icarus reference guide

Aspen IcarusReference Guide

Icarus Evaluation Engine (IEE) V7.2

Version V7.2July 2010

Generation No: 13 (G13)

Chapters with “G13” in the footer are new for this edition. Chapter generation numbers are also indicated in the Table of Contents.

Copyright (c) 2001-2010 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 02141-2201USAPhone: 781-221-6400Toll Free: (888) 996-7100Website http://www.aspentech.com

http://www.aspentech.com

PrefaceAspen 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 SystemsIcarus 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 DocumentThis 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 DocumentThis 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 UsersLike 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 DocumentationIn addition to this reference manual, AspenTech provides the following documentation for Aspen Economic Evaluation V7.0.

• Aspen Engineering V7.1 Known Issues

• Aspen Engineering V7.1 What’s New

• Aspen Engineering V7.1 Installation Guide

• Aspen IPS V7.1 Installation Guide

• Aspen IPS V7.1 User Guide

• Aspen Process Economic Analyzer V7.1 User Guide

• Aspen In-Plant Cost Estimator V7.1 User Guide

• Aspen Capital Cost Estimator V7.1 User Guide

• Icarus Technology Application Programming Interface

• Manpower Productivity Expert User Guide

iv 2

Online Technical Support CenterAspenTech customers with a valid license and software maintenance agreement can register to access the Online Technical Support Center at:

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You use the Online Technical Support Center to:

• Access current product documentation.

• Search for technical tips, solutions, and frequently asked questions (FAQs).

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• Submit and track technical issues.

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• 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-mailCustomer 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:

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Support Centers Hours of Operation

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2 v

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiThe Technology Behind

Icarus Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiScope of Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivHow to Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivA Note to Icarus System Users . . . . . . . . . . . . . . . . . . . . . . . . . . ivRelated Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivOnline Technical Support Center . . . . . . . . . . . . . . . . . . . . . . . . . . vPhone and E-mail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Introduction to Process Equipment (G6) 5Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Process Equipment Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . 6List of Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Agitators (G6) 1Agitators (AG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Agitated Tanks (AT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Blenders (BL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Kneaders (K). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Mixers (MX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Compressors (G6) 1Air Compressors (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Gas Compressors (GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Fans, Blowers (FN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Drivers (G11) 1Electrical Motors (MOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Turbines (TUR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Heat Transfer (G10) 1Heat Exchangers (HE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Reboilers (RB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Furnaces, Process Heaters (FU) . . . . . . . . . . . . . . . . . . . . . . . . . . 39Icarus Supported TEMA Types . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Packing, Linings (G6) 1Introduction to Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Introduction to Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Packing, Linings (PAK, LIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Suggested Lining Difficulty Adjustments . . . . . . . . . . . . . . . . . . . . 9

Contents (G11)

Contents (G11) iii

Pumps (G10) 1Centrifugal Pumps (CP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Gear Pumps (GP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Piston, Other Positive Displacement Pumps (P) . . . . . . . . . . . . . . . 21Pump Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Towers, Columns (G6) 1Introduction to Towers and Columns . . . . . . . . . . . . . . . . . . . . . . 2Double Diameter Towers (DDT) . . . . . . . . . . . . . . . . . . . . . . . . . . 7Single Diameter Towers (TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Vacuum Systems (G6) 1Condensers (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ejectors (EJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Vacuum Pumps (VP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Vessels (G10) 1Horizontal Tanks (HT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Vertical Tanks (VT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Crushers, Mills and Stock Treatment (G6) 1Crushers (CR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Flakers (FL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Mills (M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Stock Treatments (ST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Drying Systems (G6) 1Crystallizers (CRY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Evaporators (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Wiped Film Evaporators (WFE) . . . . . . . . . . . . . . . . . . . . . . . . . . 7Air Dryers (AD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Dryers (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Drum Dryers (DD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Rotary Dryers (RD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Tray Drying Systems (TDS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Solids Conveying (G10) 1Conveyors (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Cranes (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Elevators, Lifts (EL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Feeders (FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Hoists (HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Scales (S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Separation Equipment (G7) 1Centrifuges (CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Dust Collectors (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Filters (F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Separation Equipment (SE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Thickeners (T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

iv Contents (G11)

Screens (VS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Utility Service Systems (G6) 1Cooling Towers (CTW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Steam Boilers (STB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Heating Units (HU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Refrigeration Units (RU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Electrical Generators (EG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Water Treatment Systems (WTS) . . . . . . . . . . . . . . . . . . . . . . . . 8

Flares and Stacks (G6) 1Flares (FLR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Stacks (STK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Introduction to Plant Bulks (G6) 1Introduction to Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2List of Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Piping (G10) 1Piping Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Pipe Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Standard Equations for Pipe Diameter (Old) . . . . . . . . . . . . . . . . . 44Standard Equations for Pipe Diameter (New). . . . . . . . . . . . . . . . . 46Utility Piping Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Utility Station Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Default Piping Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Pipe Materials - Ferrous Materials . . . . . . . . . . . . . . . . . . . . . . . . 53Pipe Materials - Non-Ferrous Materials . . . . . . . . . . . . . . . . . . . . . 56Plastic and Resin Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Lined Steel Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Icarus’ Pipe Fabrication, Erection and Testing Procedures . . . . . . . . 64Valve and Fitting Options for Installation Bulk Piping . . . . . . . . . . . 66Valve Trim Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Civil (G8) 1Civil Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Foundation Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Typical Structure Live Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Soil Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Specifying Seismic Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15How Icarus Calculates Wind Load and Seismic Shear . . . . . . . . . . . 15Example of Equipment Foundation Design. . . . . . . . . . . . . . . . . . . 16Example of Pile Foundation for an Equipment . . . . . . . . . . . . . . . . 17

Steel (G6) 1Steel Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Instrumentation (G10) 1Instrumentation Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Sensor Loop Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Contents (G11) v

Remote Control Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Transmitter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Electrical (G13) 1Electrical Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Schematic of Transmission Line . . . . . . . . . . . . . . . . . . . . . . . . . . 17Substation Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Electrical & Control Hook-Ups for Electric Motors . . . . . . . . . . . . . . 19Power Distribution Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Wire Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23UK, EU, and JP Country Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Electrical Class/Division . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24International Electrical Code (IEC) . . . . . . . . . . . . . . . . . . . . . . . . 25

Insulation and Fireproofing (G8) 1Insulation Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Insulation Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Fireproofing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Insulation Schedules - System Default Tables . . . . . . . . . . . . . . . . 5Customizing Insulation Specifications . . . . . . . . . . . . . . . . . . . . . . 15

Paint (G6) 1Introduction to Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Paint Plant Bulks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2How Icarus Systems Paint Equipment. . . . . . . . . . . . . . . . . . . . . . 3

Site Development (G6) 1Introduction to Site Development . . . . . . . . . . . . . . . . . . . . . . . . 2Demolition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Drainage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Earthwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Fencing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Landscaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Roads - Slabs - Paving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Piling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Railroads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Buildings (G6) 1Introduction to Buildings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Adding a Building. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Building Types and Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Default floor Heights/Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Building Construction Range Adjustment . . . . . . . . . . . . . . . . . . . 6Calculating Building Costs and Labor . . . . . . . . . . . . . . . . . . . . . . 7

Quoted Equipment and Libraries (G6) 1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Quoted Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2User Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

vi Contents (G11)

Material Selections (G10) 1ASME Design Code - Plate Materials . . . . . . . . . . . . . . . . . . . . . . . 3ASME Design Code - Clad Plate Materials . . . . . . . . . . . . . . . . . . . 10ASME Design Code - Tube Materials . . . . . . . . . . . . . . . . . . . . . . . 11ASME Non-Ferrous Tube Materials . . . . . . . . . . . . . . . . . . . . . . . . 14BS Design Code - Plate Materials . . . . . . . . . . . . . . . . . . . . . . . . . 15BS Ferrous Plate Materials - Carbon Steel . . . . . . . . . . . . . . . . . 15BS Design Code - Clad Plate Materials . . . . . . . . . . . . . . . . . . . . . 22BS Design Code - Tube Materials . . . . . . . . . . . . . . . . . . . . . . . . . 23JIS Design Code - Plate Materials. . . . . . . . . . . . . . . . . . . . . . . . . 27JIS Design Code - Tube Materials. . . . . . . . . . . . . . . . . . . . . . . . . 35DIN Design Code - Plate Materials . . . . . . . . . . . . . . . . . . . . . . . . 39DIN Design Code - Tube Materials . . . . . . . . . . . . . . . . . . . . . . . . 47EN 13445 Design Code - Plate Materials . . . . . . . . . . . . . . . . . . . . 51EN 13445 Design Code - Tube Materials . . . . . . . . . . . . . . . . . . . . 56Lining Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Casting Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Packing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Units of Measure (G6) 1Introduction to Units of Measure . . . . . . . . . . . . . . . . . . . . . . . . . 2Units of Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Project Specifications and their Use of Units of Measure . . . . . . . . . 8

Field Manpower Titles and Wage Rates (G13) 1US Country Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2UK Country Base *** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4JP Country Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6EU Country Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Engineering (G13) 1Design and Construction Engineering Disciplines and Wage Rates . . 2Engineering Expenses and Indirects (Aspen Capital Cost Estimator and

Aspen Process Economic Analyzer ) . . . . . . . . . . . . . . . . . . . . . . 12Standard Engineering Drawing Types (Aspen Capital Cost Estimator and

Aspen Process Economic Analyzer) . . . . . . . . . . . . . . . . . . . . . . 17

Construction Equipment(G4) 1Introduction to Construction Equipment Rental . . . . . . . . . . . . . . . 2Construction Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Base Indices (G13) 1Base Indices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Code Accounts (G10) 1Introduction to Code Accounts. . . . . . . . . . . . . . . . . . . . . . . . . . . 2Indirect Codes and Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 6Direct Codes and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Contents (G11) vii

Database Relations (G10) 1Sequence Numbers of Attributes in Relations . . . . . . . . . . . . . . . . 3Relationship of Database Relations. . . . . . . . . . . . . . . . . . . . . . . . 7DETAILS Relation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DESIGN Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10REMARKS Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10PROJDATA Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11NEWCOA Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11CERATE Relation (F-Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11EQRENT Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12CRWSCH Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12CSTCTRL Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13CUSSPC Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13REPGRP Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14CNTRCT Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14COMPONENT Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14INDIRECTS Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15K (CUSSPC)-TABLE Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16R-TABLE Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16QSUM Relations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16STORED REPORTS Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20STORED QUERIES Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22CERATE Relation (F-Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23T-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25U-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25V-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27W-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27X-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Y-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Z-Table Relation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Aspen Capital Cost Estimator Indirect Codes and Descriptions. . . . . 29Attribute Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Icarus Technology (G10) 1Introduction to Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Project Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Equipment Fabricate/Ship Items . . . . . . . . . . . . . . . . . . . . . . . . . 10Barchart Report Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Notes for Defining the Standard Control Center . . . . . . . . . . . . . . . 22Notes for Defining the PLC Control Center. . . . . . . . . . . . . . . . . . . 26Overview of System Input Specifications for Power Distribution. . . . 27Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Usage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Reporting of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Project Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

viii Contents (G11)

Cost Reporting: Currency and System Base Indices . . . . . . . . . . . . 39Construction Overhead - Prime Contractor Basis . . . . . . . . . . . . . . 61Contracts: Description/Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Reserved (G7) 1

Glossary (G5) 1

Contents (G11) ix

x Contents (G11)

This chapter contains information on the following topics:

Introduction

Process Equipment Categories

List of Process Equipment

1 Introduction to Process Equipment (G6)

1 Introduction to Process Equipment (G6) 1-5

IntroductionChapters 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 CategoriesIcarus’ process equipment is divided into the following categories. Each category is assigned an item symbol for identification purposes.

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

1-6 1 Introduction to Process Equipment (G6)

List of Process EquipmentThe 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)

Agitated Tanks (AT)

GC Gas Compressor WFE Wiped Film Evaporator

GP Gear Pump WTS Water Treatment System

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


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




Blenders (BL)

Kneaders (K)

Mixers (MX)

Chapter 3: Compressors

Air Compressors (AC)


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


STATIONARY Stationary upright double-arm kneader

TILTING Tilting double-arm kneader

VAC TILTING Vacuum tilting double-arm kneader


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


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)

Fans, Blowers (FN)

Chapter 4: Drivers

Electrical Motors (MOT)

Turbines (TUR)

Chapter 5: Heat Transfer

Heat Exchangers (HE)


CENTRIF Centrifugal compressor - horizontal

CENTRIF IG Centrifugal - integrated gear

RECIP GAS Reciprocating compressor - integral gas engine

RECIP MOTR Reciprocating compressor


PROPELLER Propeller fan

VANEAXIAL Vaneaxial fan

CENTRIF Centrifugal fan

ROT BLOWER General purpose blower

CENT TURBO Heavy duty, low noise blower


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


GAS Gas turbine with combustion chamber

CONDENSING Steam turbine driver, condensing type

NON COND Steam turbine driver, non-condensing


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


Reboilers (RB)

Furnaces, Project Heaters (FU)

Chapter 6: Packing, Linings

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


KETTLE Kettle type reboiler with floating head

U TUBE U-tube kettle type reboiler

THERMOSIPH Thermosiphon type reboiler


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



Packing, Linings (PAK, LIN)

Chapter 7: Pumps

Centrifugal Pumps (CP)

Gear Pumps (GP)

Piston, Other Positive Displacement Pumps (P)


PACKING Packing, variety of vessel packings

ACID BRICK Acid brick lining

MONOLITHIC Castable, refractory or gunned mix

OTHER Lining - other than acid brick, monolithic


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 Standard external gear rotary pump

CANNED RTR Canned rotary gear pump

MECH SEAL Mechanical seal gear pump


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


Chapter 8: Towers, Columns

Double Diameter Towers (DDT)

Single Diameter Towers (TW)

Chapter 9: Vacuum Systems

Condensers (C)

Ejectors (EJ)

RECIP MOTR Reciprocating positive displacement plunger pump

HD STOCK High density stock pump

ROTARYLOBE Sanitary rotary lobe pump

AIR DIAPH Sanitary air diaphragm pump


PACKED Packed double-diameter tower

TRAYED Trayed double-diameter tower


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


BAROMETRIC Barometric condenser


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)

Chapter 10: Vessels

Horizontal Tanks (HT)

Vertical Tanks (VT)

Chapter 11: Crushers, Mills and Stock Treatment


WATER SEALS Water-sealed vacuum pump

MECHANICA Mechanical oil-sealed vacuum pump

MECH BOOST Mechanical booster vacuum pump


MULTI WALL Multi-wall horizontal drum

HORIZ DRUM Horizontal drum

JACKETED Jacketed horizontal drum

SAN TANK Sanitary horizontal drum


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


Crushers (CR)

Flakers (FL)

Mills (M)

Stock Treatment (ST)

Chapter 12: Drying Systems


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


DRUM Rotary drum flaker


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


REFINER Double disk refiner

DEFLAKE DK Plate or tackle type deflaker

DEFLAKE CN Conical type deflaker


Crystallizers (CRY)

Evaporators (E)

Wiped Film Evaporators (WFE)

Air Dryers (AD)

Dryers (D)

Drum Dryers (DD)


BATCH VAC Batch vacuum crystallizer

MECHANICAL Mechanical scraped-surface crystallizer

OSLO Oslo growth type crystallizer


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


THIN FILM Agitated thin film evaporator

WFE SYSTEM Agitated thin film evaporator - package system


AIR DRYER Dual tower desiccant air dryer


ATMOS TRAY Atmospheric tray batch dryer

VAC TRAY Vacuum tray batch dryer

PAN Agitated pan batch dryer

SPRAY Continuous spray drying system


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


Rotary Dryers (RD)

Tray Drying Systems (TDS)

Chapter 13: Solids Conveying

Conveyors (CO)

Cranes (CE)

Elevators, Lifts (EL)


DIRECT Direct rotary dryer

INDIRECT Indirect rotary dryer

JAC VACUUM Jacketed rotary vacuum dryer

VACUUM Conical rotary vacuum dryer


ATM SYSTEM Atmospheric tray dryer

VACUUM Vacuum tray dryer

TURBO Turbo tray drying system

VAC SYSTEM Vacuum tray dryer with condenser


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


BRIDGE CRN Traveling bridge crane

HOIST Hoist with track beam


FREIGHT Freight elevator

PASSENGER Passenger elevator


Feeders (FE)

Hoists (HO)

Scales (S)

Chapter 14: Separation Equipment

Centrifuges (CT)


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


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


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


ATM SUSPEN Atmospheric suspended basket centrifuge

BATCH AUTO Auto batch filtering centrifuge

BATCH BOTM Batch bottom - suspended centrifuge


Dust Collectors (DC)

Filters (F)

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


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


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


Separation Equipment (SE)

Thickeners (T)

Screens (VS)

Chapter 15: Utility Service Systems

Cooling Towers (CTW)

SAN STEAM Culinary (sterile) steam filter

SAN STRAIN Sanitary pipe strainer


WATER CYCL Water-only cyclone - mineral separation

OIL WATER Oil-water separator - API type

PULP STOCK Pulp stock centrifugal cleaner


THICKENER Thickener/clarifier


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


COOLING Cooling tower, less pumps, field assembly

COOLING WP Cooling tower, complete, field assembly

Item Description

PACKAGED Packaged cooling tower, factory assembly


Steam Boilers (STB)

Heating Units (HU)

Refrigeration Units (RU)

Electrical Generators (EG)

Water Treatment Systems (WTS)

Chapter 16: Flares and Stacks

Flares (FLR)


BOILER Packaged boiler unit

STM BOILER Field erected boiler unit


CYLINDER Process heater type dowtherm unit


CENT COMPR Centrifugal compression refrigeration unit

MECHANICAL Mechanical compression refrigeration unit


PORTABLE Portable electrical generator - diesel

TURBO GEN Electrical generator - steam turbine drive


DEMINERAL Two stage ion exchange water treatment

SOFTENING Hot lime, zeolite water treatment system

AERATOR Surface aerator


DERRICK Derrick-supported flare stack

GUYED Guyed flare stack

SELF SUPP Self-supported flare stack

HORIZONTAL Horizontal ground flare


Stacks (STK)

THRM OX LC Recuperative thermal oxidizer

STORAGE Vapor control flare for storage/loading


STACK Stack without flare tip



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 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.

Material: *CS*, SS304, SS316, MONEL, RUBCV Driver Power: 0.75 - 3 HP [0.75 - 2.22 KW]

DIRECT

Portable, clamp-on, gear drive with explosion-proof motor. Typically used to keep solids in suspension, medium viscosity blending and dissolving.

Material:*CS*, SS304, SS316, MONEL, RUBCV Driver Power: 0.25 - 5 HP; [0.75 - 3 KW]

GEAR DRIVE

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.

Material: *CS*, SS304, SS316, MONEL, RUBCVImpeller 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 driveImpeller type: *MP3B5*

MECH SEAL

Fixed mount, top-entering, gear drive, anchor, stuffing box, explosion-proof motor. Typically used for low speed mixing on closed tanks.

Material: *CS*, SS304, SS316, MONEL, RUBCV Driver power: 0.75 - 5 HP [0.75 - 3 KW]

ANCHOR

Portable propeller mixer with motor to 7.5 HP [5.5 KW].

Material: *CS*, SSDriver power: 0.33 - 7.5 HP [0.75 - 5.5 KW]

PORT PROP

Fixed propeller mixer with motor and gear drive to 100 HP [75 KW].Includes motor, gear drive, shaft and impeller.

Material: *CS*, SSDriver power: 2 - 100 HP [1.5 - 75 KW]

FIXED PROP



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.

Material: *CS*, SS403, SS316, SS321, SS347, 304L, 316L, NI, INCNL, MONEL, HAST, TIDriver type: DRCT - Direct drive, no speed reduction BELT- Belt driven speed reduction VFD - Variable frequency drive GEAR - Gear drive speed reductionLiquid volume: Enter Capacity or Impeller DiameterImpeller diameter: Enter Capacity or Impeller DiameterAgitator orientation: Default: *VTOP* VTOP - Top entry agitator for open tanks VTCL - Top entry agitator for closed tanks SIDE - Side entry agitatorDriver 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

PULP STOCK

Sanitary reversing anchor agitator

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: MIN: 24 INCHES [610 MM], MAX: 72 INCHES [1,825 MM]

ANCHOR REV



Description Type

Sanitary counter-rotating agitator

Two-piece agitator with center armed shaft and outer frame parallel wall rotating opposite each other. 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]. Required to enter capacity.Agitator diameter: MIN: 32 INCHES [813 MM], MAX: 72 INCHES [1,825 MM]Agitator height: MIN: 24 INCHES [610 MM], MAX: 72 INCHES [1,825 MM]

COUNT ROT

Sanitary highshear homogenizing agitator

Agitator’s perforated disk rotates to create shear for homogenizing immiscible liquids. Used in the sanitary industry.If you require a foundation for this item, it must be added.Liquid volume: MIN: 3 GALLONS [0.012 M3], 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 requiredDriver 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 -

HIGH SHEAR



Description Type

HIGH SHEAR - continued

Impeller type:*INTGH*- Integral headRSDIH- Rotator stator w/ slotted disintegr. headRSSQR- Rotator stator w/ high shear screen RSGEN- Rotator stator w/ GP disintegrating head

Sanitary fixed propeller/turbine mixer.

Stainless steel material for total washdown capability and no risk of open container contamination from paint chips. If you require a foundation for this item, it must be 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 driveImpeller type: *PROP*- propeller type impeller (not available above 3 HP [2.22 KW]) TURB- turbine type impellerNo. of impellers: *1*, MIN: 1, MAX: 2Angle riser: *NO*- Angle riser not required YES- Angle riser is requiredMounting type: *UNSLF*- Unsealed flange mounting SLF- Sealed flange mounting FLWB- Flange with bridge

SAN FIXED



Description Type

Sanitary port. propeller/turbine mixer 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.If you require a foundation for this item, it must be 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

SAN PORT


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

Includes top entering impeller and geared motor-reducer, tank designed for 15 PSIG [100 KPA].Application: Defines vessel function and related pipe/instrum. model. <blank>- Standard continuous process BATCH- Batch processShell 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: Enter either Capacity or Diameter and Height.Vessel Tangent to Tangent Height: Enter either Capacity or Diameter and Height.


MIXER


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: If pressure and vacuum entered, design is for worst 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 jacketJacket 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 - Continued on next page -



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 SteelDriver Type: Default: *STD* STD - Standard motor VFD - Variable frequency driveCladding 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 requiredCladding 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]




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 impeller and geared motor reducer, supported by structural steel spanning tank top, tank without head.

