
Note
Control center no.
The Control Center Reference Number is a unique number, from
01 to 99, assigned by the user to identify each Control Center to
serve the instrumentation requirements of the various Unit
Areas. This is the same reference number used in the Unit Area
Description to identify the relationship between the Unit Area
and Control Center.
Conset
The contract set number (CONSET) identifies which group of
contractors is performing work in this Control Center. The
CONSET number must have been previously defined in Contract
Scope Data.
A Control Center Reference Number must be specified for
multiple contractor estimates. This field is not applicable for
prime contractor type estimates.
Power supply data Specifies the feeder type and source of power for this Control
Center.
Unit substation
Specifies the Reference Number of the UNIT substation serving
power to this Control Center. The Reference Number consists of
two parts, as defined by the user with Power Distribution Data.
ID - The ID portion of the Reference Number of the stand-alone
UNIT or principle UNIT substations in the family of UNIT
substations serving power to this Control Center.
No. - The “No.” portion of the Reference Number of the
subordinate UNIT substation in the family of UNIT substations
serving power to this Control Center.
Cable type
Denotes the type of power cable to be used for this Control
Center.
Cable placement
Indicates the desired method of cable placement for this Control
Center.
ABOVE - Cable run above ground.
BELOW - Cable run below grade (not available for wire/cable in
trays); including trenching, sandbed and backfill, one trench
allocated for four equipment item cable runs; cable protection
type is defined by the user in the General Project Data Electrical.
Distance to MCC
36-26
Specifies the distance to the motor control center serving power
to this Control Center.
Overview of System Input
Specifications for Power
Distribution
The following figure graphically displays the four levels of input specifications
for defining electrical installation bulks:
1
Project level
2
Area level
3
Component Level
4
Component Installation Level.
The electrical input specifications, which include default values that may be
overridden, take a few minutes to define for even the most detailed power
distribution network.
At the component level, process equipment, plant bulks and buildings give rise
to electrical bulks. Installation procedures are available for quoted items as
well as items from the user library of components.
36-27
36-28
Power Distribution
The Power Distribution Data specifies the configuration and size of a project’s
electrical power distribution system. The user may specify the location and
size of each transmission line, main and unit substation, the degree of
redundancy, and the type and method of placement of distribution cable.
The Power Distribution Data works in conjunction with the voltage levels
defined by the user for General Project Data and Area specifications and
component requirements within the unit.
Most users define the distribution configuration (for example, which main
substation is to feed which “downstream” unit substation) and cable
placement. The system will then size the components based upon power
requirements to be fulfilled in each area by drivers, lighting, tracing, etc. and
then size unit and main substation components, always heading “upstream,” to
size the
transmission line.
Mode of Supply and Distribution
The system offers the user a choice of either a US-based or UK-based mode of
electrical power supply, distribution, and associated components. The mode is
currently determined by the user’s selection of the country base location. The
following table identifies the default values and principal differences between
the two bases.
Principal Differences of Electrical Power Supply Between Country Base
Location
Electrical Power Supply Items
US Base
UK Base
Line or feeder voltage
69 KV at 60 HZ
66 KV at 50 HZ
Main Substation
Secondary voltage
(distribution and equipment voltage)
13.8 KV
11.0 KV
Unit Substation
4160 V
480 V
3300 V
415 V
Cable Types
Wire (individual
conductors) on
tray or in
conduit, or
armored cable
Multi-core cable
on tray or in
conduit, or
armored cable
Cable Gauge
AWG
MM2 gauge
Secondary voltages
(distribution and equipment voltages)
36-29
Power Distribution Components
Power distribution components are sized and cost estimated based on
information provided with General Project Data, (project cabling and
intermediate voltage levels), the Power Distribution Data (distribution
scheme), the Unit Area Data and the list of equipment and bulk items requiring
electrical power.
Figure PD-1 serves two purposes. The left side of the figure lists the major
power distribution components that are designed and reported by the system.
The right side is a schematic of a sample power distribution
network.
Figure PD-1: Illustration of Power Distribution Components
The individual components constituting a typical power distribution system
(detailed data instructions follow).
36-30
Primary Feeders - Transmission Lines
Electrical power for a processing facility is either generated directly by the
consumer or transmitted to the processing facility at high voltage (generally
less than 250 KV) on overhead transmission lines. Primary feeder lines run on
poles from the grid tie-in to a dead-end structure in the main substation
switchyard.
Main Substation
The main substation consists of one or more main transformers that distribute
power through switchgear to unit substations.
The main transformer reduces the voltage of the incoming power (at the
transmission line voltage) to a level at which it may be safely and economically
distributed through switchgear to:
1
2
Unit substation for further transformation and distribution at a lower
voltage
Drivers in the 11-14 KV class within the process plant.
A disconnect switch isolates each main transformer from its power supply
when necessary, while the oil circuit breaker protects against abnormal
conditions. Oil circuit breakers (O.C.B.) are generally used in high voltage
(over 10 KV) applications.
The main substation switchgear protects each unit substation from damage
due to abnormal operating conditions. The main substation switchgear
includes circuit breakers and metering devices that can detect an abnormal
condition and automatically open the current-carrying circuit in which the fault
occurs.
Cable from the main substation terminates at either unit substations or at
motors requiring power at the high voltage supplied by the main substation.