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: Enter either capacity or diameter and height.Vessel Tangent to Tangent Height: Enter either capacity or diameter and height.Design Temperature: Default: *68* DEG F [*20* DEG C]Operating Temperature: Default: Design Temperature.Jacket Design Gauge Pressure: Jacket pressure or thickness required to obtain jacket. Default: no jacket.Jacket Type: Default: *FULL* FULL- Full jacket PIPE- Half-pipe jacket


OPEN TOP



Description Type

OPEN TOP - continued

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 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 SteelDriver Type: Default: *STD* STD- Standard Motor VFD- Variable frequency driveCladding Material: Default *none*.Skirt or Leg Height: Enter 0.0 if hung in OPEN structure, legs provides if capacity < 10,000 GAL. [37 M3].



Description Type

OPEN TOP - continued

Manhole Diameter: Max: 48 INCHES [1200 MM].Base Material Thickness: Base material thickness including corrosion allowance.Corrosion Allowance: 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 requiredCladding 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].Fluid Density: Default: *62.40* PCF.Fluid Viscosity: Default: *1.00* CPOISE.Impeller Type: See Impellor Types table.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 diameters as ID or OD; Default: See Area Design Basis. OD- Outside diameter ID- Inside diameter



Description Type

Pressure/vacuum vessel, jacketed.

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 processBATCH- Batch processShell 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: Enter either Capacity or Diameter and Height.Vessel Tangent to Tangent Height: Enter either Capacity or Diameter and Height.Design Gauge Pressure: Default: *15* PSIG [*100* KPA] If pressure and vacuum entered, design is for worst case. Default: Pressure.Vacuum Design Gauge 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].Operating Temperature: Default: Design temperature.Jacket Design Gauge Pressure: *90* PSIG [*620* KPA]Jacket Type: Default: *FULL* FULL- Full jacket PIPE- Half-pipe jacket


REACTOR



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 - 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 SteelDriver Type: Default: *STD* STD - Standard motor VFD - Variable frequency driveCladding 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].




Description Type

REACTOR - continued

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 requiredCladding 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]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



Description Type

Pulpers are used for pulping the waste generated by mill operation or in a paper recycling process. Hence 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: *BATCH* BATCH - Batch pulper CONT- Continuous pulperTank or Vat Material: CS, SS304, *SS316*, SS321, SS347, 304L, 316L, NI, INCNL, MONEL, HAST, TIConfiguration: Default: *RECT* CYLIN- Cylindrical tank RECT- Rectangular tankHydraulic 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


MACH PULPOFF MACH


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 GEAR - Gear drive speed reductionDesign Temperature: *68.0* DEG F [*20.0* DEG C]Seal for Shaft: Default: *PACK* PACK - Packing MECH - Mechanical sealCorrosion Allowance: For CS alloys, the default is 0.125 INCHES [3 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: *10.0* FEET [*3.00* M]Number of Manholes: Default: *1*.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]. Default: *18* INCHES [*450* MM]

Application Symbol: Default: *BATCH* BATCH - Batch pulper CONT - Continuous pulperTank or Vat Material: CS, SS304, *SS316*, SS321, SS347, 304L, S16L, NI, INCNL, MONEL, HAST, TI.Configuration: Default: *CYLIN* CYLIN - Cylindrical tank RECT - Rectangular tankHydraulic 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.


OFF MACH



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*.Consistency Air Dried: Max: 18; Default: *4.0*.Impeller Type: Default: *EXTD*.<blank> - Standard rotor shaft lengthEXTD - Extended rotor shaft lengthImpeller Material: CS, SS304, *SS316*, SS321, SS347, 304L, S16L, NI, INCNL, MONEL, HAST, TIDriver Type: Default: *GEAR* BELT - Belt driven speed reduction GEAR - Gear drive speed reductionDesign Temperature: Default: *68.0* DEG F [*20.0* DEG C].Seal for Shaft: Default: *PACK*. PACK - Packing MECH - Mechanical sealCorrosion Allowance: 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 function of vessel diameter and height with a maximum diameter of 48 INCHES [1,200 MM]. Default: *18* INCHES [*450* MM].



Description Type

Conditioning cell for floatation machine.

Material:

Default: *CS*Cell Volume: 10.0 - 1,500.0 CF [0.3 - 40 M3]

COND CELL

Floatation machine, minerals separation, multi-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*

FLOAT CELL


Description of Agitated Tanks1 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

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 See Chapter 29: Units of Measure

N rotational speed of impeller

P power to shaft of impeller

PN Power number

RN Reynolds number

FD fluid density

FV fluid viscosity


Impeller Types - General Range of Basic Data**

Impeller Reynolds Number Baffles

No.Type Symbol Type D/d L/d E/d

Low - High No. B/D Ref

1 T6FB Turbine with six flat blades. B=0.25d; Blade Height = 0.2d

3 2.7-3.9 0.75-1.3 1-106 4 0.17 1

2 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 curved blades. Blade sizes same as No.1

3 2.7-3.9 0.75-1.3 1.8-106 4 0.10 1

6 T6AB Turbine with six arrowhead blades. Blade size same as No.1

3 2.7-3.9 0.75-1.3 3-106 4 0.10 1

7 STDR Shrouded turbine with six blades. 20 blade deflector ring.

2.4 0.74 0.9 20,000-90,000

0 - 2

8 STDR2 Similar to No.7, but not identical.

3 2.7-3.9 0.75-1.3 2.5-106 0 - 1

9 ST Same as No.8, but no deflector ring.

3 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 15-60,000

- - 3


Impeller Types - General Range of Basic Data** - continued

* 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.

Impeller Reynolds Number Baffles

No.Type Symbol Type D/d L/d E/d

Low - High No. B/D Ref

12 AT4B45 Axial turbine with four blades at a 45 degree angle. See No. 11

5.2 5.2 0.87 600-40,000

0 - 3

13 P4B Paddle with four blades.

3 3 0.50 200 - 70,000

0 - 3

14 P2B3 Paddle with two blades. See No.13.

3 2.7-3.9 0.70-1.3 2-106 4 0.10 1

15 MP3B2 Marine propeller with three blades. Pitch-2d; a=1.7; b=18.

3.3 2.7-3.9 0.75-1.3 2.5-106 0 - 1

16 MP3B5 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

17* 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 1.0 300-500,000

0 - 4

21 HRA Helical ribbon. Ribbon width=d/8.5;helical screw=D/30.

1.05 1.5 - 0.7-23 0 - 5


Impeller Materials

Impeller Type References

If Component Impeller Material

CLAD Match cladding

GLSCS SS316 blades/shaft

Other Match steel

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 widthD - Tank diameterd - Impeller diameterE - Impeller elevation above tank bottom.H - Tangent-to-tangent height of tank.L - Liquid level in tank.

Motor/Reducer

12 INCH Min.

H L

E

B

d

D


Blenders (BL)Rotary, batch, dry or semi-dry solids, motor and speed reducer.

Description Type

Rotary drum.

For batch blending of dry or semi-dry solids. Includes motor and drive.

Material: *CS*, SSBlender 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

BLENDER

Rotary double-cone.

For batch blending of dry solids. Includes motor and drive.

Material: *CS*, SS316Blender Volume: 5 - 350 CF [0.02 - 9 M3]Driver Speed: 30 x Hz RPM

Material: GSLCSBlender Volume: 2 - 165 CF [0.06 - 2.5 M3]Driver Speed: 30 x Hz RPM

.ROTARY

Sanitary kettle blender without agitator.

Used for “gentle” blending or folding of viscous mixtures. Add agitator separately.

If you require a foundation for this item, it must be added.

Liquid Volume: MIN: 50 GALLONS [0.19 M3], MAX: 600 GALLONS [0.19 M3]


KETTLE


Blenders (BL) - continued

Description Type

KETTLE - continued

Operating Temperature:*68 DEG F [20 DEG C]Cover Type: *LFTHG*- Lift-off or hinged cover NONE- No cover requiredLift off cover to 80 GAL [0.3 M3], else hinged cover.Jacket option: *NO*- Jacket not required YES- Jacket is requiredMounting type: *RIM*- Rim mounting LEGS- Leg type mounting

Sanitary rotary bowl blender.

Consists of a stainless steel drum with motor drive mounted on a frame. Used for wet or dry mixtures.


Material:

SS304, *SS316*

Liquid Volume:

MIN: 25 GALLONS [0.1 M3],

MAX: 160 GALLONS [0.6 M3]

Mounting type:

*FIXD*- Fixed type blender PORT- Portable type blender on casters

ROTARY-BOWL


Blenders (BL) - continued

Description Type

Sanitary, multi-shell, staggered blender

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, solids-liquids 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.


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 blendingSOL-LIQ- Solids-liquids blendingDriver type:*WVRDC*- Washdown, VFD rated, direct drive, CSWVCDC- Washdown, VFD controlled, direct drive, CSProduct 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].*

MSHELSTAG


Kneaders (K)Jacket, motor, motor reducer, cover, nozzles and agitator.

Description Type

Stationary, upright double-arm.

Material: *CS*, SS304, SS316, MONELLiquid Volume: 100 - 750 GALLONS [0.4 to 2.8 M3]

STATIONARY

Tilting, double-arm.


TILTING

Vacuum, tilting, double-arm.


VAC TILTNG


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.

Material: *CS*Driver power: 5 - 40 HP [4 - 30 KW]Driver speed: Max: 60 x HZ; Default: *30 x HZ*

EXTRUDER

Extruder muller type with open motor.

Material: *CS*Driver Power: 3 - 75 HP [2.22 - 55 KW]Driver Speed: Max: 60 x HZ; Default: *30 x HZ*

MULLER EXT

Pan includes motor and drive.

Material: *CS*Mixer Volume: 4 - 40 CF [0.2 - 1.1 M3]Driver speed: Max: 60 x HZ; Default: *30 x HZ*

PAN

Portable propeller mixer with motor to 7.5 HP [5.5 KW].Includes motor driver.

Material: *CS*, SSDriver power: 0.33 - 7.5 HP [0.75 - 5.5 KW]

PORT PROP

Fixed propeller mixer with motor and gear drive to 100 HP [75 KW].

This item is a top entering mixer including a gear drive, TEFC motor, shaft and impeller.

Material:

*CS*, SSDriver power: 2 - 100 HP [1.5 - 75 KW]

FIXED PROP


Mixers (MX) - continued

Description Type

Sigma double-arm non-vacuum mixer with motor and drive.

Material: *CS*Driver power: 2 - 100 HP [2.22 - 6.0 KW]Mixer Volume: 1 - 70 CF [0.05 - 1.9 M3]Driver speed: Max: 60 x HZ; Default: *30 x HZ*

SIGMA

Spiral ribbon includes motor and drive.

Material: *CS*Driver power: 5 - 50 HP [4 - 37.5 KW]Mixer Volume: 10 - 395 CF [0.3 - 11 M3]Driver speed: Max: 60 x HZ; Default: *30 x HZ*

SPIRAL RIB

Static mixer used for instantaneous mixing of two fluid streams.

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]


STATIC



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 100Enter 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]



Description Type

Two roll includes motor and drive.

Material: *CS*Driver power: 50 - 300 HP [37.5 - 224 KW]Driver speed: Max: 60 x HZ; Default: *30 x HZ*

TWO ROLL

Sanitary high-speed Norman-type mixerFor 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.


Material: SS304, *SS316*Liquid Volume: MIN: 50 GALLONS [0.19 M3], MAX: 300 GALLONS [1.13 M3]Impeller type: FRZN- Frozen food mixing *NFRZ*- Non-frozen food mixingDriver type: *WXXBC*- Washdown, belt drive, CS WVRBC- Washdown, VFD rated, belt drive, CS WVCBC- Washdown, VFD controlled, belt drive, CS

HIGH SPEED

Sanitary ribbon blender

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).

If you require a foundation for this item, it must be added. - Continued on next page -

RIBBON



Description Type

RIBBON - continued

Material: SS304, *SS316*Blender type: *1SHAFT* - Single shaft blender2SHAFT - Twin shaft blender (available only for capacities of 500 - 750 GALLONS [1.9 - 2.85 M3] Liquid volume: MIN: 10 GALLONS [0.038 M3], 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 onlyDefault: STD for twin shaft, NONE for single shaftJacket option: NO- Jacket not required *YES* - Jacket requiredNot applicable for twin shaft blender type.Leg material: CS- Carbon steel *SS*- Stainless steelNot applicable for twin shaft blender type.Seal for shaft: *STD*- Standard shaft seal MECO- Clean-In-Place steam proof sealApplicable for twin shaft only



Description Type

RIBBON - continued

Operating temperature: MIN: 68 DEG F [20 DEG C]

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.If you require a foundation for this item, it must 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.

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.

PISTON HOM

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 16 0.625 16

2000 7.5 ---- ---- 1.51 401

6000 22.7 3.52 902 ---- ----

9000 37.4 3.1253 803 ---- ----



Description Item

Sanitary shear pump homogenizer.

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 requiredDriver power: MIN: 5.5 HP [4.0 KW], MAX: 100 HP [75 KW]Driver type: TVRZC- TEFC, VFD rated, CS *TVCZC*- TEFC, VFD controlled, CSNumber of stages: *1*, MIN: 1, MAX: 3The shear pump homogenizer is provided with 3 stages; however, if only 1 or 2 stages are required, then the other stages are blocked.

SHEAR HOM



Air Compressors (AC)

Gas Compressors (GC)

Fans, Blowers (FN)

3 Compressors (G6)

3 Compressors (G6) 3-1

Air Compressors (AC)For plant or instrument air.

For all air compressors, capacity is at inlet temperature and pressure.

Description Type

Packaged unit including motor driver.

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]


CENTRIF M

3-2 3 Compressors (G6)

Air Compressors (AC) - continued

Description Type

CENTRIF M - continued

Design temperature Inlet:

-50 - 200 DEG F [-45 - 90 DEG C];

Default:

*68* DEG F [*20* DEG C]Design gauge pressure Inlet: Default: *0* PSIG [*0* KPA]

Packaged unit including turbine driver.

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)Actual gas flow rate: 1000 - 25000 CFM [1,700 - 42,400 M3/H]Design gauge pressure Outlet: 15 - 325 PSIG [105 - 2,240 KPA]Design temperature Inlet: -50 - 200 DEG F [-45 - 90 DEG C]; Default: *68* DEG F [*20* DEG C]Design gauge pressure Inlet: Default: *0* PSIG [*0* KPA]

CENTRIF T

Integral gasoline engine driver, base plate, coupling, 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]

Design temperature Inlet:

Default: *68* DEG F [*20* DEG C]

Design gauge pressure Inlet:

Default: *0* PSIG [*0* KPA]

RECIP GAS


Air Compressors (AC) - continued

Description Type

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).

Material: *CS*Design gauge Pressure outlet: Max: 6,000 PSIG [41,300 KPA]Design gauge pressure Inlet: Default: *68* PSIG [*20* KPA]Driver Power: Max: 15,000 HP [11,000 KW]Design temperature Inlet: Default: *68* DEG F [*20* DEG C]

RECIP MOTR

Single stage, non-lubricated, packaged reciprocating compressor for oil-free air; includes motor and drive, coupling, base plate, cooler.

Material: *CS*Actual gas flow rate: 75 - 1,100 CFM [130 - 1,850 M3/H]Design gauge pressure Outlet: 90 - 150 PSIG [620 - 1,000 KPA]Design temperature Inlet: -50 - 200 DEG F [-45 - 90 DEG C]; Default: *68* DEG F [*20* DEG C]

Design gauge pressure Inlet:

Default:*0* PSIG [*0* KPA]

SINGLE 1 S

Two stage, non-lubricated, packaged reciprocating air compressor for oil-free air; includes motor and drive, coupling, base plate, and cooler.

Material: *CS*Actual gas flow rate: 80 - 700 CFM [140 - 1,150 M3/H]Design gauge pressure Outlet: 150 - 500 PSIG [1,040 - 3,400 KPA]Design temperature Inlet: -50 - 200 DEC F [-45 - 90 DEG C]; Default: *68* DEG F [*20* KPA]Design gauge pressure Inlet: Default: *0* PSIG [*0* KPA]

SINGLE 2 S


Gas Compressors (GC)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.

Casing material: See “Casting Materials” in Chapter 28 for a complete list of materials. Default: *CS*.Actual gas flow rate Inlet: 500 - 200000 CFM [850 - 339000 M3/H]Design temperature Inlet: -200 - 200 DEG F [-125 - 90 DEG C];Default - *68* DEG F [*20* DEG C]Design gauge pressure Outlet: Max: 2000 PSIG [13750 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]


CENTRIF


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 driverTurbine 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 reducerLube oil system: Default: *YES* YES - Lube system required NO - No lube oil system

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*.Actual gas flow rate Inlet: 500 - 70,000 CFM [850 - 118,900 M3/H]Design gauge pressure Inlet: -0.4 -100 PSIG [-2.7 - 689 KPA]; Default: *0.0* PSIG [*0.0* KPA]Design temperature Inlet: 32 - 200 DEG F [0 - 90 DEG C]; Default: *68* DEG F [*20* DEG C]Design gauge pressure Outlet: Max: 700 PSIG [4825 KPA]Design temperature Outlet: -200 - 200 DEG F [-125 - 90 DEG C]Number of impellers: 2 - 4


CENTRIF IG



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 gasMolecular weight: Default based on chosen gas type.Specific heat ratio: Default based on chosen gas type.Compressibility factor Inlet: Default: *1.0*.Compressibility factor Outlet: Default: *1.0*.Intercooler required: Default: *YES* YES - Cooler required NO - None requiredAfter cooler Required: Default: *NO*. YES - Cooler required NO - None requiredMaximum interstage temperature: 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 GAS ENGINE - Gas engine driver MOTOR- Motor driver TURBINE- Turbine driver




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 systemShop 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.

Actual gas flow rate Inlet: Max: 200,000 CFM [339,000 M3/H]Inlet Temperature: -200 - 200 DEG F [-125 - 90 DEG C]; Default: *68* DEG F [*20* DEG C]


Max: 6,000 PSIG [41,000 KPA]

Molecular weight:

Default: *30*

Specific heat ratio:

Default: *1.22*

Maximum interstage temperature:

Specify the maximum temperature

reached during compression before inter-cooling.

Max: 400 DEG F [200 DEG C];

Default: *270* DEG F [135 DEG C].


RECIP MOTR



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- Turbine driverTurbine 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 reducerLube 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.

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]

RECIP GAS


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.

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

CENT TURBO


Fans, Blowers (FN) - continued

Description Type

Centrifugal fan.

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*Actual gas flow rate: 700 - 150,000 CFM [1,200 - 254,800 M3/H]Fan outlet gauge pressure: 0 - 15 IN H2O [0 - 3,700 PA]; Default: *6* IN H2O [*1,500* PA]

CENTRIF

Propeller fan.

Material: *CS*Actual gas flow rate: 1,000 - 15,000 CFM [1,700 - 25,400 M3/H]

PROPELLER


Fans, Blowers (FN) - continued

Description Type

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.

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];

Default: *8* PSIG [*55* KPA]Speed: 900 - 3,600 RPM

ROT BLOWER

Vaneaxial fan.

Material:

*CS*Actual gas flow rate: 2,300 - 40,000 CFM [3.950 - 67,900 M3/H]

VANEAXIAL



Electrical Motors (MOT)

Power Level

Standard Motor Sizes

Synchronous Motor Speeds (RPM)

Turbines (TUR)

4 Drivers (G11)

4 Drivers (G11) 4-1

Electrical Motors (MOT)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:

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 (weather- protected (rain, snow, air-borne particles) WPII- Severe outdoor service (outside weather-protected service)


OPEN

4-2 4 Drivers (G11)

Electrical Motors (MOT) - continued

Description Type

OPEN - continued

Driver Type: Default: *STD* STD- Standard motor VFD- Variable frequency driveSpeed: 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 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 cooledSpeed: Range: (3.7 x HZ) - (30 x HZ) RPM; Default: *(30 x HZ)* RPM

SYNCHRON

Totally-enclosed fan-cooled motors (TEFC)

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.


ENCLOSED

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 VFD- Variable frequency driveSpeed: Range: (20 x HZ) - (60 x HZ) RPM; Default: *(30 x HZ)* RPM.

Explosion-proof motors for Class I Division 1 hazardous use.

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 VFD- Variable frequency driveSpeed: Range: (20 x HZ) - (30 x HZ) RPM; Default: *(30 x HZ)* RPM.

EXP PROOF

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.

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) RPMHigh Speed: (1.4 x HZ) - (58 x HZ) RPMDriver Power: 0.5 - 400 HP [0.75 - 300 KW]

VARY SPEED

4 Drivers (G11) 4-5

Power LevelPower 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]

1 HP to under MDP (*200* HP)[.75 KW to under MDP (*150* KW)]

MDP (*200* HP) to 4,000 HP[MDP (*150* KW) to 3,000 KW]

Greater than 4,000 HP [3,000 KW]

110 V

Low Voltage*230/480* V

4,160 V

13,800 V

240v

Low Voltage*415* V

3,300 V

11,000 V

Frequency 60 Hertz 50 Hertz

10000 - 37000 KW: Increments of1000 KW

4-6 4 Drivers (G11)

Standard Motor SizesHP KW

0.125 0.25 0.333 0.5 0.75 1 1.5 2 3 5 7.5101520253040506075100125150200

200 - 500 HP:increments of 50 500 - 1000 HP:increments of 100 1000 - 2500 HP:increments of 250 2500 - 6000 HP:increments of 500 6000 - 20000 HP:increments of 100020000 - 40000 HP:increments of 250040000 - 50000 HP:increments of 5000

0.751.111.502.223.04.05.57.511.015.018.522.030.037.545.055.075.080808595100106112

118125132140150160170180190200212224236250265280300315335375400425450475

5005305605606006306707107508009001000112012501400160018002000224025002500280031503550

4000450050005600630071008000900010000

4 Drivers (G11) 4-7

Synchronous Motor Speeds (RPM)60 Hertz Service 50 Hertz Service

18001200900720600514450400360327300277257240225

15001000750600500428375333300272250231214200187

4-8 4 Drivers (G11)

Turbines (TUR)Description Type

Steam turbine driver includes condenser and accessories.

Material: Default: *CS*Power Output: 10 - 30,000 HP [8 - 22,300 KW]Steam Gauge Pressure: Max: 1,600 PSIG [11,000 KPA]; Default: *400* PSIG [*2,700* KPA]Speed: Max: 3,600 RPM; Default: *3,600* RPM

CONDENSING

Non-condensing type steam turbine driver includes accessories.

Material: Default: *CS*Power Output: 10 - 30,000 HP [8 - 22,300 KW]Steam Gauge Pressure: Max: 1,600 PSIG [11,000 KPA]; Default: *400* PSIG [*2,700* KPA]Speed: Max: 3,600 RPM; Default: *3,600* RPM

NON COND

4 Drivers (G11) 4-9

Gas turbine includes fuel gas combustion chamber and multi-stage turbine expander.

Material: Default: *CS*Power Output: 1,000 - 370,000 HP [750 - 276,000 KW

GAS

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.

Actual gas flow rate Inlet: Range: 5 - 200,000 CFM [8.5 - 339,800 m3/hr] Required fieldDesign gauge pressure Inlet: Range: (>0) - 3000 PSIG [(>0) - 20,684 kPag] Required fieldDesign temperature Inlet: Range: -450 to 600 DEG F [-267 to 315 DEG C] Default: *70* DEG F [*21* DEG C]Design gauge pressure Outlet: Range: 0 - 1 ,000 PSIG [0 - 6,894 kPag] Required fieldPower output: Range: (>0) - 2,000 HP [(>0) - 1,500 kW]Molecular weight: Range: 1 - 500 Default: *29* Default molecular weight is that of airSpecific heat ratio: Range: 1.04 - 2 Default: *1.4* Default specific heat ratio is that of airCompressibility factor Inlet: Range: 0.05 - 3 Default: *1* Default compressibility factor assumes an ideal gasIsentropic efficiency: Range: 30 - 100 PERCENT Default: *85* PERCENTNumber of spare cartridges: Min: 0 Default: *0*

TURBOEXP

Description Type

4-10 4 Drivers (G11)


Heat Exchangers (HE)

Reboilers (RB)

Furnaces, Process Heaters (FU)

TEMA Exchanger Construction Nomenclature

Icarus Supported TEMA Types

5 Heat Transfer (G10)

5 Heat Transfer (G10) 5-1

Heat Exchangers (HE)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 5 Heat Transfer (G10)

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.

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.: Default: *150* PSIG [*1,000* KPA]Inlet temperature 1st service: Default: *300* DEG F [*150* DEG C]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


AIR COOLER



Description Type

AIR COOLER - continued

Louver type symbol: Default: *FACE* FACE- Face louvers only SIDE- Side louvers only BOTH- Face + side louvers NONE- No louversFin 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 tubesFin 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 finsTube 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: 13Tube pitch: Default: *2.25* INCHES [55.0 MM]Number of fans per bay: Range: 1-3

Fixed tube sheet shell and tube exchangers.

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. - Continued on next page -

FIXED T S



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: Enter either heat transfer area or number of shells, tubes/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.Tube design gauge pressure: Default: *150* PSIG [*1,000* KPA]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]; Default: *1.0* INCHES [*25* 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: 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] for other materials.




Description Type


Shell operating temperature: Default: design temperatureTube 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.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 BWGTube wall thickness: Enter tube gauge or thickness, not both, 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 materialsTube seal type: Default: *SEALW* EXPND- Expanded tube-to-tubesheet joints SEALW- Seal welded tube joints STRNW- Strength welded tube jointsTube pitch: 1.25 x tube outside diameterTube pitch symbol: Default: *TRIANGLE* DIAMOND- Diamond tube pitch SQUARE- Square tube pitch TRIANGULAR- Triangular tube pitchShell 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.




Description Type


Expansion joint: Default: *NO* NO- No expansion joint in shell YES- Expansion joint required in shellTube 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 sidesNumber of tube passes: Default: *1*Number of shell passes: Default: *1*Stress relief: Default: See Area Design Basis. CODE - Provide stress relief if code requires YES - Provide stress relief NO - No stress relief requiredWeld 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 workRegulation 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



Description Type

Floating head shell of 48 INCHES [1200 MM] 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: Enter either heat transfer area or number of shells, tubes/shell and tube data. Number of shells: Enter either heat transfer area or 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.Tube design gauge pressure: Default: *150* PSIG [*1,000* KPA]Tube design temperature: Default: 400 DEG F [200 DEG C] for copper alloys; 650 DEG F [340 DEG C] other materialTube operating temperature: Default: design temperatureTube outside diameter: 0.25 - 6.0 INCHES [6 - 150 MM]; Default: *1.0* INCHES [*25* MM]Shell material: Default: A285C to 900 DEG F [482 DEG C], SS304 for higher temperaturesShell design gauge pressure: Default: 150 PSIG [1,000 KPA]


FLOAT HEAD



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 materialShell operating temperature: Default: design temperatureTube side pipe material: See Pipe Materials in Chapter 18.Shell side pipe material: See Pipe Materials in Chapter 18.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 BWGTube wall thickness: Enter tube gauge or thickness, not both, 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 materialsTube seal type: Default: *SEALW* EXPND- Expanded tube-to-tubesheet joints SEALW- Seal welded tube joints STRNW- Strength welded tube jointsTube pitch: Default: 1.25 x tube outside diameterTube pitch symbol: Default: *TRIANGULAR* DIAMOND- Diamond tube pitch SQUARE- Square tube pitch TRIANGLE- Triangular tube pitchShell 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. - Continued on next page -



Description Type

FLOAT HEAD - continued

Expansion joint: Default: *NO* NO - No expansion joint in shell YES - Expansion required in shellTube sheet material: See Tube Materials in Chapter 28.Tube sheet corrosion allowance: 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: Default: 0.125 INCHES [3 MM] if cladding material specified, otherwise 0.0.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 sidesNumber of tube passes: Default: *2*Number of shell passes: Default: *1*Stress relief: Default: See Area Design Basis. CODE - Provide stress relief if code required YES - Provide stress relief NO - No stress relief requiredWeld 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 workRegulation type: For Japanese country base only. Required government regulation and testing. Default: *NONE* NONE - No special regulations PV - Pressure vessel regulations HPG - High pressure gas regulations



Description Type

U-tube shell and tube exchangers. TEMA type BEU U-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: Enter either heat transfer area or number of shells, tubes/shell and tube data.Number of shells: Enter either heat transfer area or number of shells, tubes/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 data.Tube design gauge pressure: Default: *150* PSIG [*1,000* KPA]Tube design temperature: Default: *400* DEG F [*200* DEG C] for copper alloys; other material: *650* DEG F [*340* DEG C]Tube operating temperature: Default: design temperatureTube outside diameter: Range: 0.25 - 6.0 INCHES [6 - 150 MM]; Default: *1.0* INCHES [*25* MM]Shell material: Default: *A285C* to 900 DEG F [482 DEG C], SS304 for higher temperatures


U TUBE



Description Type

U TUBE - continued

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 materialsShell operating temperature: Default: design temperatureNumber of tubes per shell: Enter either heat transfer area or number of shells, tubes/shell and tube data.Tube length extended: 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 BWGTube 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 seal type: Default: *SEALW* EXPD - Expanded tube-to tubesheet joints SEALW - Seal welded tube joints STRNW - Strength welded tube jointsTube pitch: Default: 1.25 x tube outside diameterTube pitch symbol: Default: *TRIANGULAR* DIAMOND- Diamond tube pitch SQUARE- Square tube pitch TRIANGULAR- Triangular tube pitchShell diameter: Max: 192 INCHES [4,875 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




Description Type

U TUBE - continued

Expansion joint: Default: *NO* NO - No expansion joint in shell YES - Expansion joint required in shellTube 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: 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* SHELL - Cladding on shell side only TUBE - Cladding on tube side only BOTH - Cladding on both shell and tube sidesNumber of tube passes: Default: *2*Number of shell passes: Default: *1*Stress relief: Default: See Project Design Basis. CODE - Provide stress relief if code requires YES - Provide stress relief NO - No stress relief requiredWeld X-ray: Max: 100; Default: *20*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 workRegulation type: Japanese country base only. Required government regulations and testing. Default: *NONE*. NONE - No special regulations PV- Pressure vessel regulations HPG- High pressure gas regulations



Description Type

Fixed tube, float. head, u-tube exchanger

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. coverShell 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 flowRear 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 tubesheetHeat exchanger design option:*<BLANK>*- Standard exchanger designTBWNB- Tube bundle design only, w/o system bulks Design/cost option for TBWNB only


TEMA EXCH



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- MonelTube design gauge pressure: *150 PSIG [1,000 KPA]*Tube design temperature: Default: 400 DEGF [200 DEGC] for copper alloys; other mat’l: 650 DEGF [340 DEGCTube operating temperature: Default: design temperatureTube outside diameter: *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 - Continued on next page -



Description Type


INCNL- InconelShell design gauge pressure: *150 PSIG [1,000 KPA]*Shell design temperature: Default: 400 DEGF [200 DEGC] for copper alloys; 650 DEGF [340 DEGC] other mat’lShell operating temperature: Default: design temperature

Tube side pipe material: 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- HastelloyShell side pipe material: See materials listed above for Tube side pipe materialNumber of tubes per shell: Enter either heat transfer area or no. of shells, tubes/shell and tube data.Tube length extended: 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 BWGEnter tube gauge or thickness, not both, including corrosion allowance.Tube wall thickness: MIN: 0.02 INCHES [0.6 MM], MAX 0.34 INCHES [8.6 MM]Enter tube gauge or thickness, not both, including corrosion allowance.




Description Type


Tube corrosion allowance: Default: 0.0025 INCHES [0.06 MM] for CS, 0.0 for other materials.Tube seal type:EXPND- Expanded tube-to-tubesheet joints*SEALW*- Seal welded tube jointsSTRNW- Strength welded tube jointsTube pitch: Default: 1.25 x tube outside diameter.Tube pitch symbol: DIAMOND- Diamond tube pitch SQUARE- Square tube pitch TRIANGULAR- Triangular tube pitchShell diameter: MAX: 192 INCHES [4,875 MM]Shell wall thickness: Shell thickness including corrosion all. Shell corrosion allowance: 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 Tube sheet material: 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- InconelTube sheet corrosion allowance: Default: lesser of 50 x tube corr. all., or 0.25 INCHES [6 MM].Channel material: Default: tubesheet material - Continued on next page -



Description Type


Cladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified; otherwise: 0.0Cladding 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 CCladding location: *SHELL*- Cladding on shell side only TUBE- Cladding on tube side only BOTH- Cladding on both shell and tube sidesNumber of tube passes: * 1*Number of shell passes: * 1*Stress relief: Default: see Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredWeld X-ray: * 20*, MAX: 100Vendor grade: STAND- Standard vendor *HIGH*- Specialty vendor for high grade or custom workRegulation 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 -



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.



Description Type

Pre-engineered (standard) U-tube exchanger for use as a sample cooler or other miscellaneous application.

Heat transfer area: Enter either heat transfer area or number of 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 brassTube design gauge pressure: Default: *150* PSIG [*1,000* KPA]Tube design temperature: Default: *250* DEG F [*120* DEG C]Tube operating temperature: Default: design temperatureTube outside diameter: 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 - Continued on next page -

PRE ENGR



Description Type

PRE ENGR - continued

Shell design gauge pressure: Default: *150* PSIG [*1,000* KPA]Shell design temperature: Default: *250* DEG F [*120* DEG C]Shell operating temperature: Default: design temperatureNumber of tubes: Enter either heat transfer area or number of tubes and tube data.Tube length extended: 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: Enter tube gauge or thickness, not both, including corrosion allowance. Range: 16 - 20 BWGTube wall thickness: Enter tube gauge or thickness, not both, including corrosion allowance; Range: 0.035 - 0.065 INCHES [0.900 - 1.65 MM]Tube corrosion allowance: Default: *0.0025* INCHES [*0.06* MM] for CS, *0.0* for other materialsTube pitch: Default: *.25 x tube outside diameter*Tube pitch symbol: Default: *TRIANGULAR* DIAMOND- Diamond tube pitch SQUARE- Square tube pitch TRIANGULAR- Triangular tube pitchShell diameter: Range: 4.00 - 10.00 INCHES [102.0 - 254.0 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



Description Type

Electric immersion tank heater.

Material: Default: *CU*CU- CopperSS304- SS304Power output: Range: 6 -200 KW

HEATER ELC

Heating/cooling coil with spiral or serpentine coil of 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]

HEATER STM

Bare-tube double-pipe heat exchanger.

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.


JACKETED


Heat Exchangers (HE) - continued.

Description Type

JACKETED - continued

Material: Default: *CS* CS- Carbon steel SS- Stainless steelHeat transfer area: 10 - 1,000 SF [1 - 90 M2]Tube length: Range: 8 - 25 FEET [2.5 - 7.5 M]; Default: *20* FEET [*6* M]Number of tubes per shell: Default: *1* 1- 1 tube per shell 7- 7 tubes per shellDesign 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.

Material: Default: *CS* CS- Carbon steel SS- Stainless steelHeat 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]; Default: *20* FEET [*6* M]Number of fins: Range: 12 - 48; Default: *24*Design gauge pressure: Max: 6,000 PSIG [40,000 KPA]Number of tubes per shell: Default: *1* 1- 1 tube per shell 7- 7 tubes per shell

FIN TUBE



Description Type

All-graphite heat exchanger.

Material: Default: *GRAPH*Heat transfer area: Range: 8 - 150 SF [1.0 - 13.5 M2]

CROSS BORE

Rietz type thermascrew conveyor with motor and drive.

Material: Default: *CS* CS- Carbon steel SS304- SS304Heat transfer area: 10 - 400 SF [1 - 37 M2]

ONE SCREW

Twin screw thermascrew conveyor with motor and drive.

Material: Default: *CS* CS- Carbon steel SS304- SS304Heat transfer area: 10 - 400 SF [1 - 37 M2]

TWO SCREW

Graphite tube with carbon steel shell exchanger.

Heat transfer area: Range: 80 - 9,730 SF [7.5 - 870 M2]Tube length: Range: 6 - 20 FEET [2 - 6 M]

SHELL TUBE



Description Type

Spiral plate heat exchanger.

Material: Default:*SS304* SS304- SS304 SS316- SS316 TI- Titanium HAST- HastelloyHeat transfer area: Range: 40 - 1,330 SF [4 - 123 M2]Tube design gauge pressure: Range: 150 - 300 PSIG [1,000 - 2,000 KPA]; Default: 150 PSIG [1,000 KPA]

SPIRAL PLT

Tank suction heater without tank.

Material: Default: *CS*Heat transfer area: Range: 135 - 4,000 SF [13 - 370 M2]

SUC HEATER

Waste heat boiler for generation of steam, hot 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]

WASTE HEAT



Description Type

Plate and frame heat exchanger.

Plate material: Default: *SS304* SS304- SS304 SS316- SS316 S04L- 304L S16L- 316L HAST- HastelloyHeat transfer area: Range: 10 - 2,000 SF [1.0 - 185 M2]Number of plates: Max: 500Design gauge pressure: Max: 350 PSIG [2,410 KPA]; Default: *200* PSIG [*1,380* KPA]Design temperature: Max: 400 DEG F [204 DEG C]; Default: *200* DEG F [*93* DEG C]

PLAT FRAM

Sanitary corrugated double pipe exchanger

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.

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.


CORRUGATED

(Close-up of piping)

Double pipe size:

Inch-Pound Metric

Symbol Outer Tube

Inner Tube

Outer Tube

Inner Tube

3x20 3 Inches 2 Inches 75 MM 50 MM

4x25 4 Inches 2.5 Inches 100 MM 60 MM

4x30 4 Inches 3 Inches 100MM 75 MM





Description Type

CORRUGATED - continued

Number of tube passes: 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)

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- IncludedExpansion tank: *NONE*- Not included INCL- IncludedCondensate return pump: *NONE*- Not included INCL- Included

HOT WATER

Sanitary multi-zone plate+frame exchanger

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


MULTI P F



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 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.Number of plates Zone 2: Enter either total area or no. of plates for Zone 2.Plate area Zone 3: Enter either total area or no. of plates for Zone 3.Number of plates Zone 3: Enter either total area or no. of plates for Zone 3.

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



Description Type

Sanitary direct steam heat module

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]

STM HE MOD


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 vapor-liquid disengagement so that only vapor is returned to the distillation column, not a vapor-liquid mixture.

Description Type

Kettle reboilers with floating head.

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: Enter either heat transfer area or number of shells, tubes/shell and tube data.Number of shells: Enter either heat transfer area or number of shells, tubes/shell and tube data.Tube material: See Chapter 28 for tube materials. Default: *A 214* to 800 DEG F [482 DEG C], *304S* for higher temperatures - Continued on next page -

KETTLE


Reboilers (RB) - continued

Description Type

KETTLE - continued

Heat exchanger design option:*<BLANK>*- Standard exchanger designTBWNB- Tube bundle design only, w/o system bulksDesign/cost option for TBWNB onlyTube design gauge pressure: Default: *150* PSIG [*1,000* KPA]Tube design temperature: Default: *400* DEG F [*200 DEG C] for copper alloys; other material: *650* DEG F [*340* DEG C]Tube operating temperature: Default: design temperatureTube outside diameter: Default: 0.25 - 6.0 INCHES [6 - 150 MM]; Default: *1.0* INCHES [*25* MM]Shell material: See Chapter 28 for materials. Default: *A285C* to 900 DEG F [482 DEG C], *SS304* for higher temperaturesShell 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 materialShell operating temperature: Default: design temperatureNumber of tubes per shell: Enter either heat transfer area or number of shells, tubes/shell and tube data.Tube length extended: Range: 8 - 60 FEET [2.5 - 18 M]; Default: *20* FEET [*6* M]Tube gage: Enter tube gauge or thickness, not both, including corrosion allowance. Range: 1 - 24 BWGTube 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




Description Type

KETTLE - continued

Tube pitch: Default: 1.25 x tube outside diameterTube pitch symbol: Default: *TRIANGULAR* DIAMOND- Diamond tube pitch SQUARE- Square tube pitch TRIANGULAR- Triangular tube pitchShell diameter: Max: 192 INCHES [4,875 MM]; Default: *1.5 x port diameter*Shell wall thickness: Shell wall thickness including corrosion allowance.Shell corrosion allowance: Default: *0.125* INCHES [*3* MM] for CS, *0.0* for other materials.Tube sheet material: See Chapter 28 for tube materials.Tube sheet corrosion allowance: Default: Lessor 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 cladding materials.Cladding location: Default: *SHELL* SHELL- Cladding on shell side only TUBE- Cladding on tube side only BOTH- Cladding on both shell and tube sidesNumber of tube passes: Default: *2*Duty: Default: 0.004 x surface area (SF); 0.01262 x surface area (M2).Vaporization: Max: 100; Default: *90*Specific gravity tower bottoms: Default: *0.50*Molecular weight bottoms: Default: *100*Heat of vaporization: Default: *150* BTU/LB [*350* KJ/KG]



Description Type

KETTLE - continuedStress relief: Default: See Area Design BasisCODE- Provide stress relief if code requiresYES- Provide stress reliefNO- No stress relief requiredTEMA type: Default: *BKT*

Horizontal or vertical thermosiphon reboilers. 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 headH-FXD - Horizontal: fixed tubesheetH-UTUB - Horizontal: u-tubeV-FXD - Vertical: fixed tubesheet - Continued on next page -

THERMOSIPH



Description Type

Thermosiphon - continuedV-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 ofshells, tubes/shell and tube data.Number of shells: Enter either heat transfer area or number ofshells, tubes/shell and tube data.Tube material: See Chapter 28 for materials.Default: *A 214* to 900 DEG F [*482* DEG C],*304S* for higher temperaturesHeat exchanger design option:*<BLANK>* - Standard exchanger designTBWNB - Tube bundle design only, w/o system bulksDesign/cost option for TBWNB onlyTube 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 temperatureTube outside diameter: Range: 0.25 - 6.0 INCHES [6 - 150 MM];Default: *1.0* INCHES [*25* MM]Shell material: See Chapter 28 for materials.Default: *A285C* to 900 DEG F [482 DEG C],*SS304* for higher temperatureShell 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 temperatureTube side pipe material: See Chapter 18 for pipe materials.Shell side pipe material: See Chapter 18 for pipe materials. - Continued on next page -



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 pitchSQUARE - Square tube pitchTRIANGULAR - Triangular tube pitchShell 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.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 0.0Cladding material: See Chapter 28 for materials.Cladding location: Default: *SHELL*SHELL - Cladding on shell side onlyTUBE - Cladding on tube side onlyBOTH - Cladding on both shell and tube sidesNumber 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 BasisCODE - Provide stress relief if code requiresYES - Provide stress reliefNO - No stress relief requiredTEMA type: Default: Based on the specified thermosiphon design symbol.


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 .u-tube. and .kettle. reboilers are kettle type reboilers in the nomenclature of the chemical process industry.Heat transfer area: Enter either heat transfer area or number of shells, tubes/shell and tube data.Number of shells: Enter either heat transfer area or number of shells, tubes/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 data.Tube design gauge pressure: Default: *150* PSIG [*1,000* KPA]Tube design temperature: Default: *400* DEG F [*200* DEG C] for copper alloys; other material: *650* DEG F [*340* DEG C]Tube operating temperature: Default: design temperatureTube outside diameter: Range: 0.25 - 6.0 INCHES [6 - 150 MM]; Default: *1.0* INCHES [*25* MM]Shell material: Default: *A285C* to 900 DEG F [482 DEG C], SS304 for higher temperaturesShell 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 temperatureTube 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. - Continued on next page -

U TUBE



U Tube continued

Description Type

Tube length extended: Range: 8 - 120 FEET [2.5 - 36 M]; Default: *40* FEET [*12 M]Tube gage: Enter tube gauge or thickness, not both,including corrosion allowance. Range: 1 - 24 BWGTube 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 pitchSQUARE - Square tube pitchTRIANGULAR - Triangular tube pitchShell diameter: Max: 192 INCHES [4,875 MM];Default: *1.5 x port diameter*Shell wall thickness: Shell thickness including corrosion allowance.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.Default: Lesser of 50 x tube corrosion allowance, or 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*SHELL - Cladding on shell side onlyTUBE - Cladding on tube side onlyBOTH - Cladding on both shell and tube sidesNumber 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 BasisCODE - Provide stress relief if code requiresYES - Provide stress reliefNO - No stress relief requiredTEMA type: Default: *BKU*

U TUBE


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 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 - Continued on next page -

BOX


Furnaces, Process Heaters (FU) - continued

Description Type

BOX - continued

Design gauge pressure: Max: 6,000 PSIG [41,000 KPA]; Default: *500* PSIG [*3,500* KPA]Design temperature: Max: 1,500 DEG F [815 DEG C]; Default: *750* DEG F [*400* 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.

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 GPM [L/S] in place of gas flow. Process type: GAS- Gas process fluid LIQ- Liquid process fluidDesign gauge pressure: Max: 6,000 PSIG [41,000 KPA]; Default: *500* PSIG [*3,500* KPA]Design temperature: Max: 1,500 DEG F [815 DEG C]; Default: *750* DEG F [*400* DEG C]

HEATER

Pyrolysis.

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


PYROLYSIS


Furnaces, Process Heaters (FU) - continued

Description Type

PYROLYSIS - continued

Design gauge pressure: Max: 6,000 PSIG [41,000 KPA]; Default: *500* PSIG [*3,500* KPA]Design temperature: Max: 1,500 DEG F [815 DEG C]; Default: *750* DEG F [*400* DEG C]

Box-type reformer without catalyst.

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 fluidDesign gauge pressure: Max: 6,000 PSIG [41,000 KPA]; Default: *500* PSIG [*3,500* KPA]Design temperature: Max: 1,500 DEG F [815 DEG C]; Default: *750* DEG F [*400* DEG C]

REFORMER

Gas or oil fired vertical cylindrical type for low heat duty range moderate temperature with long contact time.