Unit Substations
Electrical equipment is normally not evenly dispersed throughout a process
facility. Heavy power users (pumps, compressors, etc.) usually are located
within well-defined boundaries. The substations serving these areas of high
load-density are called unit substations or load centers because they are
located near the center or the electrical load.
The transformer in the unit substation reduces the voltage of power supplied
by the main substation to the voltage required for the equipment served by
this substation. The power path consists of motor starters, power cable, and
control wire.
The on/off switch for the motor is connected by control wire to a set of
contacts in the motor starter, which, when closed, allows power to be sent to
the motor.
The motor starter provides a means of starting and stopping the motor and
also protects the motor from abnormal operating conditions.
When several motor starters are installed together in a common cabinet, they
become a motor control center (MCC). Each MCC is protected from abnormal
operating conditions by unit substation switchgear.
36-31
Redundancy
When designing an electrical distribution system, a decision must be made as
to the degree and type of redundancy to be built into the power distribution
system. The greater the degree of redundancy, the more reliable the system.
The additional equipment required for increased reliability will make the power
distribution system more expensive.
The system offers the user two options:
1
The simple radial system
2
The spot network system.
Both radial and spot systems are illustrated in Figure PD-2.
The following table lists the characteristics of each option.
Characteristics
Simple Radial
Spot Network
Redundancy
0%
100%
Cost
Less expensive
More expensive
Reliability
Less reliable
More reliable
Typical usage:
Spare parts
Skilled maintenance
On-hand
On-hand
Scarce
Scarce
Severity of shutdown
Not critical
Critical
Referring to Figure PD-2A for an illustration of a simple radial system, a single
main substation transformer is shown to distribute power to two unit
substation transformers and a 5,000 HP motor. The unit substation
transformers in turn are shown to distribute power via switchgear and MCC’s
to the equipment in the appropriate Areas.
Should a unit substation or main substation transformer fail, the equipment
served by these would be inoperative.
The spot network system has 100% redundancy. It is the most expensive and
the most reliable power distribution system. Each set of switchgear is fed by
two transformers. Either transformer is capable of handling the entire electrical
load by itself. This system is commonly used in remote locations where
replacement parts and skilled power system maintenance personnel
are scarce.
Figure PD-2B is an illustration of a spot network system. Two transformers in a
single main substation are shown delivering power to two unit substations.
Each unit substation contains two transformers which in turn distribute power
via switchgear and MCC’s to the process equipment classified in the
appropriate Area.
Should one transformer fail in either the main or unit substation, the
companion transformer would carry the entire load.
36-32
Figure PD-2B Schematic= Spot Network System
36-33
Some sections of a process plant are more critical to the continuous operation
of the plant than other sections. For example, a section of the plant which
operates in the batch mode may have sufficient surge capacity so that the rest
of the facility would continue operating until repairs were made if this section
lost power. The user may therefore want to specify some substations to be
spot network systems and others to be simple radial systems. Further, one
user might require several main substations. A general example showing
combinations of multiple systems of simple radial and spot networks is shown
in Figure PD-3.
Usage Instructions
Power Distribution Information
The Power Distribution Data provides the means of designating each
transmission LINE, MAIN, and UNIT substation and the cable between them.
The transmission line provides power to a “family” of MAIN and UNIT
substations.
If the MAIN substation provides service to one or more UNIT substations, each
may be described in detail using the input parameters in the Power
Distribution Data.
A unit substation may be designated to supply power to one or more areas,
and/or to supply power at reduced voltage to another UNIT substation. In the
latter case, the higher voltage UNIT substation is termed a principle UNIT
substation, providing power to one or more subordinate unit substations. The
relationship between principle and subordinates is indicated by defining a
group “ID” and individual member “No.”, thus forming the unit substation
reference number.
The Substation Reference Number is important for accumulating power usage.
This reference number points to those Unit Areas to be served by the
referenced unit substation.
All equipment in an Area, except motors driven at the distribution voltage,
must be served by the referenced UNIT substation. Should a motor require
power at the distribution voltage, than a separate power line would
automatically be “drawn” from the MAIN substation serving that unit. Should a
motor require power at some voltage not supplied by the referenced UNIT
substation, then the system will make that voltage available by:
1
Creating a new UNIT substation that draws power from the MAIN
substation serving the referenced substation, if it is of single tap type, or
2
Drawing power form another tap from the referenced substation, if it is of
the multi-tap type.
Substation Buildings
Substation buildings are not automatically generated and must be specified
separately using the Building Data.
36-34
Non-Standard Power Networks
The user may wish to incorporate a power distribution network of special
design. Practiced users use a strategy based upon one or more system power
estimates, using the system design methods in combination with user-selected
power equipment bulk items.
Figure PD-3: Illustrative Example of Multiple Main and Unit Substations with
Radial and Spot Network Systems
Unreferenced Area Requiring Power
One UNIT substation is generated to serve those Areas for which a substation
reference number was not specified.
Absence of Power Distribution Data
If no Power Distribution Data is specified, the system generates one UNIT
substation and one MAIN substation to serve the entire facility. The
36-35
characteristics of the substations and components are determined from the
default values for the Power Distribution Data.