Material: See Chapter 28 for materials. Default: *CS*Duty: Max: 500 MMBTU/H [145 MEGAW]Standard gas flow rate: 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 fluidDesign gauge pressure: Max: 6,000 PSIG [41,000 KPA]; Default: *500* PSIG [*3,500* KPA]Design temperature: Max: 1,500 DEG F [815 DEG C]; Default: *750* DEG F [*400* DEG C]

VERTICAL


TEMA Exchanger Construction Nomenclature


Icarus Supported TEMA TypesShell and Tube Heat Exchangers

U - TUBE FLOAT HEAD FIXED-T-S

Front End Stationary Head Types

Shell Types

Rear End Head Types

A, B, C

E, F, G, H, J, X

U

A, B, C

E, F, G, H, J, X

P, S, T, W

A, B, N

E, F, G, H, J, X

L, M, N

ReboilersFront End Stationary Head Types

U-TUBE THERMOSIPH KETTLE

Front End Stationary Head Types

Shell Types

Rear End Head Types

A, B, C

K,

U

A, B, C, N

E**, J*

L, M, N, P*, S*, T*, U*

A, B, N

K

T

TEMA CLASS B: Equipment cost includes shell, tube bundle, nozzles and saddles. * Horizontal only **Vertical only



Introduction to Packing

Introduction to Lining

Packing, Linings (PAK, LIN)

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 Packing, Linings (G6) 6-1

Introduction to PackingThere 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 6 Packing, Linings (G6)

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


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,


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 LiningA 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 BrickThese 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 MixesThese 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 LiningsFluorocarbon 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.


Glass LiningsGlass linings are shop installed and are all satisfactory for a wide range of corrosive services at temperatures up to 450 DEG F.

Refractory BrickThese 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 LiningsResin 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 LiningsThese 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 LiningsLead 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 LiningsZinc 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.


Zinc can also be supported in an epoxy base paint and brushed, rolled or sprayed onto the steel.

Packing, Linings (PAK, LIN)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 type: See Chapter 28 for packing materials.

PACKING


Brick and mortar for acid service applied to protect a membrane coating from deterioration under 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 fclayMortar type: Default: *FUR* FUR- Furfural base motar SIL- Silicone base motarLining adjustment: See “Suggested Lining Difficulty Adjustment.” Range: 1 - 10; Default: *4*

ACID BRICK

Castable refractory or gunned mixes.

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 anchorLining thickness: Max: 9 INCHES [225 MM]; Default: 4 INCHES [100 MM]


MONOLITHIC

Description Type


Packing, Linings (PAK, LIN) - continued

Suggested Lining Difficulty Adjustments

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.

Lining material: See Chapter 28 for lining materials. Default: *EPLCS*Lining adjustment: See “Suggested Lining Difficulty Adjustment.” Range: 1 - 10; Default: *4*

OTHER

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



Centrifugal Pumps (CP)

Gear Pumps (GP)


Pump Efficiencies

7 Pumps (G10)

7 Pumps (G10) 7-1

Centrifugal Pumps (CP)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 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: See Chapter 28 for materials. Default: *CS*Liquid flow rate: MAX: 2,000 GPM [125 L/S]


ANSI

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. Default: *75* FEET [*25* M]Speed: Range: 1,200 - 3,600 RPM; Default: *1,800* RPM.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 sealDesign temperature: MAX: 500 DEG F [260 DEG C]; Default: *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S]Pump efficiency: Range: 10 - 100Steam 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 1112- API primary seal piping plan number 1213- API primary seal piping plan number 1321- API primary seal piping plan number 2122- API primary seal piping plan number 2223- API primary seal piping plan number 2331- API primary seal piping plan number 3132- API primary seal piping plan number 3241- API primary seal piping plan number 412- API primary seal piping plan number 2


7 Pumps (G10) 7-3


Description Type

ANSI - continued

Secondary seal pipe plan: Default: *NONE* 51- API secondary seal piping plan number 51 52- API secondary seal piping plan number 52 53- API secondary seal piping plan number 53 54- API secondary seal piping plan number 54 61- API secondary seal piping plan number 61 62- API secondary seal piping plan number 62Cooling 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 LPipe plan pipe type: Default: *WELD* TUBE- Tubing THRD- Threaded pipe/fittings *WELD*- Welded pipe/fittings WFLG- Welded/flanged pipe fittingsPipe plan material type: Default: Based on casing material. A 106- A 106 304P- SS304 316P- SS316

Plastic ANSI single stage pump.

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, 350 FEET [105 M] at 60 x HZ]; Default: *75* FEET [*25* M]Speed: Range: 1,800 - 3,600 RPM; Default: *1,800* RPMFluid specific gravity: Range: 0.2 - 50; Default: 1.0 - Continued on next page -

ANSI PLAST

7-4 7 Pumps (G10)


Description Type

ANSI PLAST - continued

Driver type: Default: *MOTOR* NONE- No driver MOTOR- Standard motor driver VFD- Variable frequency motor driver TURBINE, - Turbine driver GAS ENGINE- Gas engine driverSeal type: Default: *SNGL* PACK- Packing SNGL- Single mechanical seal TNDM- Tandem mechanical seal DBLE- Double mechanical sealDesign temperature: MAX: 250 DEG F [107 DEG C]; Default *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S]Pump efficiency: Range: 1 - 100Steam gauge pressure: Steam pressure for turbine drivers only. Default: *400* PSIG [2,800 KPA].

API 610 type available in a variety of casing materials.

Casing material: See Chapter 28 for materials.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] RPMSpeed: Range: 1,800 - 3,600 RPM; Default: *1,800*Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*Driver power: MIN: >0If 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.


API 610

7 Pumps (G10) 7-5


Description Type

API 610 - continued

Driver type: Default: MOTOR NONE- No driver *MOTOR*- Standard motor driver VFD- Variable frequency motor driver TURBINE, - Turbine driver GAS ENGINE- Gas engine driverSeal type: Default: *SNGL* PACK- Packing *SNGL*- Single mechanical seal TNDM- Tandem mechanical seal DBLE- Double mechanical sealDesign temperature: MAX: 850 DEG F [450 DEG C]; Default: *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S]Pump efficiency: Range: 10 - 100Steam gauge pressure: Steam pressure for tubine 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 13- API primary seal piping plan number 13 21- API primary seal piping plan number 21 22- API primary seal piping plan number 22 23- API primary seal piping plan number 23 31- API primary seal piping plan number 31 32- API primary seal piping plan number 32 41- API primary seal piping plan number 41 2- API primary seal piping plan number 2Secondary seal pipe plan: Default: *NONE* 51- API secondary seal piping plan number 51 52- API secondary seal piping plan number 52 53- API secondary seal piping plan number 53 54- API secondary seal piping plan number 54 61- API secondary seal piping plan number 61 62- API secondary seal piping plan number 62


7-6 7 Pumps (G10)


Description Type

API 610 - continued

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 LPipe plan pipe type: Default: *WELD* TUBE- Tubing THRD- Threaded pipe/fittings *WELD*- Welded pipe/fittings WFLG- Welded/flanged pipe fittingsPipe plan material Type: Default: Based on casing material. A 106- A 106 304P- SS304 316P- SS316

API 610 in-line pump

Casing material: See Chapter 28 for materials. Default: *CS*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.Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*Driver type: *STD*- Standard motor VFD- Variable frequency drive NONE- No driver


API 610 IL

7 Pumps (G10) 7-7


Description Type

API 610 IL - continued

Seal type: PACK- Packing *SNGL*- Single mechanical seal TNDM- Tandem mechanical seal DBLE- Double mechanical sealDesign temperature: MAX: 850 DEG F [450 DEG C]; Default: *120* DEG F [*50* DEG C].Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S].Pump efficiency: Range: 10 - 100Primary seal pipe plan: Default: *11* 11- API primary seal piping plan number 11 12- API primary seal piping plan number 12 13- API primary seal piping plan number 13 21- API primary seal piping plan number 21 22- API primary seal piping plan number 22 23- API primary seal piping plan number 23 31- API primary seal piping plan number 31 32- API primary seal piping plan number 32 41- API primary seal piping plan number 41 2- No primary seal piping planSecondary seal pipe plan: Default: *NONE* 51- API second seal piping plan number 51 52- API second seal piping plan number 52 53- API second seal piping plan number 53 54- API second seal piping plan number 54 61- API second seal piping plan number 61 62- API second seal piping plan number 62Cooling 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

7-8 7 Pumps (G10)


Description Type

High speed vertical in-line API 610 centrifugal pump 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] Default: *500* FEET [*150* M] Speed:Range: 1,800 - 3,600 RPM; Default: *1,800*Note: Applies to motor speed, not impeller speed.Fluid specific gravity:Range: 0.2 - 5.0; Default: *1.0*Driver power:MIN: >0Note: 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 TURBINE, - Turbine driver GAS ENGINE - Gas engine driverSeal type: Default: *SNGL* PACK - Packing *SNGL* - Single mechanical seal TNDM - Tandem mechanical seal DBLE - Double mechanical sealDesign temperature: MAX: 850 DEG F [450 DEG C] Default: *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S]Pump efficiency: Range: 10 - 100


HIGH SPEED

7 Pumps (G10) 7-9

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 13 - API primary seal piping plan number 13 21 - API primary seal piping plan number 21 22 - API primary seal piping plan number 22 23 - API primary seal piping plan number 23 31 - API primary seal piping plan number 31 32 - API primary seal piping plan number 32 41 - API primary seal piping plan number 41 2 - API primary seal piping plan number 2Secondary seal pipe plan: Default: *NONE* 51 - API secondary seal piping plan number 51 52 - API secondary seal piping plan number 52 53 - API secondary seal piping plan number 53 54 - API secondary seal piping plan number 54 61 - API secondary seal piping plan number 61 62 - API secondary seal piping plan number 62Cooling 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 LPipe plan pipe type: Default: *WELD* TUBE - Tubing THRD - Threaded pipe/fittings *WELD* - Welded pipe/fittings WFLG - Welded/flanged pipe fittingsPipe plan material type: Default: Based on casing material. A 106 - A 106 304P - SS304 316P - SS316


Description Type

7-10 7 Pumps (G10)

Vertical axial flow pump for flows greater than 1600 GPM [100 L/S]. Includes pumping unit and motor driver.

Material: See Chapter 28 for materials. Default: *CS*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: MAX: 500 DEG F [260 DEG C]; Default: *120* DEG F [*50* DEG C]Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*

AXIAL FLOW

Horizontal pump with canned motor.

Casing material: See Chapter 28 for materials. Default: *CS*Liquid flow rate: MAX: 400 GPM [25 L/S]Fluid head: MAX: 200 FEET [60 M]; Default: *75* FEET [*25* M]Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*Design temperature: MAX: 850 DEG F [450 DEG C]; Default: *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S]Pump efficiency: Range: 10 - 100

CANNED

Single and multistage centrifugal pumps available in a 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: Default: *75* FEET [*25* M]


CENTRIF

Description Type

7 Pumps (G10) 7-11


Description Type

CENTRIF - continued

Fluid specific gravity: Range: 0.2 - 5.0; Default: 1.0Driver type: Default: MOTOR NONE- No driver *MOTOR*- Standard motor driver VFD- Variable frequency motor driver TURBINE, - Turbine driver GAS ENGINE- Gas engine driverSeal type: PACK- Packing *SNGL*- Single mechanical seal TNDM- Tandem mechanical seal DBLE- Double mechanical sealDesign temperature: Default: *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S]Pump efficiency: Range: 10 - 100Steam gauge pressure: Steam pressure for turbine drivers only. Default: *400* PSIG [*2,800* KPA].

General service, cast iron for flows to 2000 GPM [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; Default: *1,800* RPM.Fluid specific gravity: 0.2 - 5.0; Default: *5.0*Driver type: NONE- No driver *MOTOR*- Standard motor driver VFD- Variable frequency motor driver TURBINE, - Turbine driver GAS ENGINE- Gas engine driver


GEN SERV

7-12 7 Pumps (G10)


Description Type

GEN SERV - continued

Seal type: PACK- Packing *SNGL*- Single mechanical seal TNDM- Tandem mechanical seal DBLE- Double mechanical sealDesign temperature: MAX: 250 DEG F [120 DEG C]; Default: *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S]Pump efficiency: Range: 10 - 100Steam gauge pressure: Steam pressure for turbine drivers only. Default: *400* PSIG [*2,800* KPA].

General service in-line pump.Includes pump and motor driver.

Casing material: See Chapter 28 for materials. Default: *CS*Liquid flow rate: MAX: GPM x head [FEET] < 43,000, L/S x head [M] < 825.Fluid head: Default: *75* FEET [*25* M]Speed: Range: 1,200 - 3,600 RPM; Default: *1,800* RPM.Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*Driver type: *STD*- Standard motor VFD- Variable frequency drive NONE- No driver Seal type: PACK- Packing *SNGL*- Single mechanical seal TNDM- Tandem mechanical seal DBLE- Double mechanical sealDesign temperature: MAX: 500 DEG F [260 DEG C]; Default: *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1.0* CPOISE [*1.0* MPA-S]Pump efficiency: Range: 10 - 100

IN LINE

7 Pumps (G10) 7-13


Description Type

Vertical motor with turbine impeller for wet pits, tanks and sumps.Includes pumping unit and motor driver.

Material: See Chapter 28 for materials. Default: *CS*Liquid flow rate: MAX: Flow (GPM) x Head (FT) < 430,000 [Flow (L/S) x Head (M) < 8250]Fluid head: Default: *75* FEET [*25* M]; MAX: Flow (GPM) x Head (FT) < 430,000 [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*

TURBINE

Low consistency stock pump.

Casing material: *CI*- Cast ironSS316- SS316Liquid flow rate: Range: 100 - 28,000 GPM [6.4 - 1,765 L/S]Fluid Head: Range: 15 - 350 FEET [4.6 - 106 M]Speed: Default: *1,800* RPMFluid specific gravity.: Range: 0.2 - 5.0; Default: 1.0Driver type: NONE- No driver *MOTOR*- Standard motor driver VFD- Variable frequency driver TURBINE- Turbine driver GAS ENGINE- Gas engine driverDesign temperature: Default: *120* DEG F [*50* DEG C]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 - 100Steam gauge pressure: Steam pressure for turbine drivers only. Default: *400*PSGI [*2,800 KPA].

PULP STOCK

7-14 7 Pumps (G10)


Description Type

Standard ANSI magnetic drive pump.

Casing material: *SS*- Stainless steel C 20- Carpenter 20 HASTC- Hasteloy CLiquid flow rate: MAX: 300 GPM [18.9 L/S] at 30 x HZ, 600 GPM [37.8 L/S] at 60 x HZFluid 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; Default: *3,600* RPMFluid specific gravity: Range: 0.2 - 5.0; Default: *1*Driver type: *MOTOR*- Standard motor driver VFD- Variable frequency driver NONE- No driverDesign gauge pressure: MAX: 275 PSIG [1,895 KPA]Design temperature: MAX: 450 DEG F [230 DEG C]; Default: *120* DEG F [*50* DEG C]Fluid viscosity: Default: *1* CPOISE [*1* MPA-S]Pump efficiency: Range: 10 - 100

MAG DRIVE

Sanitary centrifugal pump

For use as a product mover in a wide range of sanitary and industrial applications. Material of construction is SS316.


SAN PUMP

Pump size selection:

Symbol InletInch- Pound Metric

OutletInch-

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 100 MM 3 INCHES 75 MM

40X40 4 INCHES 100 MM 4 INCHES 100 MM

7 Pumps (G10) 7-15


Description Type

SAN PUMP - continuedRequired: select pump size or enter capacity and head.Fluid head: MAX: 365 FEET [109 M] (at maximum speed)

Required: enter capacity and head or select pump size.Liquid flow rate: MAX: 1,000 GPM [62.5 GPM] (at maximum speed)

Required: enter capacity and head or select pump size.

Design gauge pressure: *45 PSIG [310 KPA]*, MAX: 45 PSIG [310 KPA]Design temperature: *68 DEG F [20 DEG C]*, MAX: 120 DEG F [50 DEG C]Fluid specific gravity: *1.0*, MIN: 0.25, MAX: 5.0Pump efficiency: MIN: 10, MAX: 100Driver type: *TXXDC*- Standard TEFC motor WXXDC- Washdown TEFC motor WVRDC- VFD rated motor only (no controller) WVCDC- VFD rated motor with controllerSeal type: *SNGL*- Single mechanical seal SNGW- Single mechanical seal w/ water cooling DBLW- Double mechanical seal w/ water cooling

SAN PUMP

Speed Maximum Head Inch- Pound Metric

*30xHZ* 92 FEET 28 M

60XHZ 365 FEET 63 M

Speed Maximum Head Inch- Pound Metric

*30xHZ* 610 GPM 38.4 L/S

60XHZ 1,000 GPM 63 L/S

Speed

Inch- Pound Metric

Default 1,800 RPM 1,500RPM

MIN: 1,800 RPM 1,500RPM

MAX: 3,600 RPM 3,000 RPM

7-16 7 Pumps (G10)


Description Type

Sanitary fluming pump with feeder hopper

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]Fluid specific gravity: *1.0*, MIN: 0.2, MAX: 5.0 (of water-product mixture).Pump efficiency: MIN: 10, MAX: 100


FLUME PUMP

7 Pumps (G10) 7-17

Centrifugal Pumps (CP) - continued.

Description Type

FLUME PUMP - continued.

Enclosure type: OPEN- Closed frame unit *CLOSE*- Open frame unit

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]

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 Type

Standard external gear rotary pump

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 steelCI- Cast ironSS- Stainless steelBRONZ- BronzLiquid 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.

GEAR

Canned rotor gear pumpExplosion-proof motor, to 570 GPM [35 L/S].

Material: *SS316*Liquid flow rate: 40 - 570 GPM [3 - 35 L/S]Speed: MAX: 1,800 RPM; Default: *1,800* RPMViscosity: Default: *32* CSTOKE [*32* MM2/S]

CANNED RTR

7 Pumps (G10) 7-19

Gear Pumps (GP) - continued

Description Type

Mechanical seal gear pumpWith mechanical seal, to 480 GPM [30 L/S]. Includes motor driver.

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.

MECH SEAL

7-20 7 Pumps (G10)

Piston, Other Positive Displacement Pumps (P) Description Type

Reciprocating simplex with steam driver.

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: Default: *68* DEG F [*20* DEG C]Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*Driver power: Range: 3 - 10 HP [2.22 - 7.5 KW]

SIMPLEX

Reciprocating duplex with steam driver.

Material: Default: *CS*Liquid flow rate: MAX: 1,000 GPM [62 L/S]Fluid head: MAX: 1,000 FEET [300 M]Temperature: Default: *68* DEG F [*20* DEG C]Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*Driver power: Range: 2 - 100 HP [1.5 - 7.5 KW]

DUPLEX

Triplex (plunger) with pump-motor driver.

Material: Default: *CS*Liquid flow rate: MAX: 1,000 GPM [62 L/S]Fluid head: MAX: 1,000 FEET [300 M]Temperature: Default: *68* DEG F [*20* DEG C]Fluid specific gravity: Range: 0.2 - 5.0; Default *1.0*Driver power: Range: 2 -100 HP [1.5 - 75 KW]

TRIPLEX

7 Pumps (G10) 7-21

Piston, Other Positive Displacement Pumps (P) - continued

Description Type

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 steelSS316- SS316Liquid flow rate: Range: 0.012 - 600 GPM [1.3 - 37.5 L/S]Temperature: Default: *68* DEG F [*20* DEG C]Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*

DIAPHRAGM

Slurry pump.

Material:

Default: *SS316*

Liquid flow rate:

Range: 1.5 - 25 GPM [0.1 - 1.5 L/S]

Fluid specific gravity:

Range: 0.2 - 5.0; Default: *1.0*Temperature: Default: *68* DEG F [*20* DEG C]

SLURRY

7-22 7 Pumps (G10)


Description Type

Rotary (sliding vanes) pump. Includes motor driver.

Material: Defaults*Liquid flow rate: Range: 10 - 750 GPM [0.7 - 47 L/S]Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*Temperature: Default: *68* DEG F [*20* DEG C]

Material: BRONZLiquid flow rate: Range: 25 - 450 GPM [1.6 - 28 L/S]Fluid specific gravity: Range: 0.2 - 5.0; Default: *1*Temperature: Default: *68* DEG F [*20* DEG C]

ROTARY

Reciprocating plunger pump.

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.


RECIP MOTR

7 Pumps (G10) 7-23


Description Type

RECIP MOTR - continued

Material: See Chapter 28 for materials. Default: *CS*Liquid flow rate: Min: 0.01 GPM [0.4 L/S]Temperature: Default: *68* DEG F [*20* DEG C]Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*Driver power: MAX: 1,000 HP [750 KW]

High density stock pump with twin intermeshing screws.

Casing material: *SS316*, SS317Stock flow rate air dried: Flow rate of air dried (AD) solids in pumped fluid. MAX: 1,500 TPD [56 TON/H]Design gauge pressure Outlet: MAX: 160 PSIG [1,100 KPA] to 550 TPD [20 TON/H], else 100 PSIG [688 KPA].Design temperature: Default: *120* DEG F [*50* DEG C]Consistency air dried: Percent by weight of air dried (AD) solids in fluid. Range: 10 - 20; Default: *10*Fluid specific gravity: Range: 0.2 - 5.0; Default: *1*Pump efficiency: Range: 10 - 100Driver type: NONE- No driver *MOTOR*- Standard motor driver VFD- Variable frequency motor driver TURBINE, - Turbine driver GAS ENGINE- Gas engine driverSpeed: Default: *1,800* RPM [*1,500* RPM]Steam gauge pressure: Steam pressure for turbine drivers only. Default: *400* PSIG [*2,800* KPA].

HD STOCK

7-24 7 Pumps (G10)


Description Type

Sanitary rotary lobe pump

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.

Required: select pump size or enter capacity and exit pressure.Liquid flow rate: MAX: 520 GPM [32.8 L/S]Required: select pump size or enter capacity and exit pressure.Design gauge pressure Outlet: MAX: 200 PSIG [1,375 KPA]Required: select pump size or enter capacity and exit pressure.Impeller speed: MAX: 10 x Hz RPMFluid specific gravity: *1.0*, MIN: 0.2, MAX: 5.0Fluid 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 DBLE- Double mechanical sealRelief cover type: *STD*- Standard cover MAN- Manual relief cover

ROTARYLOBE

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

7 Pumps (G10) 7-25

Piston, Other Positive Displacement Pumps (P) - continued.

Pump Efficiencies

Description Type

Sanitary air diaphragm pump

Material of construction is SS316.


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]Design gauge pressure: MAX: 110 PSIG [750 KPA]Design temperature: MIN: 68 DEG F [20 DEG C], MAX: 300 DEG F [148 DEG C]Fluid specific gravity: *1.0*, MIN: 0.2, MAX: 5.0

AIR DIAPH

Pump Type Default EfficiencyCentrifugal Pumps < 50 GPM = 60%All Other Pumps 82%Hi-Density Stock Pump Calculated using an empirical correlation.

7-26 7 Pumps (G10)

7 Pumps (G10) 7-27

7-28 7 Pumps (G10)


Introduction to Towers and Columns

Tower/Column Applications

Tower/Column Internals

Description of Towers/Columns

Materials of Construction

Shell and Head Design

Double Diameter Towers (DDT)

Single Diameter Towers (TW)

8 Towers, Columns (G6)

8 Towers, Columns (G6) 8-1

Introduction to Towers and ColumnsTowers 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 ApplicationsTowers 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 8 Towers, Columns (G6)

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 InternalsTrays — 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


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.


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.


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 ConstructionThe 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 non-ferrous 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 DesignTypically, 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.


Double Diameter Towers (DDT)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


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.

Application: Defines vessel function and related pipe/instrumentation model. Default: *ABSORB* ABSORB- Absorption DESORB- Desorption DISTIL- Distillation with thermosiphon reboiler (not included)


PACKED


Double Diameter Towers (DDT) - continued

Description Type

PACKED - continued

DIS-RB- Distillation with kettler reboiler (not included)EXTRAC- ExtractionGAS-AD- Gas adsorptionLIQ-AD- Liquid adsorptionSTRIPP- 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: See Chapter 28 for materials. Default: *NONE*Packing height Bottom: Default: *0.0* FEET [*0.0* M]Cladding material Bottom: See Chapter 28 for materials. Default: *NONE*Skirt height: Default: 1.5 x bottom diameter; enter 0.0 if vessel hung in OPEN structure.Manhole diameter Bottom: Max: 48 INCHES [1,200 MM]Thickness Bottom section: Base material thickness including corrosion allowance.Corrosion allowance Bottom: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Cladding thickness Bottom: Default: 0.125 INCHES [3 MM] if cladding material is specified; otherwise: 0.0.Stiffening ring spacing Bottom: Default stiffeners designed for vacuum only, enter 0.0 if not required.




Description Type

PACKED - continued

Base material Top: For clad plate, specify the backing plate material (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: See Chapter 28 for materials. Default: *NONE*Packing height Top: Default: *0.0* FEET [*0.0* M]Cladding material Top: See Chapter 28 for materials. Default: *NONE*Pipe material Top: See Chapter 18 for pipe materials.Manhole diameter Top: Max: 48 INCHES [1,200 MM]Thickness Top section: Base material thickness including corrosion allowance.Corrosion allowance Top: Default 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Cladding thickness Top: Default: 0.125 INCHES [3 MM] if cladding material is specified; otherwise: 0.0.Stiffening ring spacing Top: Default stiffeners designed for vacuum only, enter 0.0 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




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: If pressure and vacuum entered, design is for worst case. Default: pressure.Weld efficiency: 50 - 100; ASME/JIS codes only, where allowed for thin wall vessels; Default: Area Design Basis.Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredMolecular weight Overhead prod: Default: 50 for distillation and stripping applications; otherwise 30.Number body flange sets Bottom: Number of sets (pairs) of body flanges of same diameter as vessel.Number body flange sets Top: 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 diameterASME design basis: Default: *D1NF*, applicable only forASME code design. D1NF- ASME Division 1 - no fatigue analysis D1F- ASME Division 1 - with fatigue analysis D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 - with fatigue analysis



Description Type

Trayed double diameter tower. Available tray types include: bubble cap, sieve, turbo grid, valve and clips and supports without trays.

Tray type: Default: *VALVE* VALVE- Valve trays BUBBL- Bubble cap trays TURBO- Turbo grid trays SIEVE- Sieve trays NONE.- No traysApplication: Defines vessel function and related 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)Base material Bottom: For clad plate, specify the backing plate material (cladding is defined below). See Chapter 28 for materials. Default: *A 515*.Design gauge pressure Bottom: Default: Specified top section pressure, or 50 PSIG [350 KPA]; negative for vacuum.Design temperature Bottom: 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*


TRAYED



Description Type

TRAYED - continued

Cladding material Bottom: See Chapter 28 for materials. Default: *NONE*.Pipe material Bottom: See Chapter 18 for pipe materials.Skirt height: Default: 1.5 x bottom diameter; enter 0.0 if vessel hung in OPEN structure.Manhole diameter Bottom: Max: 48 INCHES [1,200 MM]Thickness Bottom section: Base material thickness including corrosion allowance.Corrosion allowance Bottom: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Cladding thickness Bottom: Default: 0.125 INCHES [3 MM] if cladding material is specified; otherwise: 0.0.Stiffening ring spacing Bottom: Default stiffeners designed for vacuum only, enter 0.0 if not required.Base material Top: For clad plate, specify the backing plate material (cladding if 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].Top Tray material or packing: Specify tray material for trays or packing material for packed section. Default: *NONE*.Number trays/Packed height Top: Enter number of trays for trayed sections or packing height for packed sections. Default: *0.0*.Cladding material Top: See Chapter 28 for materials. Default: *NONE*.Pipe material Top: See Chapter 18 for pipe materials.Manhole diameter Top: Max: 48 INCHES [1,200 MM]




Description Type

TRAYED - continued

Thickness Top section: Base material thickness including corrosion allowance.Corrosion allowance Top: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Cladding thickness Top: Default: 0.125 INCHES [3 MM] if cladding material is specified; otherwise: 0.0.Stiffening ring spacing Top: Default stiffeners designed for vacuum only, enter 0.0 if not required.Wind or seismic design: Default: vessel design for wind and seismic loads defined in Project Basis. W+S- Wind and seismic design required WIND- Wind design only SEIS- Seismic design only NONE- Delete wind and seismic designFluid volume: For seismic design; fluid volume as a% of vessel volume (water assumed); Max: 100; Default: *20*.Vacuum design gauge pressure: If pressure and vacuum entered, design is for worst case. Default: pressure.Weld efficiency: Range: 50 - 100; ASME/JIS codes only, where allowed for thin wall vessels; Default: Area Basis.Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredMolecular weight Overhead prod: Default: 50 for distillation and stripping applications; otherwise - 30.Number body flange sets Bottom: Number of sets (pairs) of body flanges of same diameter as vessel.Number body flange sets Top: Number of sets (pairs) of body flanges of same diameter as vessel.




Description Type

TRAYED - continued

Diameter option: Default: See Area Design Basis. OD- Outside diameter ID- Inside diameterASME design basis: Applicable only for ASME code design. See following entries for fatigue data. D1NF- ASME Division 1 - no fatigue analysis D1F- ASME Division 1 - with fatigue analysis D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 with fatigue analysisStart 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: ASME fatigue only. Thousands of deviations from 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].


Single Diameter Towers (TW)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 (OPN-STL-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 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.

If a packing type is not specified, a packed column is designed and costed with distributor and support plates for average density packing.


PACKED


Single Diameter Towers (TW) - continued

Description Type

PACKED - continued

Application: Defines vessel function and related pipe/instrumentation model; Default: *ABSORB* 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)Shell Material: For clad plate, specify the backing plate material (cladding is defined below). See Chapter 28 for materials. Default: *A 515*.Design Gauge Pressure: If pressure and vacuum entered, design is for worst case. Default: pressure *15* PSIG [*100* KPA].Vacuum Design Gauge Pressure: If pressure and vacuum entered, design is for worst case. Default: pressure.Design Temperature: Default: 400 DEG F [200 DEG C] for copper alloys; 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.




Description Type

PACKED - continued

Cladding Material: See Chapter 28 for cladding materials. 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. W+S- Wind and seismic design required WIND- Wind design only SEIS- Seismic design only NONE- Delete wind and seismic designFluid Volume: For seismic design; fluid volume as a% of vessel volume (water assumed). Max: 100; Default: *20*.Manhole Diameter: Max: 48 INCHES [1,200 MM].Base Material Thickness: Base material thickness including corrosion allowance.Corrosion Allowance: Default: 0.125 INCHES [3 MM] for CS; 0.0 for other material. Double if jacketed.Number of Body Flange Sets: Number of sets (pairs) of body flanges of same diameter as vessel.Weld Efficiency: ASME/JIS Codes only, where allowed for thin wall vessels; Default: Area Basis; Range: 50 - 100.Stress Relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding Thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise - 0.0.Stiffening Ring Spacing: Default stiffeners designed for vacuum only, enter 0.0 if not required.Jacket Design Gauge Pressure: Jacket pressure or thickness required to obtain jacket. Default: No jacket.Jacket Type: Default: *FULL*. FULL- Full jacket PIPE.- Half-pipe jacket - Continued on next page -



Description Type

PACKED - continued

Jacket Thickness: Jacket pressure or thickness required to obtain jacket. Default: No jacket.Jacket Material: See Chapter 28 for materials. Default: *CS*.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. OD- Outside diameter ID- Inside diameterASME Design Basis: Applicable only for ASME code design. See following entries for fatigue data. D1NF- ASME Division 1 - no fatigue analysis D1F- ASME Division 1 - with fatigue analysis D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 with fatigue analysisStart 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: ASME fatigue only. Thousands of deviations from design temperature in equipment life. Default: *0*.Temperature Amplitude: ASME fatigue only. Amplitude of temperature deviation as a percent of design temperature.



Description Type

Trayed single diameter tower. Available tray types include: bubble cap, sieve, turbo grid, valve and clips and supports without trays.Tray Type: Default: *VALVE* VALVE- Valve tray BUBBL- Bubble cap trays TURBO- Turbo grid trays SIEVE- Sieve trays NONE- No traysApplication: Defines vessel function and related 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 STRIPP- Stripping with thermosiphon reboiler (not included) STR-RB- Stripping with kettle reboiler (not included)Shell Material: For clad plate, specify the backing plate material (cladding is defined below). Default: *A 515*.Vessel Tangent to Tangent Height: Default: 15 FEET [4.5 M] plus tray stack height.Design Gauge Pressure: If pressure and vacuum entered, design is for worst case. Default: pressure *15* PSIG [*100* KPA].Vacuum Design Gauge Pressure: If pressure and vacuum entered, design is for worst case. Default: pressure.Design Temperature: Default: 400 DEG F [200 DEG C] for copper alloys; otherwise material: 650 DEG F [340 DEG C].Tray Material: See Chapter 28 for materials. Default: *A285C*.Number of Trays: Min: 2


TRAYED



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: See Chapter 28 for cladding materials. 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. W+S- Wind and seismic design required WIND- Wind design only SEIS- Seismic design only NONE- Delete wind and seismic designFluid Volume: For seismic design; fluid volume as a% of vessel volume (water assumed). Max: 100; Default: *20*.Manhole Diameter: Max: 48 INCHES [1,200 MM].Base Material Thickness: Base material thickness including corrosion allowance.Corrosion Allowance: Default: 0.125 INCHES [3 MM] for CS; 0.0 for other material. Double if jacketed.Number of Body Flange Sets: Number of sets (pairs) of body flanges of same 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: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise - 0.0.Stiffening Ring Spacing: Default stiffeners designed for vacuum only, enter 0.0 if not required.Jacket Design Gauge Pressure: Jacket pressure or thickness required to obtain jacket. Default: No jacket. - Continued on next page -



Description Type

TRAYED - continued

Jacket Type: Default: *FULL* FULL- Full jacket PIPE- Half-pipe jacketJacket Thickness: Jacket pressure or thickness required to obtain jacket. Default: No jacket.Jacket Material: See Chapter 28 for materials. Default: *CS*.Head Type: ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torishpherical (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. OD- Outside diameter ID- Inside diameterTray Thickness: Default: *0.187* INCHES [*4.50* MM];Max: 0.375 INCHES [9.00 MM]ASME Design Basis: Applicable only for ASME code design. See following entries for fatigue data. D1NF- ASME Division 1 - no fatigue analysis D1F- ASME Division 1 - with fatigue analysis D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 with fatigue analysisStart 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*.




Description Type

TRAYED - continued

Temperature Cycles x 1000: ASME fatigue only. Thousands of deviations from design temperature in equipment life. Default: *0*.Temperature Amplitude: ASME fatigue only. Amplitude of temperature deviation as a percent of design temperature.

Tray stack only, for single- and double-diameter towers.

Optional tray types include: bubble-cap, turbo grid, seive and valve.

Tray Material: See Chapter 28 for materials. Default: *CS*.Number of Trays: Min: 1.Tray Type: BUBBL- Bubble cap trays TURBO- Turbo grid trays SIEVE- Sieve trays VALVE- Valve traysTray 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].

TRAY STACK

Direct contact heat exchanger tower includes distributors, packing supports, nozzles; may include packing.

Shell Material: For clad plate, specify the backing plate material (cladding is defined below). See Chapter 28 for 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.Vessel Tangent to Tangent Height: Enter either flowrate or diameter and height.


DC HE TW



Description Type

DC HE TW - continued

Design Gauge Pressure: If pressure and vacuum entered, design is for worst case. Default: pressure 15 PSIG [100 KPA].Vacuum Design Gauge Pressure: If pressure and vacuum entered, design is for worst case. Default: pressure.Design Temperature: Default: 400 DEG F [200 DEG C] for copper alloys; other material: 650 DEG F [340 DEG C].Operating Temperature: 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].Packing Type Section 2: Default: None for OPEN top, else 68PVC. See Chapter 28 for packing materials.Packing Height Section 2: Max: Tangent to tangent height less height of packing No. 1.Cladding Material: See Chapter 28 for cladding materials. 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. W+S- Wind and seismic design required WIND- Wind display only SEIS- Seismic design only NONE- Delete wind and seismic designFluid Volume: For seismic design, fluid volume as a% of vessel volume (water assumed). Max: 100; Default: *20*.Manhole Diameter: Max: 48 INCHES [1,200 MM].




Description Type

DC HE TW - continued

Base Material Thickness: Base material thickness including corrosion allowance.Corrosion Allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other material, double if jacketed.Number of Body Flange Sets: Number of sets (pairs) of body flanges of same diameter as vessel.Weld Efficiency: ASME/JIS codes only, where allowed for thin wall vessels; Default: See Area Basis; Range: 50 - 100%.Stress Relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding Thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise 0.0.Stiffening Ring Spacing: Default stiffeners designed for vacuum only, enter 0.0 if not required.Jacket Design Gauge Pressure: Jacket pressure or thickness required to obtain jacket. Default: No jacket.Jacket Type: Default: *FULL* FULL- Full jacket PIPE- Half-pipe jacketJacket Thickness: Jacket pressure or thickness required to obtain jacket. Default: No jacket.Jacket Material: See Chapter 28 for materials. Default: *CS*.Head Type: ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME) OPEN- Open top/TORI bottomDiameter Option: Defines desired diameter as ID or OD; Default: See Area Design Basis. OD- Outside diameter ID- Inside diameter



Description Type

Temperature swing adsorption unit includes vessel pair(s), distributors, packing supports, and valve skid; may include heater (steam or electric), packing.

Shell Material: For clad plate, specify the backing plate material (cladding is defined below). See Chapter 28 for 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: Enter either flowrate or diameter and height.Vessel Tangent to Tangent Height: Enter either flowrate or diameter and height.Number of Vessel Pairs: Number of vessel pairs in configuration, one vessel per pair absorbing at a time.Design Gauge Pressure: If pressure and vacuum entered, design is for worst case. Default: pressure 15 PSIG [100 KPA].Vacuum Design Gauge Pressure: If pressure and vacuum entered, design is for worst case. Default: pressure.Design Temperature: Default: 400 DEG F [200 DEG C] for copper alloys; other material: 650 DEG F [340 DEG C].Packing Type Section 1: See Chapter 28 for packing materials; Default: *13XMS*.Packing Height Section 1: Max: Tangent to tangent height less 1.0 FEET [0.3 M].Packing Type Section 2: Default: *ALMNA* (Alumina).Packing Height Section 2: Max: Tangent to tangent height less height of packing No. 1.Cladding Material: See Chapter 28 for cladding materials. Default: *NONE*.Skirt Height: Enter 0.0 skirt height if tower hung in OPEN structure; Default: 1.5 x diameter.


TS ADSORB



Description Type

TS ADSORB - continued

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- Seismic design only NONE- Delete wind and seismic designFluid Volume: For seismic design, fluid volume as a% of vessel volume (water assumed). Max: 100; Default: *20*.Manhole Diameter: Max: 48 INCHES [1,200 MM].Base Material Thickness: Base material thickness including corrosion allowance.Corrosion Allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other material, double if jacketed.Number of Body Flange Sets: Number of sets (pairs) of body flanges of same diameter as vessel.Weld Efficiency: ASME/JIS codes only, where allowed for thin wall vessels; Range: 50 - 100%; Default: See Area Basis.Stress Relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding Thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise 0.0.Stiffening Ring Spacing: Default stiffeners designed for vacuum only, enter 0.0 if not required.Jacket Design Gauge Pressure: Jacket pressure or thickness required to obtain jacket. Default: No jacket.Jacket Type: Default: *FULL* FULL- Full jacket PIPE- Half-pipe jacketJacket Thickness: Jacket pressure or thickness required to obtain jacket. Default: No jacket.Jacket Material: See Chapter 28 for materials. Default: *CS*. - Continued on next page -



Description Type

TS ADSORB - continued

Head Type: ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME) OPEN- Open top/TORI bottomHeater Type: *ELEC*- Electric heater STEAM- Steam heater NONE- No heaterSteam Gauge Pressure: Default: *150* PSIG [*1,000* KPA] Applies to steam gas heater onlyDiameter Option: Defines desired diameter as ID or OD; Default: See Area Design Basis. OD- Outside diameter ID- Inside diameter



Condensers (C)

Ejectors (EJ)

Vacuum Pumps (VP)

9 Vacuum Systems (G6)

9 Vacuum Systems (G6) 9-1

Condensers (C)Barometric condenser

Description Type

Barometric for condensing of motive steam between ejector stages.

Material: Default: *CS*Water flow rate: Range: 200 - 5,000 GPM [15 - 315 L/S]

BAROMETRIC

Material: CIWater 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 9 Vacuum Systems (G6)

Ejectors (EJ)100 PSIG [690 KPA] steam

Description Type

One stage of non-condensing ejection. 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- HastelloyAir 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]

SINGLE STG

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.


.TWO STAGE


Ejectors (EJ) - continued

Description Type

TWO STAGE - continued

Material: Default: *CS* CS- Carbon steel SS- Stainless steel HAST- HastelloyAir ejection rate: Range: 10 - 150 LB/H [4.6 -68 KG/H]Suction absolute pressure: Range: 10 - 200 MM HG [1,340 - 26,600 PA]

Non-condensing two single stage ejectors without 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- HastelloyAir ejection rate: Range: 10 - 120 LB/H [4.6 - 50 KG/H]Suction absolute pressure: Range: 5 - 100 MM HG [670 - 13,3000 PA]

2 STAGE



Description Type

Four stages of ejection with barometric condenser 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- HastelloyAir ejection rate: Range: 10 - 110 LB/H [4.6 - 48 KG/H]Suction absolute pressure: Range: 0.5 - 10 MM HG [67 - 1,330 PA]

4 STAGE B

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 ejectors are used to produce suction for vacuum 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.

Material: Default: *CS* CS- Carbon steel SS- Stainless steel HAST- HastelloyAir ejection rate: Range: 10 - 110 LB/H [4.6 - 48 KG/H]Suction absolute pressure: Range: 0.25 - 5.0 MM HG [33 - 660 PA]

4 STAGE



Description Type

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 ejectors are used to produce suction for vacuum distillation, vacuum crystallizers and vacuum evaporators.This item is a five stage ejector with one barometric condenser between the fourth and fifth ejectors.

Material: Default: *CS* CS- Carbon steel SS- Stainless steel HAST- HastelloyAir ejection rate: Range: 10 - 110 LB/H [4.6 - 48 KG/H]Suction absolute pressure: Range: 0.5 - 1.0 MM HG [7 - 130 PA]

5 STAGE B


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.

Material: Default: *CS* CS- Carbon steel SS316- SS316Actual gas flow rate: Range: 30 - 4,000 CFM [55 - 6,750 M3/H]

WATER SEAL

Mechanical oil-sealed vacuum pump.

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 steelActual gas flow rate: Range: 30 - 700 CFM [55 - 1,150 M3/H]Number of stages: Range: 1 - 2; Default: *1*

MECHANICAL

Mechanical booster includes motor and drive.Ultimate pressure 0.0001 MM HG [0.0135 PA].

Material: Default: *CS* CS- Carbon steelActual gas flow rate: Range: 120 - 2,000 CFW [205 - 3,375 M3/H]

MECH BOOST



Horizontal Tanks (HT)

Vertical Tanks (VT)

10 Vessels (G10)

10 Vessels (G10) 10-1

Horizontal Tanks (HT)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.

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.


HORIZ DRUM

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: Defines vessel function and related piping/instrumentation model. Default: *blank*blank- Standard continuous process vessel BATCH- Batch process vessel STORAGE- Storage vessel RECVR- Receiver KO- Knock-out drumShell material: For clad plate, specify the backing plate 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. 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.


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 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.Design gauge pressure: If pressure and vacuum entered, design is for worst case; Default: *15* PSIG [*100* KPA] pressure.Vacuum design gauge pressure: If pressure and vacuum entered, design is for worst case. Default: pressure.Design temperature: Default: 650 DEG F [340 DEG C] ferrous material; 250 DEG F [120 DEG C] other material.Operating temperature: Default: design temperature. The operating temperature is used in the calculation of piping and insulation thickness.Cladding material: See Chapter 28 for cladding materials.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: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.


10-4 10 Vessels (G10)


Description Type


Weld efficiency: ASME/JIS codes only, where allowed for thin wall vessel; Default: Area Basis. Range: 50 - 100.Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise: 0.0.Stiffening ring spacing: Default stiffeners designed for vacuum only, enter 0.0 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. ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME)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

Multi-wall design for high pressure service with total 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.


MULTI WALL

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*blank- Standard continuous process vessel BATCH- Batch process vessel STORAGE- Storage vessel RECVR- Receiver KO- Knock-out drumShell material: For clad plate, specify the backing plate material. (Cladding is defined below.) See Chapter 28 for materials. Default: *A 515*.Liquid volume: Enter either capacity or diameter and length.Vessel diameter: Enter either capacity or diameter and length.Vessel tangent to tangent length: Enter either capacity or diameter and length.Design gauge pressure: If pressure and vacuum entered, design is for worst case. Default: *15* PSIG [*100* KPA].Vacuum design gauge pressure: If pressure and vacuum entered, design is for worst case. Default: pressure.Design temperature: Default: 650 DEG F [340 DEG C] ferrous material; 250 DEG F [120 DEG C] other material.Operating 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*.Allowance for internals:

Specify an allowance for internals as a percent of basic vessel weight. Default: *0.0*.Diameter of drip leg: Drip leg (boot) diameter and length must be specified if required. - Continued on next page -

10-6 10 Vessels (G10)


Description Type


Height of drip leg: Drip leg (boot) diameter and length must be specified if required.Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other material.Weld efficiency: ASME/JIS codes only, where allowed for thin wall vessels; Default: Area Basis. Range: 50 - 100.Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified; otherwise: 0.0.Stiffening ring spacing: Default stiffeners designed for vacuum only, enter 0.0 if not required.Head type: ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME)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

Jacketed horizontal pressure/vacuum drum.