Reporting of Results
Project estimate reports will be prepared as follows:
1
Component: Electrical materials local to a component would be reported in
the detailed listing of field materials and manpower for the component; for
example, power and signal cable, local and remote start/stop switches,
indicator lights, electrical heat tracing, lights, masts, and grounding.
2
Area: MCC (Motor Control Centers cabinetry and starters), MCC equipped
space (empty cabinetry), area lighting, lighting and heat tracing
transformers and associated panels, switchgear and cabling, ground grid,
cable trays testing.
3
Project: UNIT and MAIN substation costs of transformers, switchgear,
cabling, transformer concrete pads, grounding, transmission LINE,
structures, testing, etc.; costs are reported against the last Unit Area in the
project data.
Power Description Data
A series of data is used to identify a unique segment of the power distribution
network. Individual types of one or more Power Distribution Data includes the
following:
•
Transmission LINE
•
MAIN substation
•
Stand-alone UNIT or family of UNIT substations.
The sequence of Power Distribution Data designates the top-down hierarchy of
the user’s power distribution network.
If no Power Distribution Data is specified, the system sizes and costs a MAIN
substation and UNIT substation to provide power to the various load centers
contained in the Unit Area descriptions. The characteristics of the substations
and electrical components are defined by the General Project - Electrical Data,
Unit Area - Electrical Data, and power requirements (power and supply
voltage). The entire power network is conditioned by the country base location
defined for the project.
Project Definition
Project Title Data is used to convey user descriptions and specifications for the
following major items:
36-36
•
Project title and document data.
•
Country base location - establishes basis for design procedures, currency,
and evaluation of costs and man-hours.
•
Currency data - used to enter the display costs in all reports in a currency
other than the system currency base for the country base location of
the estimate.
•
Units of Measure - used to select either of two system-defined base sets of
units of measure: I-P (Inch-Pound) or METRIC. See “Units of Measure” for
a complete definition of these and other user-defined sets of units
of measure.
•
Rates to be applied for evaluating costs of freight, taxes, contingencies,
fee, and special charges.
The specification of the Project Title Data should be prepared and reviewed
carefully. Special consideration should be given to this data since it controls
the content and numeric values of the entire project.
Country Base
Table T-1 illustrates the differences in style upon selection of the “country
base.” The differences are summarized in this table according to the hierarchy
of the system; the tabulation does not imply relative importance of each item.
Designation of the country base location is mandatory, as the country base
defines the style of engineering, materials selection and costs, and
construction manpower and costs. Specifically, the country base
location defines:
•
Base monetary unit (which may be redefined)
•
Base set of units of measure (which may be redefined)
•
Base indices for system costs of material, construction, design engineering,
and construction management, important for purposes of escalating
an estimate
•
Base construction manpower pool: crafts, productivity, wage rates, crew
mix, work week, and shift work (which may be adjusted to suit the actual
manpower pool)
•
Base of engineering: disciplines, wage rates, and expenses (which may be
adjusted to reflect the rates, productivities, etc. for the proposed scope
of engineering)
•
Base of design codes and installation standards and practices, for example,
vessel design, electrical power distribution (which may be selected or
adjusted).
Currency Base
The user-designated country base location implies a base monetary unit, for
example, Dollars for US, Pounds Sterling for UK, Thousand Yen for JP, Euros
for EU, and Saudi Arabian Riyals for Saudi Arabia. You can define a currency
unit for the estimate and provide a conversion for the estimate currency
relative to the base monetary unit. Once the currency base is defined by the
user, all user-entered costs, such as freight rates, ready-mix cost, wage rates,
lump sum costs, and equipment or bulk costs, are expected to be in the userdefined currency units. The system uses the user-defined currency and
36-37
conversion value to convert system-developed costs from the system
monetary base to the user-defined currency.