Application: Defines vessel function and related piping/instrumentation model. Default: *blank* blank- Standard continuous process vessel BATCH- Batch process vessel STORAGE- Storage vessel RECVR- Receiver KO- Knock-out drum


JACKETED

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: Enter either capacity or diameter and length.Vessel diameter: Enter either capacity or diameter and length.Vessel tangent to tangent length: Enter either capacity or diameter and length.Design gauge pressure: If pressure and vacuum entered, design is for worst case; Default: *15* PSIG [*100* KPA].Vacuum design gauge pressure: If pressure and vacuum entered, design is for worst case; Default: pressure.Design temperature: Default: 650 DEG F [340 DEG C] ferrous material; 250 DEG F [120 DEG C] other materials.Operating temperature: Default: design temperature.Cladding material: See Chapter 28 for materials.Jacket design gauge pressure: Default: *90* PSIG [*620* KPA].Jacket type: Default: *FULL* FULL- Full jacket PIPE- Half-pipe jacket

Jacket material:

See Chapter 28 for materials. Default: *CS*.

Manhole diameter:

Default: *18* INCHES [450 MM]; Max: 48 INCHES [1,200];

Number of manholes: Default: *1*.

Allowance for internals:

Specify an allowance for internals as a percent of basic vessel weight. Default: *0.0*.

Diameter of drip leg:

Drip leg (boot) diameter and length must be specified if required.

Height of drip leg:

Drip leg (boot) diameter and length must be specified if required.


10-8 10 Vessels (G10)


Description Type


Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 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. Range: 50 - 100.Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified; otherwise: 0.0.Stiffening ring spacing: Default stiffeners designed for vacuum only, enter 0.0 if not required.Head type: ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME)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

Sanitary horizontal drum

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]Enter either capacity or diameter and length.Vessel diameter: MAX: 10 FEET [3 M]Enter either capacity or diameter and length. - Continued on next page -

SAN TANK

10 Vessels (G10) 10-9


Description Type

SAN TANK - continued

Vessel length: MAX: 15 FEET [4.5 M]Enter either capacity or diameter and length.Operating temperature: *68 DEG F [20 DEG C]*Head type: *TORI*- Torispherical (ASME) CON15- 15 degree cone headJacket type: *NONE*- No jacket DMPLE- 90 PSIG [620 KPA] dimple jacket

10-10 10 Vessels (G10)

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

Cylindrical vertical pressure/vacuum vessel. Use minus pressure for vacuum design.

Application: Defines vessel function and related piping/instrumentation model. Default: *blank*blank- Standard continuous process vessel BATCH- Batch process vessel STORAGE- Storage vessel RECVR- Receiver KO- Knock-out drum

Shell material:

For clad plate, specify the backing plate material. See Chapter 28 for materials. Default: *A 515*.


CYLINDER

10 Vessels (G10) 10-11

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 straight side length-to-diameter ratio is chosen by the system, considering cost and practicability.

Vessel diameter: Enter either capacity or diameter and height. A value must be specified if vessel capacity is not specified. If both vessel capacity and height (or length) are specified, the diameter is calculated from these values. If both vessel capacity and diameter are specified, the height (or length) is calculated from these values.Vessel tangent to tangent height: Enter either capacity or diameter and height. See Diameter.Design gauge pressure: If pressure and vacuum entered, design is for worst case; Default: *15* PSIG [*100* KPA].Vacuum design gauge pressure: If pressure and vacuum entered, design is for worst case; Default: pressure.Design temperature: Default: 650 DEG F [340 DEG C] ferrous material, 250 DEG F [120 DEG C] other material.Operating temperature: Default: design temperature.


10-12 10 Vessels (G10)


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.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- Seismic design only NONE- Delete wind and seismic designFluid volume: For seismic design, fluid volume as a% of vessel volume (water assumed). Max: 100; Default: *20*.Manhole diameter: Max: 48 INCHES [1,200 MM]; Default: 18 INCHES [450 MM].Number of manholes: Default: *1*.Allowance for internals: Default: *0.0*; Specify an allowance for internals as a percent of basic vessel weight.Demister thickness: Default: *12* INCHES [*300* MM]Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM for CS, 0.0 for other materials.Number of body flange sets: Number of sets (pairs) of body flanges of same diameter as vessel.Weld efficiency: ASME/JIS codes only, where allowed for thin wall vessels; Defaults: Area Basis. Range: 50 - 100.


10 Vessels (G10) 10-13


Description Type


Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding material: If no cladding material is specified, the system assumes that the vessel is not clad regardless of any input for cladding thickness. See Chapter 28 for materials.Cladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise 0.0. See Cladding Material.Stiffening ring spacing: Default stiffeners designed for vacuum only, enter 0.0 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. ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME)Head thickness Top: Base material thickness including corrosion allowance.Head thickness Bottom: Base material thickness including corrosion allowance.Diameter option: Defines desired diameter as ID or OD; Default: See Area Design Basis. OD- Outside diameter ID- Inside diameterASME design basis: Applicable only for ASME code design. See following entries for fatigue data. Default: *D1NF*. D1NF- ASME Division 1 - no fatigue analysis D1F- ASME Division 1 - with fatigue analysis D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 - with fatigue analysisStart stop cycles x 1000: ASME fatigue only. Thousands of start-up cycles during the full equipment life. Range: 5.00 - 0.02. - Continued on next page -

10-14 10 Vessels (G10)


Description Type


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 process 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: *0*.Temperature cycles x 1000: ASME fatigue only. Thousands of deviations from design temperature in equipment life. Default: *0*.Temperature amplitude: 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).

Application: Defines vessel function and related piping/instrumentation model. Default: *blank*blank- Standard continuous process vessel BATCH- Batch process vessel STORAGE- Storage vessel RECVR- Receiver KO- Knock-out drumShell material: For clad plate, specify the backing plate material. See Chapter 28 for materials. Default: *A 515*.Liquid volume: Enter either capacity or diameter and height.Vessel diameter: Enter either capacity or diameter and height.Vessel tangent to tangent height: Enter either capacity or diameter and height.Design gauge pressure: If pressure and vacuum entered, design is for worst case. Default: *15* PSIG [*100* KPA].Vacuum design gauge pressure: If pressure and vacuum entered, design is for worst case.


MULTI WALL

10 Vessels (G10) 10-15


Description Type


Design temperature: Default: 650 DEG F [340 DEG C] ferrous material, 250 DEG F [120 DEG C] other material.Operating temperature: Default: design temperature.Skirt height: Skip if legs required, enter 0.0 if hung in OPEN 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].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- Seismic design only NONE- Delete wind and seismic designFluid volume: Max: 100; Default: *20*; For seismic design; fluid volume as a% of volume (water assumed).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*.Demister thickness: Default: *12* INCHES [*300* MM]Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Number of body flange sets: Number of sets (pairs) of body flanges of same diameter as vessel.Weld efficiency: ASME/JIS codes only, where allowed for thin wall vessels; Range: 50 - 100; Default: Area Basis.


10-16 10 Vessels (G10)


Description Type


Stress relief: Default: see Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding material: See Chapter 28 for cladding materials.Cladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise - 0.0.Stiffening ring spacing: Default stiffeners designed for vacuum only, enter 0.0 if not required.Head type: ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME)Head thickness Top: Base material thickness including corrosion allowance.Head thickness Bottom: Base material thickness including corrosion allowance.Diameter option: Defines desired diameter as ID or OD; Default: see Area Design Basis. OD- Outside diameter ID- Inside diameterASME design basis: Applicable only for ASME code design. See following entries for fatigue data. Default: *D1NF*. D1NF- ASME Division 1 - no fatigue analysis D1F- ASME Division 1 - with fatigue analysis D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 - with fatigue analysisStart stop cycles x 1000: ASME fatigue only. Thousands of start-up cycles during the full equipment life. Range: 5.00 - 0.02.Pressure Cycles x 1000: ASME fatigue only. Thousands of deviations from design pressure during equipment life. Default: *0*.


10 Vessels (G10) 10-17


Description Type


Pressure amplitude: ASME fatigue only. Amplitude of process 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: *0*.Temperature cycles x 1000: ASME fatigue only. Thousands of deviations from design temperature in equipment life. Default: *0*.Temperature amplitude: ASME fatigue only. Amplitude of temperature as a percent of design temperature. Default: *0*.

Jacketed, cylindrical, vertical pressure/vacuum vessel.

Application: Defines vessel function and related piping/instrumentation model. Default: *blank*blank- Standard continuous process vessel BATCH- Batch process vessel STORAGE- Storage vessel RECVR- Receiver KO- Knock-out drumShell material: For clad plate, specify the backing plate material. (Cladding is specified below.) Default: *A 515*.Liquid volume: Enter either capacity or diameter and height.Vessel diameter: Enter either capacity or diameter and height.Vessel tangent to tangent height: Enter either capacity or diameter and height.Design gauge pressure: If pressure and vacuum entered, design is for worst case. Default: *15* PSIG [*100* KPA].Vacuum design gauge pressure: If pressure and vacuum entered, design is for worst case. Default: pressure.Design temperature: Default: 650 DEG F [340 DEG C] ferrous material, 250 DEG F [120 DEG C] other material.Operating temperature: Default: design temperature.


JACKETED

10-18 10 Vessels (G10)


Description Type


Jacket design gauge pressure: Default: *90* PSIG [*620* KPA].Jacket type: Default: *FULL* FULL- Full jacket PIPE- Half-pipe jacketJacket material: See Chapter 28 for materials. Default: *CS*.Skirt height: Skip if legs required, enter 0.0 if hung in OPEN 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].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- Seismic design only NONE- Delete wind and seismic designFluid volume: Max: 100; Default: *20*; For seismic design; fluid volume as a% of vessel volume (water assumed).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*.Demister thickness: Default: *12* INCHES [*300* MM]Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other material, double if jacketed.Number of body flange sets: Number of sets (pairs) of body flanges of same diameter as vessel.Weld efficiency: ASME/JIS codes only, where allowed for thin wall vessels; Range: 50 - 100; Default: Area Basis.


10 Vessels (G10) 10-19


Description Type


Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress relief requiredCladding material: See Chapter 28 for cladding materials.Cladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise - 0.0.Stiffening ring spacing: Default stiffeners designed for vacuum only, enter 0.0 if not required.Head type: ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME)Head thickness Top: Base material thickness including corrosion allowance.Head thickness Bottom: Base material thickness including corrosion allowance.Diameter option: Defines desired diameter as ID or OD; Default: see Area Design Basis. OD- Outside diameter ID- Inside diameterASME design basis: Applicable only for ASME code design. See following entries for fatigue data. Default: *D1NF*. D1NF- ASME Division 1 - no fatigue analysis D1F- ASME Division 1 - with fatigue analysis D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 - with fatigue analysisStart stop cycles x 1000: ASME fatigue only. Thousands of start-up cycles during the full equipment life. Range: 5.00 - 0.02.Pressure cycles x 1000: ASME fatigue only. Thousands of deviations from design pressure during equipment life.


10-20 10 Vessels (G10)


Description Type


Default: *0*.Pressure amplitude: ASME fatigue only. Amplitude of process 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: *0*.Temperature cycles x 1000: ASME fatigue only. Thousands of deviations from design temperature in equipment life. Default: *0*.Temperature amplitude: ASME fatigue only. Amplitude of temperature as a percent of design temperature. Default: *0*.

High Pressure Gas/Liquid Storage

Sphere pressure/vacuum design to 3000 PSIG [20500 KPA]. Use minus pressure for vacuum design.

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: For clad plate, specify the backing plate material. See Chapter 28 for materials. Default: *A 515*.


SPHERE

10 Vessels (G10) 10-21


Description Type

SPHERE - continued

Liquid volume:

Enter either capacity or diameter.Vessel diameter: Enter either capacity or diameter.Design gauge pressure: -15 - 3,000 PSIG [-100 - 20,5000]; Default: 15 PSIG [100 KPA].Design temperature: Max: 1,500 DEG F [815 DEG C]; Default: *68* DEG F [*20* DEG C].Operating temperature: Default: design temperature.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*.Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Cladding material: See Chapter 28 for cladding materials.Cladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise - 0.0.Diameter option: Defines desired diameter as ID or OD; Default: see Area Design Basis. OD- Outside diameter ID- Inside diameterASME design basis: Applicable only for ASME code design. See following entries for fatigue data. Default: *D1NF*. D1NF- ASME Division 1 - no fatigue analysis D1F- ASME Division 1 - with fatigue analysis D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 - with fatigue analysis


10-22 10 Vessels (G10)


Description Type

SPHERE - continued

Start stop cycles x 1000: ASME fatigue only. Thousands of start-up cycles during the full equipment life. Range: 5.00 - 0.02.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 process 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: *0*.Temperature cycles x 1000: ASME fatigue only. Thousands of deviations from design temperature in equipment life. Default: *0*.Temperature amplitude: ASME fatigue only. Amplitude of temperature as a percent of design temperature. Default: *0*.

Spheroid to 750000 GALLONS [2840 M3]. Field erected.

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).


SPHEROID

10 Vessels (G10) 10-23


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: For clad plate, specify the backing plate material. See Chapter 28 for materials. Default: *A 515*.Liquid volume: Enter either capacity or diameter and height. Range: 60,000 - 750,000 GALLONS [230 - 2,840 M3]; Vessel diameter: Enter either capacity or diameter and height.Vessel height: Enter either capacity or diameter and height.Design gauge pressure: Range: 0.0 - 15 PSIG [0.0 - 100 KPA]; Default: *15* PSIG [*100* KPA].Design temperature: Default: *68* DEG F [*20* DEG C].Operating temperature: Default: design temperature.Manhole diameter: Max: 48 INCHES [1,200 MM]; Default: *18* INCHES [*450* MM].Number of manholes: Default: *1*.Allowance for internals: Default: Specify an allowance for internals as a percent of basic vessel weight. Default: *0.0*.Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Cladding material: See Chapter 28 for cladding materials.


10-24 10 Vessels (G10)


Description Type

SPHEROID - continued

Cladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise - 0.0.Diameter option: Defines desired diameter as ID or OD; Default - see Area Design Basis. OD- Outside diameter ID- Inside diameter

Near-Atmospheric Liquid 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.

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.

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.


STORAGE

Flat roof tank

Floating roof tank

10 Vessels (G10) 10-25


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 M2]. 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].

Open top tanks are designed and constructed according to user-generated design code standards. Open top tanks have a maximum temperature of 250 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*.Capacity units: Unit of measure for the capacity entry. Enter capacity unit symbol as entered in project specifications. If units are not changed, enter GALLONS [M3] or BARRELS [M3].

Liquid volume (gallons/barrels): Enter either capacity (see capacity unit entry for units) 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 - Continued on next page -

Cone roof tank

Lifter roof tank

Open top tank

10-26 10 Vessels (G10)


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 roofBottom type: Default: *FLAT* FLAT- Single flat bottom DBL- Double bottomDesign gauge pressure: 0.0 - 2.5 PSIG [0.0 - 17 KPA]; Default: *0.05* PSIG [*0.35* KPA].Design temperature: Default: *68* DEG F [*20* DEG C].Operating temperature: Default: design temperature.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*.Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: *0.125* INCHES [*3* MM] for CS, *0.0* for other materials.Cladding material: See Chapter 28 for cladding materials.Cladding thickness: Default: *0.125* INCHES [*3* MM] if cladding material is specified; otherwise: *0.0*.Fluid specific gravity: Range: 0.2 - 5.0; Default: *1.0*.Diameter option: Defines desired diameter as ID or OD; Default: See Area Design Basis.OD- Outside diameterID- Inside diameterFlame 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 Vessels (G10) 10-27


Description Type

Cryogenic storage tank - double wall, superinsulated.

Shell material: See Chapter 28 for materials. Default: *SS304*.Liquid volume: Enter either capacity or diameter and height. Range: 300.0 - 60,000.0 GALLONS [1.20 - 227.00 M3].Vessel diameter: Enter either capacity or diameter and height.Vessel tangent to tangent height: Enter either capacity or diameter and height.Design gauge pressure: If both pressure and vacuum are entered, design is for worst case. Default: 250.0 PSIG [1,720 KPA].Vacuum design gauge pressure: If both pressure and vacuum are entered, design is for worst case. Default: pressure.Design temperature: Default: -320.0 DEG F [-195 DEG C].Operating temperature: Default: design temperature.Jacket design gauge pressure: Min: -14.70 PSIG [-100.0 KPA]; Default: -14.70 PSIG [-100.0 KPA]Jacket material: See Chapter 28 for materials. Default: *CS*.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.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- Seismic design only NONE- Delete wind and seismic designFluid volume: For seismic design, fluid volume as a% of vessel volume (water assumed).Manhole diameter: Max: 48.0 INCHES [1,200.0 MM]; Default: 18.0 INCHES [450.0 MM] - Continued on next page -

CRYOGENIC

10-28 10 Vessels (G10)


Description Type

CRYOGENIC - continued

Number of manholes: Default: *0*.Allowance for internals: Specify an allowance for internals as a percent of basic vessel height.Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Weld efficiency: ASME/JIS codes only, where allowed for thin wall vessels. Range: 50 - 100; Default: Area Basis.Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress reliefStiffening ring spacing: Default stiffeners designed for vacuum only, enter ‘0.0’ if not required.Head type: ELLIP- 2:1 ellipsoidal HEMI- Hemispherical TORI- Torispherical (ASME)Diameter option: Defines desired diameter as ID or OD. Default: See Area Design Basis. OD- Outside diameter ID- Inside diameter

Flat bottom dome top. FRP to 30000 GALLONS [113 M3], HAVEG to 7000 GALLONS [26 M3].Fiberglass Reinforced Plastic Storage Tank: Filament-wound 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.

Haveg Storage Tank.

Material: Default: *FRP* FRP- FRP HAVEG- HavegLiquid volume: Volume or diameter + height required input Range: 1,000 - 30,000 GALLONS [3.8 - 113 M3] - Continued on next page -

PLAST TANK

10 Vessels (G10) 10-29


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.Design gauge pressure: Range: 0.00 - 15.00 PSIG [0 - 100 KPA]; Default: *0.05* PSIG [*0.3* KPA].Temperature: Max: 300 DEG F [120 DEG C]; Default: *68* DEG F [*20* DEG C].

Wooden storage tanks to 50000 GALLONS [1890 M3].

Material: Default: *CYPRS* CYPRS- Cypress REDWD- Redwood PINE- Pine FIR- FirLiquid volume: Volume or diameter + height required input. Range: 800 - 50,000 GALLONS [3.1 - 189 M3].Vessel diameter: Volume or diameter + height required input.Design gauge pressure: Range: 0.0 - 0.05 PSIG [0.0 - 0.3 KPA]. Default: *0.05* PSIG [*0.3* KPA].Temperature: Max: 250 DEG F [120 DEG C]; Default: *68* DEG F [*20* DEG C].

WOOD TANK

Near-Atmospheric Gas Storage

Telescoping gas holder.Low pressure gas vessel.

Shell material: For clad plate, specify the backing plate material. See Chapter 28 for materials. Default: *A285C*.Gas volume: Enter either capacity or diameter and height.Vessel diameter: Enter either capacity or diameter and height.Vessel height: Enter either capacity or diameter and height. - Continued on next page -

GAS HOLDER

10-30 10 Vessels (G10)


Description Type

GAS HOLDER - continued

Design gauge pressure: Range: 0.0 - 2.5 PSIG [0.0 - 17 KPA]; Default: *0.05* PSIG [*0.35* KPA].Design temperature: Default: *68* DEG F [*20* DEG C].Operating temperature: Default: Design temperature.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*.Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] if cladding material is specified; otherwise 0.0.Cladding material: See Chapter 28 for materials.Cladding thickness: Default: 0.125 INCHES [3 MM] if cladding material is specified, otherwise 0.0.Diameter option: Defines desired diameter as ID or OD. Default: - See Area Design Basis. OD- Outside diameter ID- Inside diameter

Atmospheric Solid/Liquid Storage

Cone bottom, flat top storage bin.

Shell material:

For clad plate, specify the backing plate material. See Chapter 28 for materials. Default: *A285C*.

Liquid volume:

Enter either capacity or diameter and height.

Vessel diameter:


Vessel height:



CONE BTM

10 Vessels (G10) 10-31


Description Type

CONE BTM - continued

Design gauge pressure: 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.Operating temperature: Default: Design temperature.Vessel leg height: Enter ‘0.0’ if bin hung in OPEN structure; Default: *4* FEET [*1.25* M].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*.Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: *0.125* INCHES [*3* MM] for CS, *0.0* for other materials.Number of body flange sets: Number of sets (pairs) of body flanges of same diameter as vessel.Stress relief: Default: See Area Design Basis CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress reliefCladding material: See Chapter 28 for materials.Cladding thickness: Default *0.125* INCHES [*3* MM] if cladding material is specified; otherwise: *0.0*.Head thickness Top: Base material thickness including corrosion allowance.Head thickness Bottom: Base material thickness including corrosion allowance.


10-32 10 Vessels (G10)


Description Type

CONE BTM - continued

Diameter option:

Defines desired diameter as ID or OD;

Default - see Area Design Basis.

OD- Outside diameter

ID- Inside diameter

ASME design basis:

Applicable only for ASME code design.

See following entries for fatigue data.

Default: *D1NF*.

D1NF- ASME Division 1 - no fatigue analysis

D1F- ASME Division 1 - with fatigue analysis

D2NF- ASME Division 2 - no fatigue analysis D2F- ASME Division 2 - with fatigue analysisStart Stop cycles x 1000: ASME fatigue only. Thousands of start-up cycles during the full equipment life. Range: 5.00 - 0.02.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 process 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: *0*.Temperature cycles x 1000: ASME fatigue only. Thousands of deviations from design temperature in equipment life. Default: *0*.Temperature amplitude: ASME fatigue only. Amplitude of temperature as a percent of design temperature. Default: *0*.

Live bottom storage bin.

Shell material: For clad plate, specify the backing plate material. See Chapter 28 for materials. Default: *A285C*.Solid volume: Enter either capacity or diameter and height.


LIVE BTM

10 Vessels (G10) 10-33


Description Type

LIVE BTM - continued

Vessel diameter: MAX: 15 FEET [4.69 M] Enter either capacity or diameter and height.Vessel height: Enter either capacity or diameter and height.Design temperature: Default: *68* DEG F [*20* DEG C]Operating temperature: Default: Design temperature.Vessel leg height: Enter ‘0.0’ if bin hung in OPEN structure; Default: *4* FEET [*1.25* M].