Table T-1: System Default Values Affected by Selection of Country Base
Primary Effect of Selected Country Base
Item Description US Base
UK Base
JP Base
EU Base
ME Base
Base monetary
Unit
US Dollars
Pounds Sterling
Thousand Yen
Euros
Saudi Arabian
Riyals
Base Units of
Measure
I-P
METRIC
METRIC
METRIC
I-P
Units of Measure revise I-P variable revise METRIC
variable
revise METRIC
variable
revise METRIC
variable
revise I-P variable
System Base
Indices
UK indices
JP indices
EU indices
ME indices
33KV (50HZ)
33KV (50HZ)
33KV (50HZ)
115KV (60HZ)
BS5500
JIS
DIN
ASME (Section VIII,
Division 1)
US indices
Electrical Feeder 34.5KV (60HZ)
Line Voltage
(and entire mode
of distribution)
Pressure Vessel
Design Code
(materials and
temperature/
stress
relationships)
ASME (Section
VIII, Division 1)
Depth of
Concrete
Footings
48 INCHES [1200 36 INCHES [1000 36 INCHES [1000 36 INCHES [1000 30 INCHES (750
MM]
MM]
MM]
MM]
MM)
Structural Steel AISC
Shapes (INCHAISC
POUND/METRIC)
AISC
BSI
AISC
BSI
AISC
Euronorm
I-P: AISC
METRIC: Euronorm
•
•
•
•
•
•
•
•
•
•
Note 1: See
Below
Manpower pool;
base of crafts,
crew mix,
productivity,
wage rates
•
•
•
•
•
Houston/Gulf
Coast
100,000 MHR
Union
1 shift
40 hr. week
•
•
•
Northwest UK
100,000 MHR
Site or Nat’l
Agreement
1 Shift
40 hr. week
Bonus
Tokyo, Japan
100,000 MHR
Union
1 shift
40 hr. week
•
•
•
•
Rotterdam,
Netherlands
100,000 MHR
Site
Agreement
1 shift
40 hr. week
•
•
•
•
Dhahran, Saudi
Arabia
100,000 MHR
Site Agreement
1 shift
40 hr. week
Project
Schedule:
duration
Adjusted US
MHRS
Adjusted UK
MHRS
Adjusted JP MHRS Adjusted EU MHRS Adjusted ME MHRS
Equipment
Rental/Plant
rental rates
US rates and
selection
UK rates and
selection
JP rates and
selection
EU rates and
selection
ME rates and
selection
UK Base
JP Base
EU Base
ME Base
Engineering
US Base
Department:
base of
disciplines, wage
rates,
productivity ,
and expenses
36-38
Primary Effect of Selected Country Base
Item Description US Base
UK Base
JP Base
EU Base
Prime
Contractors:
construction
overheads
From adjusted UK
MHRS or user
entry Uk indirect
rates
From adjusted JP
MHRS or user
entry JP indirect
rates
From adjusted EU From adjusted ME
MHRS or user
MHRS or user entry
entry EU indirect ME indirect rates
rates
Contract Fee
Costs reduced to
Structure: based $, US indirect
on costs reduced rates
to base time
Costs reduced to
£, UK indirect
rates
Costs reduced to
Thous ¥, JP
indirect rates
Costs reduced to
€, EU indirect
rates
Power
Distribution
MAIN
distribution
voltage UNIT
voltage Wire
types
60 HZ
13.8 KV
4160V
wire (trayed or in
conduit) or
armored US wire
gauge
50 HZ
11KV
3300 V
multi-core cable
(trayed or in
conduit) or
armored gauge in
MM2)
50 HZ
11KV
3300 V
multi-core cable
(trayed or in
conduit) or
armored gauge in
MM2)
50 HZ
60 HZ
11KV
13.8 KV
3300 V
multi-core cable
(trayed or in
conduit) or
armored gauge in
MM2)
Process
equipment
US cost models,
US base costs
UK cost models,
UK base costs
JP cost models, JP EU cost models,
base costs
EU base costs
Bulks: piping,
civil, steel,
instrumentation,
electrical,
insulation, paint
US cost modes,
US type
descriptions, US
base costs
UK costs modes,
UK type
descriptions, UK
base costs
JP cost modes, JP EU cost modes, EU ME cost modes, ME
type descriptions, type descriptions, type descriptions,
JP base costs
EU base costs
ME base costs
User-specified
supplemental
cost
none
none
none
From adjusted US
MHRS or user
entry US indirect
rates
none
ME Base
Costs reduced to
SAR, ME indirect
rates
ME cost models, ME
base costs
none
Note 1: If GB150 Equipment Design is selected:
°
I-P: AISC
°
METRIC: Chinese Structural Shapes per GB/T 11263
Cost Reporting: Currency and System
Base Indices
Costs developed by the system without assistance of user-entered rates,
costs, and so on, are evaluated at the reported values of the System Base
Indices for the designated country base. See Indexing/Escalation Data.
Cost Reporting: Currency and Escalation
Costs provided by the user in the form of a cost, cost per unit, etc., are
presumed to be in the user-defined currency and valued at a point in time
reflected by the user-specified values for the User Base Indices.
System-developed costs will be elevated from the system base to the user
base condition by index ratio and further escalated by escalation indices.
36-39
Units of Measure
The country base location, once designated by the user, implies a base set of
units of measure, for example, I-P for US, METRIC for UK, EU, JP, and ME. You
can reverse this choice, or create a hybrid unit of measure, by defining the
variable to be revised, the label for the new unit of measure, and the
conversion from old to new unit of measure. However, such redefinition could
have unpredictable downstream effects; for example, in selection of plates,
wire, tubing, pipe, and so on.
Again, all user input is expected to be in the defined set of units of measure
and all reporting by the system conforms to the established set of units
of measure.
Workforce
Two of the most significant variables that account for construction cost
differences from one location to another are the productivity of field manpower
and the wage rates that prevail for each geographic area.
The system recognizes four country base locations — US, UK, JP, EU, and ME.
Upon selecting a country base location, the user obtains a base set of crafts,
wage rates, crew mixes, production rates, and so on, for field manpower
consistent with the selected country base location.
The Workforce Data can be used to change the system base wage rates,
workweek, and productivities. This input can, therefore, be an effective tool in
helping the user examine the effects of local field manpower on prospective
plant sites. In addition, modifications may be made to the system craft and
crew mixes.
Multiple Workforces
In a prime contractor estimate, the system is limited to one set of wage rates,
workweek and productivities (that is, one workforce) per estimate. In a
contracts case, however, the user may define up to nine different construction
workforces (CWF) in one project. This is accomplished by developing multiple
sets of wage rates and productivities with each set identified by a workforce
reference number. This reference number is used in the Contract Definition
Data to indicate which workforce is assigned to each contractor.