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*.

Base material thickness:

Base material thickness including corrosion allowance.

Corrosion allowance:

Default: *0.125* INCHES [*3* MM] for CS, *0.0* for other materials.

Number of body flange sets:

Number of sets (pairs) of body flanges of same diameter as vessel.Stress relief: Default: See Area Design Basis. CODE- Provide stress relief if code requires YES- Provide stress relief NO- No stress reliefCladding material: See Chapter 28 for materials.Cladding thickness: Default *0.125* INCHES [*3* MM] if cladding material is specified; otherwise: *0.0*.Diameter option: Defines desired diameter as ID or OD; Default - see Area Design Basis. OD- Outside diameter ID- Inside diameter

10-34 10 Vessels (G10)


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 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 assemblageInside length: Enter either chest dimensions or capacity.Vessel height: Enter either chest dimensions or capacity.Inside width: Enter either chest dimensions or capacity.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 45RSB- 4.5 INCHES [112 MM] red shale brick 80RSB- 8.0 INCHES [200 MM] red shale brick


CHEST REC

10 Vessels (G10) 10-35


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 roofInstallation option: Default: *GRADE* GRADE- Tile chest is constructed on grade STRUCT- Tile chest is within a structureCapacity 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*.


10-36 10 Vessels (G10)


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: Exclude portion of calculated quantity if not required or common with other items. Max: 100; Default: *0.0*.Wall length exclusion: Exclude portion of calculated quantity if not required or common with other items. Max: 100; Default: *0.0*.Wall width exclusion: Exclude portion of calculated quantity if not required or common with other items. Max: 100; Default: *0.0*.

Tile Chests, Cylindrical

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 stockInside diameter: Chest dimensions or capacity required.Vessel height: Chest dimensions or capacity required.Chest volume: Enter either dimensions (diameter, height) orcapacity; Min: 3000 GALLONS [12 M3]; Max: 300000 GALLONS [1135 M3]


CHEST CYL

10 Vessels (G10) 10-37


Description Type

CHEST CYL - continued

Tile or lining type: Default: *25RSB* 25RBS- 2.5 INCH [62 MM] red shale brick 45RSB- 4.5 INCH [112 MM] red shale brick 80RSB- 8.0 INCH [200 MM] red shale brickTile 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 roofInstallation option: Default: *GRADE* GRADE- Tile chest is constructed on grade STRUCT- Tile chest is within a structureSoil 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: Exclude portion of calculated quantity if not required or common with other items. Max: 100; Default: *0.0*.Footings exclusion: Exclude portion of calculated quantity if not required or common with other items. Max: 100; Default: *0.0*.Floor exclusion: Exclude portion of calculated quantity if not required or common with other items. Max: 100; Default: *0.0*.

10-38 10 Vessels (G10)


Description Type

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: Enter either capacity or diameter and height.Vessel height: Enter either capacity or diameter and height.Tile or lining type: Default: *25RSB* 25RSB- 2.4 INCH [62 MM] red shale brick 45RSB- 4.5 INCH [112 MM] red shale brick 80RSB- 8.0 INCH [200 MM] red shale brickTile 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 roofDesign gauge pressure: Range: 0 - 2.5 PSIG [0 - 17.0 KPA]; Default: *0.05* PSIG [*0.35* KPA].Ignore this field for open top tanks.Design temperature: Default: *68* DEG F [*20* DEG C].Operating temperature: Default: Design temperature.Manhole diameter: Max: 48 INCHES [1,200 MM]; Default: *18* INCHES [450.0 MM].Number of manholes: Default: *1*.Allowance for internals: Specify an allowance for internals as a percent of basic vessel weight. Default: *0.0*.Base material thickness: Base material thickness including corrosion allowance. - Continued on next page -

CHEST MTL

10 Vessels (G10) 10-39


Description Type

Corrosion allowance: Default: *0.125* INCHES [*3* MM] for CS, *0.0* for other materials.Cladding material: See Chapter 28 for cladding materials.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: Defines desired diameter as ID or OD. Default: See Area Design Basis.Bottom type: Default: *FLAT* FLAT- Single flat bottom DBL- Double bottom

CHEST MTL

Sanitary vertical cylindrical vessel

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 tankLiquid Volume: MAX: 5,000 GALLONS [18.9 M3]Enter either capacity or diameter and height.Vessel Diameter: MAX: 9.25 FEET [2.8 M]Enter either capacity or diameter and height.Vessel Height: MAX: 10 FEET [3 M]Enter either capacity or diameter and height.Operating temperature: 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 - Continued on next page -

SAN TANK

10-40 10 Vessels (G10)


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 CON45- 45 degree cone bottom CON60- 60 degree cone bottomJacket type: *NONE*- No jacket DMPLE- 90 PSIG [620 KPA] dimple jacket

10 Vessels (G10) 10-41

10-42 10 Vessels (G10)


Crushers (CR)

Flakers (FL)

Mills (M)

Stock Treatment (ST)

11 Crushers, Mills and Stock Treatment (G6)

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 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

CONE

11-2 11 Crushers, Mills and Stock Treatment (G6)

Crushers (CR) - continued

Description Type

Primary and secondary crushing of hard and medium hard materials such as limestone, stone and rock.

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

GYRATORY

Overhead eccentric jaw crusher for primary and 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].

ECCENTRIC



Description Type

Swing jaw crusher for primary and secondary 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].

JAW

Rotary crusher for coarse, soft materials, such as gypsum, phosphate rock, pitch, mica, cocoanut shells.

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].

ROTARY

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.

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 [125 - 1,330 TON/H].Product size: Range: 2 - 6 INCHES [50 - 150 MM].

S ROLL LT



Description Type

S ROLL LT - continued

Single roll crusher for medium duty primary and/or secondary crushing for coal and other friable materials.

Material: Default: *CS*.Crusher flow rate: Range: 105 - 840 TPH [95 - 760 TON/H].Product size: Range: 2 - 8 INCHES [50 - 200 MM].

Single roll crusher for heavy duty primary and/or secondary crushing for coal and other friable materials.

Material: Default: *CS*.Crusher flow rate: Range: 175 - 1,000 TPH [155 - 900 TON/H].Product size: Range: 2 - 8 INCHES [50 - 200 MM].

S ROLL MED

S ROLL HVY

Sawtooth crusher. Size reduction in tearing via toothed 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].

SAWTOOTH

Reversible hammermill for secondary reduction of hard 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].

REV-HAMR



Description Type

Non-reversible hammermill for secondary crushing of bituminous and sub-bituminous coals, lignite, gypsum and some medium-hard minerals.


HAMMER MED

Non-reversible hammermill for hard materials (cement rock, limestone).


SWING HAMR

Rotary breaker for simultaneous sizing and cleaning of run-of-mine coal.

Material: Default: *CS*.Crusher flow rate: Range: 450 - 1,500 TPH [400 - 1360 TON/H].

BRADFORD

Single rotor impact breaker for primary and secondary breaking of non-abrasive quarry rock and similar materials.

Crusher flow rate: Range: 250 - 1,000 TPH [225 - 900 TON/H].

S IMPACT

Fine and medium crushing of soft non-abrasive materials.

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].

PULVERIZER



Flakers (FL)Includes motor and drive.

Mills (M)Includes mill, motor, bearings, gears, lube system and vendor-supplied instruments.

Description Type

Ring granulator for primary and secondary crushing of 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].

ROLL RING

Description Type

Drum flaker to 200 SF [18 M2] of surface.

Material: Default: *CS*.Surface area: Range: 10 - 250 SF [1 - 23 M2].

DRUM

Description Type

Attrition mill to 300 HP [224 KW].

Material:

Default: *CS*.

Driver power:

Range: 5 - 300 HP [4 - 224 KW].

Driver speed:

Max: 3,600 RPM

ATTRITION


Mills (M) - continued.

Description Type

Wet or dry autogenous mills.

Material:

Default: *CS*.

Application:

Default: *WET*

WET- Wet grinding

DRY- Dry grinding

AUTOGENOUS

Ball mill includes initial ball charge.

Material: Default: *CS*.Application: Default: *WET* WET- Wet grinding DRY- Dry grinding

BALL MILL

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].

Material: Default: *CS*.Driver power: Range: 7.5 - 30 HP [5.5 - 22 KW].Driver speed: Max: 3,600 RPM

MIKRO PULV

Roller mill to 400 HP [300 KW].

Material: Default: *CS*.Application: Default: *WET* WET- Wet grinding DRY- Dry grinding

ROLLER

Rod charger for rod mill. ROD CHARGR


Stock Treatments (ST)Description Type

Refiners are used for the refining of fibers either from 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- SS304Stock 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*.

REFINER

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

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- SS304Hydraulic capacity: Enter hydraulic capacity or rotor diameter.Range: 5.0 - 2000 GPM [0.3 - 125.0 LS].


DEFLAKE DK


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.Consistency Air Dried: 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.

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.Consistency Air Dried: Range: 1 - 10; Default: *4*.

DEFLAKE CN



Crystallizers (CRY)

Evaporators (E)

Wiped Film Evaporators (WFE)

Air Dryers (AD)

Dryers (D)

Drum Dryers (DD)

Rotary Dryers (RD)

Tray Drying Systems (TDS)

12 Drying Systems (G6)

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].

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- SS304Liquid volume: Range: 850 - 8,200 GALLONS [2.7 - 25.8 M3].

BATCH VAC

Mechanical scraped-surface crystallizer, jacketed, spiral ribbon scraper, trough, stacked in lengths of 40 FEET [12 M]. Includes motor and drive.

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.


MECHANICAL

12-2 12 Drying Systems (G6)

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 ironLength: 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 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]

OSLO


Evaporators (E)Description Type

Agitated falling film evaporator to 150 SF [13 M2] includes motor and drive.

Material: Default: *SS304* SS304- SS304 SS316- SS316Heat transfer area: Range: 4 - 150 SF [0.4 - 13 M2]

FALL FILM

Forced circulation evaporator to 10000 SF [925 M2] includes interconnecting piping, circulating pumps and drivers.

Material: Default: *CS* (Carbon steel)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

FORCED CIR

Long tube rising film evaporator to 35 SF [3.2 M2] includes interconnecting piping.

Material: SS steel tubes with SS shell.Heat transfer Area: Range: 18 - 35 SF [1.7 - 3.2 M2]

LONG TUBE


Evaporators (E) - continued

Description Type

Long tube vertical evaporator to 50000 SF [4640 M2] variety of tube and shell materials.

Karbate tubes with rubber-lined CS shell, CU tubes with other shell materials.

Material: Default: *CS* (Carbon steel)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: CUSurface area: Range: 200 - 3,000 [19 - 275 M2]

Material: RBLCSSurface area: Range: 100 - 2,700 SF [10 - 250 M2]

LONG VERT

Standard vertical tube evaporator to 7000 SF [650 M2]

CS tubes with CS shell, Cu tubes with CI shell, Pb shell with Pb-lined CS shell.

Material: Default: *CS* (Carbon steel)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]

STAND VERT


Evaporators (E) - continued

Description Type

Standard horizontal tube evaporator to 10000 SF [920 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]

STAND HOR


Wiped Film Evaporators (WFE)Includes motor and drive.

Description Type

Agitated thin film evaporator with explosion-proof motor and drive.

Material: Default: *SS316*Heat transfer area: Range: 0.95 - 27 SF [0.1 - 2.5 M2]

THIN FILM

Packaged system including condenser and stand.

Material: Default: *SS316*Heat transfer area: Range: 0.2 - 12 SF [0.02 - 1.1 M2]

WFE SYSTEM


Air Dryers (AD)Description Type

Dual tower, desiccant type, for drying of air to -40 DEG F [-40 DEG C] dew point; includes desiccant.

Material: Default: *CS* (Carbon steel)Gas flow rate: Max: 50,000 CFM [84,900 M3/H]

AIR DRYER


Dryers (D)Includes solid materials.

Description Type

Atmospheric tray batch dryer.

Material: Default: *CS*Tray area: Range: 30 - 200 SF [2.8 - 18.5 M2]

Material: SSTray area: Range: 30 - 250 SF [2.8 - 23 M2]

ATMOS TRAY

Vacuum tray batch dryer.

Material: Default: *CS* CS- Carbon steel SS- Stainless steelTray area: Range: 40 - 200 SF [3.8 - 18.5 M2]

VAC TRAY

Agitated pan batch dryer for sensitive materials. Includes motor and drive.

Material: Default: *CS* CS- Carbon steel 304CD- CS clad with 304 SS 316CD- CS clad with 316 SSSurface 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]

PAN


Dryers (D) - continued

Description Type

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]

SPRAY


Drum Dryers (DD)Includes motor and drive.

Description Type

Single atmospheric drum dryer for drying of solids on web material. on steam-heated rotating drum.

Material: Default: *CS*Tray area: Range: 10 - 200 SF [1 - 18 M2]

SINGLE ATM

Double atmospheric drum dryer for drying of solids on web material on pair of steam heated drums.

Material: Default: *CS*Tray area: Range: 25 - 400 SF [2.4 - 35 M2]

DOUBLE ATM

Single vacuum rotary drum dryer for drying of sensitive solids under vacuum.

Material: Default: *CS*Tray area: Range: 10 - 200 SF [1 - 18 M2]

SINGLE VAC

Rotary drum cooker-cooler.

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: MAX: 72 INCHES [1,825 MM]


S COOKCOOL


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, CSWVCDC- Washdown, VFD controlled, direct drive, CS


Rotary Dryers (RD)Includes motor and drive unit.

Description Type

Direct contact of hot gas with moist solids with maximum surface area of 2000 SF [185 M2].

Material:

Default: *CS*

Surface area:

Range: 100 - 2,000 SF [10 - 185 M2]

DIRECT

Indirect contact of hot gases with moist solids with maximum surface area of 2000 SF[185 M2].

Material: Default: *CS*Surface area: 100 - 2,000 SF [10 - 185 M2]

INDIRECT

Jacketed rotary vacuum dryer with explosion-proof motor. Maximum capacity of 500 CF [14.1 M3].

Material: Default: *CS* CS- Carbon steel SS316- SS316Flow rate: 8 - 500 CF [0.25 - 14.1 M3]

JAC VACUUM

Conical rotary vacuum dryer with maximum capacity of 400 CF.[11.3 M3].

Material: Default: *CS* CS- Carbon steel SS- Stainless steelFlow rate: 3 - 400 CF [0.1 - 11.3 M3]

VACUUM


Tray Drying Systems (TDS)Description Type

Atmospheric tray dryer with painted steel chamber.

Material:

Default: *SS316*

Tray surface area:

Range: 80 - 300 SF [7.5 - 27.5 M2]

ATM SYSTEM

Batch tray dryer with vacuum and no trays.

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]

VACUUM

Turbo tray drying system with auxiliaries except heating system.

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

TURBO

Batch tray dryer with vacuum pump and condenser.

Material: Default: *CI*Tray Surface Area: Range: 13 - 70 SF [1.3 - 6.5 M2]

VAC SYSTEM



Conveyors (CO)

Definitions and Samples of Conveyor Section Types

Cranes (CE)


Feeders (FE)

Hoists (HO)

Scales (S)

13 Solids Conveying (G10)

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.

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]; Default: *50* PCF [*800* KG/M3]Driver Power per Section: Driver power per section if conveyor has multiple sections.


OPEN BELT

13-2 13 Solids Conveying (G10)

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: Default length = conveyor length, if length of other 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: Default length = conveyor length, if length of other two section types = 0.0.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. Default: *80* FEET [*25* M]Gallery Enclosure: Default: *NO GALLERY* GALLERY- Gallery enclosure for conveyor and walks NO GALLERY- No gallery enclosureNumber 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.



Description Type

Same as open belt conveyor but enclosed with corrugated sheet

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]; Default: *50* PCF [*800* 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 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 types = 0.0.Height Slope Section: Slope section varies from grade section height to this designated height.Length Slope Section: Default length = conveyor length, if length of other 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: Default length = conveyor length, if length of other two section types = 0.0.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. Default: *80* FEET [*25* M]


CLOSED BLT



Description Type

CLOSED BLT - continued

Gallery Enclosure: Default: *NO GALLERY*GALLERY- Gallery enclosure for conveyor and walksNO GALLERY- No gallery enclosureNumber 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.


Definitions and Samples of Conveyor Section TypesSection 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 Section 1 and 3



Description Type

Apron to 50 FEET [15 M] includes motor and drive, open pans mounted between endless chains, not enclosed (open), and floor-mounted support steel.

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 [17 - 142 TON/H]Driver Power: Range: 2 - 20 HP [1.5 - 15 KW]Product Density: MAX: 200 PCF [3,200 KG/M3]; Default: *50* PCF [*800* KG/M3]

APRON

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.

Material: Default: *CS* CS- Carbon steel SS- Stainless steel AL- AluminumConveyer 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]; Default: *50* PCF [*800* KG/M3]

PNEUMATIC



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.

Material: Default: *CS* (Carbon steel)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]

ROLLER

Screw conveyor for conveying granular or fine solids 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- SS316Conveyer 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]

SCREW

Vibrating conveyor for moving granular materials horizontally or on slight incline. Includes motor and drive, carrying trough, support base and drive springs.

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. - Continued on next page -

VIBRATING



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: Default: *CS* (Carbon steel)Pan Width: Range: 12- 36 INCHES [300 - 900 MM]

Spaced bucket centrifugal discharge elevator includes motor, drive and bucket contents discharged by centrifugal motion.

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: Default: *CS* (Carbon steel)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]; Default: *50* PCF [*800* KG/M3]

CENT BKT L



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.

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: Default: *CS* (Carbon steel)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]; Default: *50* PCF [*800* KG/M3]

CONT BKT L

Sanitary horizontal conveyor

Material: *SS304*, SS316Conveyer 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 conveyorBIDIR- bi-directional type (reversing belt conveyor)Driver power: Default *1* HPDriver type:*WVRDC*- Washdown, VFD rated, direct drive, CSWVCDC- Washdown, VFD controlled, direct drive, CS

S BELTCONV



Description Type

Sanitary vertical conveyor

Material: *SS304*, SS316Vertical lift (+) or drop (+): MIN: - 40 FEET [-12.2 M]; MAX: 40 FEET [12.2 M] Difference in elevation between feed and discharge: lift (positive), drop (negative)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 dropDriver power: Default *1* HPDriver type:*WVRDC*- Washdown, VFD rated, direct drive, CSWVCDC- Washdown, VFD controlled, direct drive, CS

S VERTICAL

Sanitary vibratory conveyor

Material: *SS304*, SS316Conveyer length: Range: 6 - 40 FEET [1.8 - 12.2M]Belt width: Available sizes: 18 INCH [450 MM] 24 INCH [600 MM] 30 INCH [750 MM] 36 INCH [900 MM]Belt support:*NONE*- No belt support will be providedBSUP- Belt support will be provided


S VIBRATRY



Description Type

S VIBRATRY - continued

Driver power: Default *1* HPDriver type:*WVRDC*- Washdown, VFD rated, direct drive, CSWVCDC- Washdown, VFD controlled, direct drive, CSNumber of lane dividers: Default *0*; MAX: 2Dewatering screen:*NONE*- De-watering screen pair not includedDWAT- De-watering screen pair includedPneumatic gate:*NONE*- Full-width pneumatic screen not includedPNUM- Full-width pneumatic screen includedDischarge type:*NONE*- No discharge existsDROP- Drop-out type dischargeBIAS- Bias type discharge

Sanitary incline conveyor

Material: *SS304*, SS316Length 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 dropLength of lead-out section: Default and MIN: *2* FEET [.6 M]Length of the conveyor at discharge end before lift or dropDriver power: Default *1* HPDriver type:*WVRDC*- Washdown, VFD rated, direct drive, CSWVCDC- Washdown, VFD controlled, direct drive, CS

S INCLINE


Cranes (CE)


Description Type

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:

Default: *CS* (Carbon steel)Crane Capacity: Range: 5 - 200 TONS [5 - 175 TON]

BRIDGE CRN

Includes hoist trolley and track beam to 30 TONS [25 TON].

Material:

Default: *CS* (Carbon steel)Crane Capacity: Range: 0.5 - 30 TONS [0.5 - 25 TON]

HOIST

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].

Elevator Capacity: Range: 2 - 10 TONS [2 - 10 TON]Height: Range: 20 - 200 FEET [7 - 60 M]

FREIGHT

Elevator for lifting personnel and small tools in process 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]

PASSENGER


Feeders (FE)Description Type

Volumetric belt feeder to 4800 CFH [135 M3/H]. Includes motor and drive.

Material: Default: *CS* (Carbon steel)Feeder Rate: Range: 120 - 4,800 CFH [3.5 - 135 M3/H]

BELT

Bin activator.

Material: Default: *CS* (Carbon steel)Diameter: Range: 3 - 15 FEET [1.0 - 4.5 M]

BIN ACTVTR

Rotary vane feeder with diameter to 36 INCHES [900 MM]. Includes motor and drive.

Material: Default: *CS* CS- Carbon steel SS- Stainless steelRotary 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=45For Dia > 20, RPM=30Assume 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.

ROTARY


Feeders (FE) - continued

Description Type

Vibrating feeder.

(includes hopper)Material: Default: *CS* CS- Carbon steel SS- Stainless steelLength: Range: 5 - 14 FEET [1.6 - 4.2 M]Feeder Width: Range: 12 - 72 INCHES [3.5 - 1,800 MM]

VIBRATING

Loss-in-weight. Gravimetric weigh belt for free-flowing 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]

WT LOSS

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] 4242B- SS bin 42 x 42 INCHES [1066 x 1066 MM] 4842B- SS bin 48 x 42 INCHES [1219 x 1066 MM] 3654B- SS bin 36 x 54 INCHES [914 x 1372 MM] 4254B- SS bin 42 x 54 INCHES [1066 x 1372 MM] 4854B- SS bin 48 x 54 INCHES [1219 x 1372 MM] FBOX- Fiber box 18 x 18 x 36 INCHES [457 x 457 x 914 MM]


DUMPER



Description Type

DUMPER - continued

Lift type: *INLIN*- Inline hydraulic lift OFF- Offset electric liftRetainer hold down: *MAN*- Manual mechanism AUTO- Automatic mechanism AUTOB- Automatic mechanism and hydraulic box retainerHydraulic power pack: *NONE*- External hydraulic power pack INCL- Self-contained hydraulic power pack

Sanitary bulk bag unloader

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

SACK DUMP

Sanitary screw feeder

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. rateMAX: 5600LB/H [2540KG/H] at 35PCF[560KG/M3] - DRY-VOLVolumetric rate: Enter mass rate or vol. rate; MAX varies with density, product and control type.MAX: 160 CFH [4.5 M3/H]


SAN SCREW



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 powderControl type: *VOL*- Volumetric control LIW- Loss-in-weight controlExtended auger length: *12 |INCHES [304 MM]*, MIN: 12 |INCHES [304 MM]Enclosure type:*WASH*- Washdown enclosureEXPR- Explosion-proof enclosure

Sanitary weigh belt feeder

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 unitOPEN- Open frame unit

SAN BELT


Hoists (HO)Description Type

5-speed electric hoist with motor driven trolley. The 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: Default: *CS* (Carbon steel)Hoist Capacity: Range: 1 - 12 TONS [1 - 10 TON]

HOIST

Single speed electric hoist, no trolley. Used for repetitive or high-speed lifting.