Wage Rates/Productivity
There are two types of wage rate and productivity data:
•
General data applicable to all crafts in the workforce
•
Specific data by craft.
The general data may be used to globally set the wage rates and productivities
of all crafts, either as a percentage of some reference base or as a fixed rate.
The reference base may be either the system base rates or the rates of a
previously defined workforce. These globally assigned rates may then be
modified for individual crafts by entering specific rate data for those crafts.
Example 1:
36-40
Suppose workforce “1” is to be assigned wage rates that are 110% of the
system base rates and a productivity of 80% of the system base (the symbol
“B” signifies the system base).
Then the general data would be coded as follows:
CWF = 1
(ALL CRAFTS -% OF BASE)
BASE = B
WAGE RATE% = 110
PROD.% = 80
Example 2:
Suppose workforce “2” is to be assigned wage rates that are 105% of the rates of
workforce “1” and a productivity equal to the system base (100%). Then a second set
of general data would be added as follows:
CWF = 2
(ALL CRAFTS -% OF BASE)
BASE = 1
WAGE RATE% = 105
PROD.% = 125
This would result in wage rates that are 110 x 105/100 = 115.5% of the
system base and a productivity that is 80 x 125/100 = 100% of the system
base. Obviously, the same result could have been obtained for workforce “2”
by using the system base “B” as the referenced base, a “WAGE RATE%” equal
to 115.5 and a PROD.%” equal to 100.
Example 3:
Suppose in workforce “2” Craft X (where X is the craft code) is to have a rate
of $17.70 per hour and a productivity of 75%. Then specific craft data would
be added for workforce “2” with the follow data:
CWF = 2
(CRAFT WAGE RATES/PRODUCTIVITIES)
CRAFT CODE = X
WAGE RATE COST/MH =17.50
PROD.%= 75
Example 4:
Suppose workforce “3” is to be assigned a fixed wage rate and productivity for
all crafts of $12.00 per hour and 90%, respectively. Then a third set of general
data would be coded as follows:
CWF=3
(ALL CRAFTS - FIXED RATES)
WAGE RATE COST/MH=12.00
PROD.%=90
Again, exceptions could be made to the fixed rates for workforce “3” by
entering specific data for individual crafts.
36-41
Unless the user had adjusted indirects, the wage rate used in the estimate
should be the actual unloaded cost (in the user-defined currency) per manhour for the craft, and should not include any fringe or burdens. Fringe
benefits, burdens, and other related construction overhead accounts are
itemized and determined separately by the system.
Data is available for deleting indirect costs from the estimate. This may be
used if the wage rates are to be considered all-inclusive rates, and separate
calculation of indirect costs is unnecessary.
The wage rates for two general crafts are itemized separately. These are craft
code 98 (Helper) and craft code 99 (Foreman). These two crafts are accorded
special treatment because they appear in most crews, and their wage rates
and productivities are typically related to the crew in which they appear. Their
wage rates may be specified as either fixed rates or crew dependent rates.
Their productivities, however, are determined by the system and are a function
of the crew productivity.
The user may enter one or more craft wage rates. Omitted rates are calculated
by the system based upon a set of system default values as tabulated
elsewhere in the Icarus Reference. The ultimate value used by the system is
determined by:
•
The degree to which the user has provided craft rates
•
The user-specified value of the Escalation and User Base Indices for
Construction in the Indexing/Escalation Data.
For instance, if a user has not submitted any Workforce Data, then the values
for wage rates for all crafts are based upon the system Base Wage Rates,
subject to:
•
Elevation to the user base of construction (UBI/SBI)
•
Escalation (EI/UBI).
If, however, the user has specified one or more craft wage rates, those rates
are taken by the system as valued at the User Base Index and subject to
escalation.
Example 5:
To illustrate escalation, suppose the user entered a craft rate of 12.00 per hour
and construction indices of 1248 for escalation and 1200 for the base (see
Indexing/Escalation Data). The system considers the user rate at the user’s
base index for “ACCUM” reporting and for “SPREAD” reporting will figure an
escalated rate of 12.00 x (1248/1200) = 12.48.
It should be noted that productivity is expressed as a percentage value; that
is, 100 implies a base productivity. A value of 50 implies a less effective
workforce, thereby doubling the system-calculated base man-hours. A value of
150 implies a more effective work force, thereby obtaining man-hours at two
thirds (100/150) of the system-calculated base man-hours. For a more
detailed description of the base or norm productivity for each craft, refer to the
discussion of productivity provided later in this section.
Crew Mix Modifications
The system crew mixes may be modified using Crew Mix Data. This data
enables the transfer of man-hours from one craft to another. By manipulating
36-42
crafts in this manner, a project may be modelled as an open or a closed shop
or some variation of the two. All or a portion of the man-hours in one craft may
be transferred to one or more other crafts. Man-hours may be deleted from
the estimate by transferring them out of a craft and by not indicating a second
craft to which they are assigned. A useful example of this procedure is the
removal of crane operators from the estimate if the rental rates for cranes
include operators.
Man-hours are transferred between crafts by indicating “FROM” which craft the
man-hours are removed and “TO” which craft they are added. The man-hours
that will be transferred are only those initially assigned to the craft by the
system and not those previously assigned to the craft by the user through
other Crew Mix Data.
Crafts 98 and 99 (Helper and Foreman) may be assigned man-hours from any
other craft, but their man-hours may not be assigned to any other single craft.
If their man-hours are reassigned, they will be allotted to the principal crafts in
each crew. The principal crafts are indicated elsewhere in the Icarus
Reference. The reason for this special condition is that these two crafts are
composite crafts that appear in most crews, and to allow their assignment to
any single other craft would distort the consistency of many crews. For
example, if man-hours were transferred from Foreman to Pipefitters, then
Pipefitters would appear incorrectly in every crew which had contained
a Foreman.
If multiple workforces are used, each workforce may be structured differently
by providing the appropriate man-hour transfers. If a workforce is defined as
having wage rates and productivities at some percentage of a previously
defined workforce, it will also use the same crew mix modifications as that
workforce. This may be changed, however, by coding new crew mix
modifications for the second workforce.
Craft Names
The name of any system base craft may be replaced by entering the craft code
and the desired name. The system base craft codes and craft names are listed
elsewhere in the Icarus Reference. In addition, a new craft may be created by
specifying a name for one of the blank craft codes. If, however, a new craft is
created, it must be assigned a wage rate and productivity and it must be
assigned some man-hours from another craft. Only one set of craft names may
be defined per estimate (that is, craft names may not be changed from one
workforce to another). It is not, however, necessary for all crafts to be used by
all workforces.
Reports
Wage rates and productivity values, as adjusted, develop man-hours and
manpower costs, craft by craft. Craft man-hours and costs are reported
against tasks performed in various system reports and summarized for the
project in the Field Manpower Summary.
Productivity Concepts
This section is devoted to a discussion of:
36-43
•
How the system utilizes a user-specified productivity value
•
The variables affecting productivity and their numeric evaluation.
The user may enter an all-crafts productivity figure and specific craft
productivity. The all-crafts productivity value, set at 100% by the system in
the absence of a user entry, will be used to establish the productivity for any
and all user-omitted craft productivities. The all-crafts productivity will not be
applied in any manner to user-specified craft productivity
User-entered craft productivities should be considered as efficiencies, and
man-hours developed by the system to perform a specific task by that craft
will be adjusted accordingly.
Example 6:
Suppose at the system’s base, six hours of Craft A are required to set a vessel.
If the productivity of Craft A were entered as 50%, then the adjusted system
value would be (100/50) x 6 = 12 hours. Thus Craft A is 50% efficient
compared to the system’s base. Similarly, a craft productivity of 200% relative
to the system’s base will indicate doubly effective craftsmen and thus half the
base man-hours.
A time-proven and extremely useful method of quantifying a complex subject
such as field productivity is as follows:
•
Establish a standard set of key variables and base conditions for each
variable
•
Evaluate, for each variable, the deviations expected for the actual
conditions from the base conditions
•
Combine the identified individual deviations, thereby forming an overall
productivity relative to the base conditions.
The five key productivity variables (PV) and their associated system-base
definitions are:
PV1:
Source of Manpower Pool, sometimes identical to location of
construction site.
US Base - Houston/Gulf Coast, time period 1972-1973.
UK Base - Northwest UK, 1979.
JP Base - Japan.
Evaluation of deviation for other sources - area data sources.
PV2:
Size of Project, as measured by total direct and subcontract field manhours.
Base - Medium-size, 100,000 man-hours of field manpower.
Evaluation of deviation for other project sizes - change in productivity
vs man-hours shown in Figure W-1.
36-44
Figure W-1: Job Size Adjustment (PV2)
PV3:
Mode of Manpower; closed or open shop.
US Base - Closed shop.
UK Base - Site or national agreement.
JP Base - Closed shop.
ME Base - Site agreement.
Evaluation of deviation - determined by construction site location and local
conditions, effect of site/national manpower agreements for the particular
project.
PV4:
Length of Work Week:
Base - 40-hour work week.
Evaluation of deviation - automatically evaluated by system based upon
user work week input on general Workforce Data, specifically through
relationships shown in Figure W-2. The system value may be offset by
creating a value of PV4 sufficient to adjust the system value to the user’s
desired value.
36-45
Figure W-2: Productivity Versus Work Week (PV4) - First Shift
PV5:
All Other Effects, such as general economy, work to be performed, kind
of manpower, quality of supervision, job conditions, weather, and so on.
Base - Reasonably average conditions, all other productivity variables
at their base value. Evaluations of deviations - Table W-1 and the
following associated discussion for this productivity variable.
Table W- 1: Productivity Element Table (PV5)
Productivity Element
Low
50
36-46
Productivity (%)
Average
85
100
115
High
140
1
General Economy
Local business trend
Construction volume
Unemployment
Prosperous
Stimulated
High
Low
Normal
Normal
Normal
Normal
Hard times
Depressed
Low
High
2
Amount of work
Site complexity
Manual Operations
Mechanized operations
Extensive
Dense
Extensive
LImited
Average
Average
Average
Average
Limited
Sparse
Limited
Extensive
3
Field Manpower Pool
Training
Wages
Supply
Poor
Poor
Low
Scarce
Average
Average
Average
Normal
Good
Good
High
Surplus
Productivity Element
Low
Productivity (%)
Average
High
4
Field Manpower Supervision
Training
Wages
Supply
Poor
Poor
Low
Scarce
Average
Average
Average
Normal
Good
Good
High
Surplus
5
Job Conditions
Management
Materials and site
Required workmanship
Length of operation
Poor
Poor
Unfavorable
First Rate
Short
Average
Average
Average
Regular
Average
Good
Good
Favorable
Passable
Long
6
Weather
Precipitation
Cold
Heat
Bad
Much
Bitter
Oppressive
Fair
Some
Moderate
Moderate
Good
Occasional
Occasional
Occasional
7
Applicability
Condition
Maintenance and repairs
Poor
Poor
Poor
Slow
Normal
Normal
Fair
Average
Good
Good
Good
Quick
8
Delays
Job Flexibility
Equipment delivery
Expediting
Numerous
Poor
Slow
Poor
Some
Average
Normal
Average
Minimum
Good
Prompt
Good
The overall productivity per craft or for all crafts is developed from the product
of the individual deviations and final conversion to a percentage figure:
Overall Productivity = PV1 x PV2 x PV3 x PV4 x PV5
In the reference charts and tables mentioned, productivity variables are each
identified as a percentage deviation from the system base of 100% for
that variable.
In developing the overall productivity, each deviation should be reduced to a
fraction by division by 100, and the final resulting figure appropriately rounded
to a significant value and then converted to a percentage for entry in the data.
Productivity Variable: Other Effects - PV3
The Productivity Element Table (Table W-1) enables you to determine
productivity for proposed plant facilities over a wide range of working
conditions and local restrictions. Productivity deviation is classified into three
basic ranges: low, average and high. The “low” end of the range indicates an
efficiency of 50% to 85%; “average” is indicated by an efficiency of 85% to
115%; and the “high” end of the range is indicated by an efficiency of 115% to
140%. These percentages are based on the amount of work a typical
construction worker can be expected to perform under a given set of
conditions. Given ideal circumstances, a field crew may achieve an
approximation of 140% efficiency. In actual estimating, you should not count
on this high degree of productivity unless the operations in the project are
highly mechanized. In manual-operations such as bricklaying, pipe fitting, and
insulating, for example, the scheduling of high-range productivity may mean
36-47
that the contractor will have to push field crews for maximum production
during the entire course of the projects.
In general, the productivity represented by this class of variables is a function
of two major factors: the present national economy and the specific local
conditions under which the work is to be accomplished for the project. The first
major factor (present economy) directly affects the productivity of the
individual construction worker. In good times, when construction jobs are
plentiful and manpower is scarce, productivity usually decreases, resulting in
increasing field costs. In normal times, average productivity and costs are the
rules. During depressions, recessions or slumps in the economy, manpower
becomes plentiful and more productive; consequently, field costs decline. The
Productivity Element Table (Table W-1) has been assembled to reflect variables
of major impact.
The second major factor (local conditions) affecting productivity relates more
directly to the project. It consists of the many variables that influence
construction activity, such as the character of the job site, volume of work to
be performed, quantity of available manpower, and other such unusual
conditions as dense or sparse plot plans, etc. Each of these variables is listed
in the Productivity Element Table. You should review these variables, keeping
in mind both the existing and foreseeable conditions that will affect the
proposed construction project. At the same time, you must make an
evaluation of the contractor as a productive unit to determine potential
performance under a given set of circumstances. A reasonable approach to
obtain a composite value of Productivity Variable 5 (PV5) is the averaging of
the eight major categories of individual elements in Table W-1.
Example 7:
After studying a proposed project, a user arrived at the following values for
individual categories of productivity:
Item
Productivity
Deviation,%
Element Category
1
General economy
9
2
Amount of work
100
3
Manpower
75
4
Manpower supervision
100
5
Job conditions
110
6
Weather
90
7
Construction equipment
110
8
Delays
100
Total
765
The average value for productivity is the total divided by eight:
Productivity Variable (PV5) = 765/8 = 99.6%.
Example 8:
Consider Example 7 to be extended to a revamp. Suppose the revamp requires
twice the man-hours of a normal grassroots project. Then, a large revamp
project (assume a 90% Job Size Productivity, Figure W-1) would be figured at
a compounded effect: Productivity per Productivity Element Table x Job Size
Productivity x Revamp Productivity =.956 x.9 x.5 = 0.43 (43% productivity).
36-48
Example 9:
Should but a small portion of the project be subject to revamp, that portion
may be described as one or more Areas or Sub-areas. In this example, the
man-hours would be adjusted by 200% values for the appropriate accounts
using code of account indexing within the area. The workforce productivities
would, of course, be entered free of the revamp effect.
Work Item Concept
The work item concept, Figure W-3 relates manpower to materials installation
requirements. The user may recall the role of the Volumetric Model to generate
a bill of material types and quantities. The role of the Work Item Model is to
develop crew requirements to accomplish the task of installing each item in the
bill of materials. Thus the Work Item Model, when applied to a particular task
such as placing ribber (Figure W-4), must develop a crew mix and man-hours
for each craft.
Figure W-3: Typical Civil Tasks and Work Items
36-49
Adjustment for Craft Productivity
The system contains several hundred Work Item Models with base manpower
requirements established for the particular country base location. A userentered craft productivity would be used to adjust the base man-hours
developed by the Work Item Models.
Adjustment for the Effective Hour
In the Work Item Models, when man-hours are assigned to crafts,
consideration is made as to the reality of work spread over a day rather than
over a short time-measured duration. Thus system-base man-hours are actual
hours, based on a 42-minute hour, reflecting the time required to initiate the
complete task. Should the project be managed under a different working time,
the productivity should be adjusted as in Figure W-5.
36-50
Figure W-5: Productivity Versus Working Minutes Per Hour
Adjustments for Work Week
The duration of the actual work week and number of shifts to be employed
during construction may be defined in the Workforce Data. Should the user’s
schedule deviate from the 40-hour, 1-shift basis for Work Item Models, the
system makes an automatic adjustment to the Work Item-developed manhours for each craft by the relationship illustrated in Figure W-6.
Figure W-6: Job Duration Versus Work Week
36-51
Engineering
The project scope is analyzed by the system’s engineering model to determine
man-hours and costs for design engineering, procurement and construction
supervision. The system-calculated values for engineering may be adjusted by
using the Engineering Data. This data allows input modifications/adjustments
at two levels:
•
An entire phase of engineering
•
A particular discipline within a phase.
The system’s engineering model may be modified by specifying total manhours and cost or by specifying a proportional adjustment to systemcalculated man-hours.
The Engineering Drawings Data may be used to modify the Basic and Detail
Engineering phases by specifying adjustments to the number and type of
drawings produced. This data may also be used to add a lump sum of
engineering hours for special drawings or specific tasks, such as small scale
models, which are not provided by the system.
Definitions of the task and work products considered for each engineering
phase are presented in Table EN-1.
Prime Contractor Engineering
The system’s Prime Contractors engineering account includes four major
categories or phases:
•
Basic engineering
•
Detail engineering
•
Procurement
•
Home office construction services.
Field supervision and project start-up are affiliated with engineering activities
and are discussed later; these are, however, considered to be construction
overhead items and are reported as contributions to the system’s construction
overhead account.
Because of the turnkey nature of the Prime Contractor mode, the Engineering
Management and Construction Management phases are inappropriate, and
these phases are excluded from Prime Contractor estimates.
Contracts - Assignment of Engineering
By use of the Contracts Description and Scope Data, each phase of
engineering may be assigned to a different contract or to the owner. Moreover,
each phase may be split between multiple engineering contracts according to
unit area. In addition, the Contracts feature allows two optional phases of
supervision to be assigned:
36-52
•
Engineering Management
•
Engineering Workforce (EWF)
When contracts have been specified, the user may create multiple engineering
workforces (EWF). The system uses the concept of an Engineering Work Force
(EWF) in order to allow the user the flexibility of specifying different
adjustments (for example, hourly rates), for different engineering contractors.
Each contract can be cross-referenced to a particular EWF (see Contract
Description). An EWF is, in effect, a description of a work force resulting from a
combination of user-specified and system default values for hourly rates,
productivity, and indirect costs. Up to 9 EWF sets may be created. An EWF set
will not be used by the system unless it is referenced by a contract that has
been assigned an engineering scope of work.
It is not necessary to define multiple engineering workforces for the contracts
mode; however, if used, the EWF numbers must be referenced by all
engineering contracts.
The EWF serves no purpose for estimates in the Prime Contractor mode (since
only one work force is possible).
Phase Adjustments
The user may specify both the total man-hours and cost for an entire phase,
however, if one is specified, the other is also required. When these totals have
been specified for a phase, any subsidiary data for that phase will not be used
by the system.
A percentage adjustment to an entire phase should be considered as an
adjustment to the scope of the estimate, rather than a productivity
adjustment. The change will be reflected in the quantity of work performed, for
example, the drawing count and other tasks listed in Table EN-1, with a
corresponding change in man-hours.
An adjustment by phase is convenient way to allow for project complexity, (see
Table EN-2), but an adjustment by discipline, which does not affect the
drawing count, may be preferable.
The user may set the appropriate profile for payroll burdens, indirects, and
expenses. If contracts are specified, this information could also be provided as
part of the Contract Description.
Only one Engineering by Phase set of data is used per phase and EWF
combination. If global (that is, phase = *) Engineering by Phase Data are
used, however, additional Engineering by Phase data may be subsequently
added to adjust individual phases separately.
Discipline Adjustments
Adjustments by discipline will not affect the number of drawings in the
estimate and should appropriately be considered as productivity or
complexity adjustments.
The user may combine phase and discipline percentage adjustments, thereby
changing both the number of drawings and the man-hours. In this case, the
overall effect is a compounding of the adjustments, since new productivity is
calculated based on the new scope of work.
36-53
Engineering Reports
If the Engineering report option is selected in the Project Title Data, detailed
reports will be provided for each phase calculated. If a total cost is specified for
any phase, that total will appear on a summary report, and the detailed report
normally prepared for that phase will not be provided.
Table EN-1: Engineering Accounts - Tasks and Work Products
BASIC ENGINEERING: Includes engineering and drafting for the following items:
• Project and Process Scope Definition
• Process Flow Diagram
• Heat and Material Bal

Icarus Reference

Transcription

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