1 SPEED

5-speed electric hoist, no trolley. Used for repetitive or high-speed lifting.

Material:

Default: *CS* (Carbon steel)Hoist Capacity: Range: 1 - 13 TONS [1 - 11 TON]

5 SPEED

Hand hoist, geared manual pull-chain driven trolley. For intermittent service, especially maintenance work.

Material: Default: *CS* (Carbon steel)Hoist Capacity: Range: 1 - 12 TONS [1 -10 TON]

HAND GT

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


Hoists (HO) - continued

Description Type

Hand hoist, no trolley. The hand hoist without trolley is 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: Default: *CS* (Carbon steel)Capacity: Range: 1 - 18 TONS [1 - 16 TON]

HAND NT

Beam scale to 2000 LBS [900 KG].

Material: Default: *CS* (Carbon steel)Scale Capacity: Range: 300 - 2,000 LBS [135 - 900 KG]

BEAM SCALE

Conveyor belt scale.

Material: Default: *CS* (Carbon steel)Belt Width: Range: 18 - 72 INCHES [450 - 1,800 MM]

BELT

Bench, dial, and beam to 3000 LBS [1350 KG].

Material: Default: *CS* (Carbon steel)Scale Capacity: MAX: 3,000 LBS [1,350 KG]

BENCH

Floor, dial, and beam full frame to 8000 LBS [3600 KG].



FULL FRAME

Floor, dial, and beam semi-frame to 8000 LBS [3600 KG].

Material:

Default: *CS* (Carbon steel)Scale Capacity: MAX: 8,000 LBS [3,600 KG]

SEMI FRAME



Description Type

Tank scale, weigh bridge and saddles 150000 LBS [68000 KG].

Material:

Default: *CS* (Carbon steel)Scale Capacity: Range: 10,000 - 150,000 LBS [4,500 - 68,000 KG]

TANK SCALE

Track scale, for weighing rail cars to 300 TONS [265 TON].

Material:

Default: *CS* (Carbon steel)Weight Capacity in Tons: Range: 150 - 300 TONS [130 - 265 TON]

TRACK

Truck scale, for weighing trucks/lorries to 60 TONS [54 TON].

Material: Default: *CS* (Carbon steel)Weight Capacity in Tons: Range: 30 - 60 TONS [25 - 54 TON]

TRUCK

Sanitary floor scale - flush mounted

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 4X5- 4x5 FEET [1.2x1.5 M] platform 4X6- 4x6 FEET [1.2x1.8 M] platform 5X5- 5x5 FEET [1.5x1.5 M] platform 5X7- 5x7 FEET [1.5x2.1 M] platform


SAN FLOOR



Description Type

SAN FLOOR - continued

Local digital indicator: *INCL*- Includes logical digital indicator NONE- Remote indicator onlyDeck surface: *PLAIN*- Glass bead sandbase TREAD- Tread plateDeck lift: *AUTO*- Automatic deck lift NONE- No deck liftFloor installation: *NEW*- No floor alteration necessary EXIST- Alter the existing floor


Scales (S)Description Type

Beam scale to 2000 LBS [900 KG].

Material: Default: *CS* (Carbon steel)Scale Capacity: Range: 300 - 2,000 LBS [135 - 900 KG]

BEAM SCALE

Conveyor belt scale.

Material: Default: *CS* (Carbon steel)Belt Width:Range: 18 - 72 INCHES [450 - 1,800 MM]

BELT

Bench, dial, and beam to 3000 LBS [1350 KG].


BENCH


Material: Default: *CS* (Carbon steel)Scale Capacity:MAX: 8,000 LBS [3,600 KG]

FULL FRAME

Floor, dial, and beam semi-frame to 8000 LBS [3600 KG].


SEMI FRAME

Tank scale, weigh bridge and saddles 150000 LBS [68000 KG].

Material: Default: *CS* (Carbon steel)Scale Capacity: Range: 10,000 - 150,000 LBS [4,500 - 68,000 KG]

TANK SCALE


Scales (S) - continued

Description Type

Track scale, for weighing rail cars to 300 TONS [265 TON].

Material: Default: *CS* (Carbon steel)Weight Capacity in Tons:Range: 150 - 300 TONS [130 - 265 TON]

TRACK

Truck scale, for weighing trucks/lorries to 60 TONS [54 TON].

Material: Default: *CS* (Carbon steel)Weight Capacity in Tons:Range: 30 - 60 TONS [25 - 54 TON]

TRUCK

Sanitary floor scale - flush mounted

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 4X5 - 4x5 FEET [1.2x1.5 M] platform 4X6 - 4x6 FEET [1.2x1.8 M] platform 5X5 - 5x5 FEET [1.5x1.5 M] platform 5X7 - 5x7 FEET [1.5x2.1 M] platformLocal digital indicator: *INCL* - Includes logical digital indicator NONE - Remote indicator onlyDeck surface: *PLAIN* - Glass bead sandblasted TREAD - Tread plateDeck lift: *AUTO* - Automatic deck lift NONE - No deck liftFloor installation: *NEW* - No floor alteration necessary EXIST - Alter the existing floor

SAN FLOOR



Centrifuges (CT)

Dust Collectors (DC)

Filters (F)

Separation Equipment (SE)

Thickeners (T)

Screens (VS)

14 Separation Equipment (G7)

14 Separation Equipment (G7) 14-1

Centrifuges (CT)Includes motor and drive unit.

Description Type

Atmospheric suspended basket.

Material:

Default: *CS*

CS- Carbon steel

SS- Stainless steelDriver Power: Range: 2 - 30 HP [1.5 - 22 KW]

ATM SUSPEN

Automatic batch filtering centrifuge to 60 INCHES [1520 MM].

Material: Default: *CS* CS- Carbon steel RBLCS- Rubber-lined CS SS316- SS316 HASTC- Hastelloy CCentrifuge diameter: Range: 24 - 60 INCHES [610 - 1,520 MM]Centrifuge capacity: Range: 3 - 30 CF [0.085 - 0.84 M3]

BATCH AUTO

14-2 14 Separation Equipment (G7)

Centrifuges (CT) - continued.

Description Type

Batch bottom-suspended filtering centrifuge with diameter to 48 INCHES [1210 MM].

Material: Default: *CS* CS- Carbon steel SS- Stainless steel RBLCS- Rubber-lined CSCentrifuge diameter: Range: 20 - 48 INCHES [510 - 1,210 MM]

BATCH BOTM

Batch bottom-driven centrifuge, top unloading, explosion-proof motor with diameter to 56 INCHES [1420 MM].

Material: Default: *CS* CS- Carbon steel RBLCS- Rubber-lined carbon steel SS316- SS316 HASTC- Hastelloy CCentrifuge capacity: Range: 2 - 20 CF [0.06 - 0.56 M3]Centrifuge diameter: Range: 18 - 56 INCHES [460 - 1,420 MM]

TOP UNLOAD

Batch bottom-driven centrifuge, bottom unloading, fixed speed hydraulic driver with diameter to 56 INCHES [1420 MM].

Material: Default: *SS316*Centrifuge diameter: Range: 12 - 56 INCHES [305 - 1,420 MM]

BOT UNLOAD

Batch top-suspended filtering centrifuge with diameter to 50 INCHES [1260 MM].

Material: Default: *CS* CS- Carbon steel SS- Stainless steel RBLCS- Rubber-lined carbon steelCentrifuge diameter: Range: 20 - 50 INCHES [510 - 1,260 MM]

BATCH TOP


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].

Material: Default: *CS*Centrifuge diameter: Range: 10 - 20 INCHES [250 - 500 MM]

DISK

Reciprocating conveyor, with continuous filtering centrifuge for free-draining granular solids, horizontal bowl, removal by reciprocating piston and diameter to 50 INCHES [1250 MM].

Material: Default: *CS* (Carbon steel)Centrifuge diameter: Range: 15 - 50 INCHES [375 - 1,250 MM]

Material: SS (Stainless steel)Centrifuge diameter: Range: 20 - 50 INCHES [500 - 1,250 MM]

RECIP CONV

Scroll conveyor with continuous filtering centrifuge, solids removal by scroll conveyor and diameter to 75 INCHES [1875 MM].

Material: Default: *CS* (Carbon steel)Centrifuge diameter: Range: 15 - 75 INCHES [375 - 1,875 MM

Material: SS (Stainless steel)Centrifuge diameter: Range: 15 - 50 INCHES [375 - 1,250 MM]

SCROLL CON

Solid bowl with diameter to 54 INCHES [1370 MM].

Material: Default: *CS* CS- Carbon steel SS316- SS316Bowl diameter: Range: 18 - 54 INCHES [460 - 1,370 MM]Dowl length: Range: 28 - 132 INCHES [720 - 3,350 MM]

SOLID BOWL


Centrifuges (CT) - continued

Description Type

Screen bowl with diameter to 54 INCHES [1370 MM].

Material: Default: *CS* CS- Carbon steel SS316- SS316Bowl diameter: Range: 18 - 54 INCHES [460 - 1,370 MM]Bowl length: Range: 28 - 132 INCHES [720 - 3,350 MM]

SCREEN BWL

High speed tubular sedimentation centrifuge, bottom 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: Default: *CS* (Carbon steel)Bowl diameter: Range: 4 - 6 INCHES [105 - 150 MM]

TUBULAR

Continuous filtration vibratory centrifuge with solids removal by vibratory screen for dewatering of coarse solids with screen diameter to 56 INCHES [1420 MM].

Material: Default: *CS* (Carbon steel)Screen diameter: Range: 48 - 56 INCHES [1,220 - 1,420 MM]

VIBRATORY

Inverting filter centrifuge.

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]

INVERTING


Dust Collectors (DC)Description Type

Centrifugal precipitator includes driver and interconnecting piping with flow rate to 10,000 CFM [16,990 M3].

Material: Default: *CS*Gas flow rate: Range: 500 - 10,000 CFM [850 - 16,990 M3/H]

CENTRF PRE

Cloth bay baghouse includes hopper bottom, airlocks 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-to-media ratio.


CLOTH BAY


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.




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: Default: *CS* (Carbon steel)Surface Area: Range: 100 - 12,000 SF [10 - 1,110 M2]Flow rate: Enter surface area, flow rate, or boiler capacity (coal-fired boiler aplx. only)Air/media ratio: Range: 1 - 4 CFM/SF [19 - 70 M2/H/M2]Air temperature: Default: *68* DEG F [*20* DEG C]Boiler capacity: Max: 3,400 MMBTU/H [1,000 MEGAW]

Baghouse with injected pulsed air Compressor for air pulse injection not included.

Material:

Default: *CS* (Carbon steel)

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:

Default: *68* DEG F [*20* DEG C]Boiler capacity: Max: 200 MMBTU/H [60 MEGAW]

PULSE SHKR



Description Type

Cyclone for gas/solid separation. Diameter to 60 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 steelDiameter: 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: Default: *68* DEG F [*20* DEG C]

CYCLONE



Description Type

Multiple cyclone with flow rate to 20,000 CFM [33,980 M3/H].

Material: Default: *CS* (Carbon steel)Gas flow rate: Range: 900 - 20,000 CFM [1,530 - 33,980 M2/H]

MULT CYCLO

High voltage electrical precipitator

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 coal-boiler application only)Removal efficiency: Min: 80.0%; Max: 99.99%Required: removal efficiency or particle load (for coal-boiler application only)Particle size (microns): Default: *0.600* micronsParticle resistance x10E10: Default: *2* OHM-IN [*5* OHM-CM]SO3 Concentration (ppm): Default: *4.50* ppm

ELC H VOLT

Low voltage electrical precipitator

Material: Default: *CS* (Carbon steel)Gas flow rate: Range: 600 - 20,000 CFM [1,020 - 33,980 M3/H]

ELC L VOLT

Washer dust collector

Material: Default: *CS*Gas flow rate: Range: 600 - 20,000 CFM [1,020 -33,980 M3/H]Air temperature: Default: *68* DEG F [*20* DEG C]

WASHERS


Filters (F)Description Type

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.

Material: Default: *CS* CS- Carbon steel SS- Stainless steelLiquid flow rate: Range: 30 - 1,200 GPM [1.9 - 75 L/S]

CARTRIDGE

Pressure leaf-dry filter with leaf area to 600 SF [55 M2].

Material: Default: *CS* CS- Carbon steel SS316- SS316Surface area: Range: 50 -600 SF [4.7 - 55 M2]

LEAF DRY

Pressure leaf-wet filter with leaf area to 600 SF [55 M2].

Material: Default: *CS* CS- Carbon steel SS316- SS316Surface area: Range: 50 - 600 SF [4.7 - 55 M2]

LEAF WET


Filters (F) - continued

Description Type

Automatic plate and frame filter with capacity to 50 CF [1.4 M3].

Material: Default: *RBLCS* RBLCS- Rubber-line CS PPLCS- Polyprop. lined CS SS316- SS316Frame 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]

PLATE FRAM

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.

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 CSApplication: Default: *MD RATE* LO RATE- Low filtration rate MD RATE- Medium filtration rate HI RATE- High filtration rate THCKNR- Used as a thickening device


ROTY DISK



Description Type

ROTY DISK - continued

Solid flow rate: Enter solid flow rate or surface area.Surface area: Enter solid flow rate or 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 streamConsistency Air Dried: 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 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.


ROTY DRUM



Description Type

ROTY DRUM - continued

Material: Default: *CS* CS- Carbon steel SS316- SS316 RBLCS- Rubber lined CS EPLCS- Epoxy lined CSApplication: Default: *MD RATE* LO RATE- Low filtration rate MD RATE- Medium filtration rate HI RATE- High filtration rate THCKNR- Used as a thickening deviceSolid flow rate: Enter solid flow rate or surface area.Surface area: Enter solid flow rate or 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 streamConsistency Air Dried: Percent of solids in the 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).

Material: Default: *CS* (Carbon steel)Feed size selection: FINE- Fine solidsMEDIUM- Medium solids

SCROLL

Sewage filter with area to 600 SF [55 M2].

Material: Default: *CS*Surface area: Range: 100 - 600 SF [10 - 55 M2]

SEWAGE



Description Type

Sparkler with area to 110 SF [10 M2].

Material: Default: *SS316* SS316- SS316 RBLCS- Rubber lined CSSurface 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]

SPARKLER

Tubular fabric filters (bank of three) with automatic or 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 steelLiquid flow rate: Range: 100 - 3,400 GPM [6.5 - 210 L/S]Mesh size: Range: 60 - 700 MESHMode of operation: Automatic cleaning and backwashing option available. Default: *NONE* NONE- No auto operation AUTO- Auto clan/backwash

TUBULAR

White water filter including centrifugal screening basket, internal showers and distributors.

Liquid flow rate: Maximum flow varies: 4750 GPM [300 L/S]at 0.001 consistency, 2500 GPM [157 L/S] at 0.1.Consistency Air Dried: Range: 0.001 to 0.1; Default: 0.1

WHITEWATER



Description Type

Compressed gas filterRemoves particulates from compressed gas. Supplied with standard 10 micron filter.Design gauge pressure Inlet: 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.

*at MAX Pressure DropTemperature: Default: *60* DEG F [*15.5* DEG C]; Max: 100 DEG F [37.5DEG 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.

Molecular weight: Default gas is air with a molecular weight of 28.96.

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]

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]



Description Type

Sanitary in-line 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.


Pipe diameter: MIN: 2 INCH [50 MM], MAX: 4 INCH [100 MM].Standard sizes: INCHMM 250 380 4100

METAL TRAP

Sanitary fluming reclaim 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: *NONE*- Not included INCL- Included

RECL REEL

Culinary (sterile) air filter

Keeps rust and other such matter out of the product. Material of construction is SS316.

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 - Continued on next page -

SAN AIR



Description Type

SAN AIR - continued

250 380 4100 6150 8200Design gauge pressure: MIN: 100 PSIG [680 KPA]Number of stages: *1*, MIN: 1, MAX: 3

Sanitary pipe filter

Removes fine particles from a given liquid or gas. Material of construction is SS316.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

SAN PIPE



Description Type

Sanitary filter 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

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.


SAN PRESS

Flow Diagram



Description Type

SAN PRESS - continued

Number of plates: The maximum number of plates depends upon the plate size:

Plate thickness: *1 INCH [25 MM]*; MIN: 1 INCH [25 MM]; MAX: 2 INCHES [50 MM]. These (i.e., the MIN and the MAX values) are the only standard plate thicknesses available.Head and stand material: CS- Carbon steel *SS*- Stainless steelPlate type: *ROUND*- Round plates SQUAR- Square platesFeed pump type: *PD *- Positive displacement pump CNTRF- Centrifugal pump NONE- No feed pump includedHydraulic closure: *HYDRL*-Hydraulic closure MANUL-Manual closure (not available for 24 INCH [600 MM] plate size)

Plate Size

Square Round

MAX No.

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] 24 INCH [600 MM] 40



Description Type

Culinary (sterile) steam filter

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.

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]*

SAN STEAM

Pipe diameter Filter body diameter

Inch-Pound Metric Inch-Pound Metric

0.75 INCHES1 INCHES2 INCHES3 INCHES4 INCHES6 INCHES8 INCHES

20 MM25 MM50 MM80 MM100 MM150 MM200 MM

1.5 INCHES2.5 INCHES4 INCHES8.6 INCHES10.7 INCHES12.8 INCHES16 INCHES

38.1 MM63.5 MM101.6 MM218.44 MM271.78 MM325.12 MM406.4 MM



Description Type

Sanitary pipe strainer

Removes large particles as a process stream passes through the strainer’s perforated plate or screen mesh. Material of construction is SS316.

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 sizeStyle: *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 bodyConfiguration: *SINGL*- Single filter TWIN- Twin filters

SAN STRAIN


Separation Equipment (SE)Description Type

Centrifugal cleaners/wet cyclones used for removal of 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 LS316- Replaceable SS316 on CSCyclone 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 dischargeConfiguration: Default: *LIN* LIN- Linear manifold RAD- Radial manifoldNumber of cyclones per manifold: Default: *1*Cone section material: Default: *SS316* SS316- SS316 316L- 316 L CS- Carbon steel


PULP STOCK


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 LS304- Replaceable SS304 on CS LS316- Replaceable SS316 on CSContainment size: Default: *MEDIUM* SMALL- Small debris, less then 40 microns MEDIUM- Medium debris, 40 - 400 microns LARGE - Large debris, 400 - 4000 micronsContainment 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].

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 liningCyclone 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

WATER CYCL


Separation Equipment (SE) - continued

Description Type

Oil-water separator - API type.

Material: Default: *CS* (Carbon steel)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*

OIL WATER


Thickeners (T)Description Type

Thickeners are used in many solid/liquid separation 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 millsRake and mechanism material: Default: *CS* CS- Carbon steel SS304- SS304 SS316- SS316 MONEL- Monel RUBCV- Rubber covered CSTank 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 CSVessel diameter: Enter tank capacity or tank dimensions. Range: 9.5 - 400 FEET [3.0 - 12.0 M]Vessel height: Enter tank capacity or tank dimensions.Liquid volume: Enter tank capacity or tank dimensions.


THICKENER


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 requiredBridge 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-bridgeDrive 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 deviceDesign temperature: Default: 190 DEG F [88 DEG C] for green liquor; else 68 DEG F [20 DEG C].Operating temperature: Default: Design temperature.Allowance for internals: Specify an allowance for internals as a percent of basic mechanism weight. Default: *0.0*Base material thickness: Base material thickness including corrosion allowance.Corrosion allowance: Default: 0.125 INCHES [3 MM] for CS, 0.0 for other materials.Number of manholes: Default: *1*Manhole diameter: Max: 480 INCHES [1,200 MM]; Default: *18* INCHES [*450* MM].


Screens (VS)Rectangular, circular.

Description Type

Rectangular single deck, open or enclosed. Rectangular double deck, open or enclosed. Rectangular triple deck, open or enclosed.

Material: Default: *CS* (Carbon steel)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

ONE DECKTWO DECKTHREE DECK

Circular single deck. Circular double deck. Circular triple deck.

Material: Default: *CS* CS- Carbon steel SS304- SS304 SS316- SS316Screen diameter: Range: 18 - 60 INCHES [450 - 1,5000 MM]Surface area: Range: 1.5 - 18 SF [0.2 - 1.7 M2]

SIFTER 1SIFTER 2SIFTER 3

Rectangular hummer-type for fine separation; 1, 2 or 3 decks.

Material: Default: *CS* CS- Carbon steel SS- Stainless steelSurface area: Range: 10 - 80 SF [1.0 - 7.4 M2]Number of decks: Range: 1 - 3

HUMMER


Screens (VS) - continued

Description Type

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 steelLiquid flow rate: Enter capacity or screen surface area.Surface area: Enter capacity or screen surface area.Frame material: Default: *CS* CS- Carbon steel SS- Stainless steelConsistency Air Dried: Percent of solids in the feed stream. 0.60 - 2.00; Default: *0.80*

LD STOCK

Mechanical bar screens are the first stage of screening 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 steelLiquid flow rate: Enter capacity or screen surface area.Surface area: Enter capacity or screen surface area.

BAR

Pressure screen used for fine screening of contaminants in a paper mill.

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.


PRESSURE



Description Type

PRESSURE - continued

Basket material:

Default: *SS316*

CS- Carbon steel

SS304- SS304 SS316- SS316Shell material: Default: *SS316* CS- Carbon steel SS304- SS304 SS316- SS316Hydraulic capacity: Enter capacity or diameter and length.Basket diameter: Enter capacity or diameter and length. Min: 60 INCHES [150 MM]Basket height: Enter capacity or diameter and length. Min: 60 INCHES [150 MM]Driver power: Max: 3,6000 RPM; Default: *1,800* RPMDesign gauge power: Default: *15* PSIG [*150* MM]Seal type: Default: *MECH* PACK- Packing MECH- Mechanical seal

Sanitary fluming dewatering shaker

Vibratory conveyor with screen for dewatering fruits and vegetables that have been carried by water-transport 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.

Material of construction is stainless steel.



SHAKER



Description Type

SHAKER - continued

Screen size:24X60- 2x24 INCHES [609 MM] x 30 INCHES [762 MM] screens36X60- 2x36 INCHES [914 MM] x 30 INCHES [762 MM] screensRequired to enter at least one of the following: size, fluming rate or solids capacity.Fluming rate: MAX: 500 GPM [31 L/S]Required to enter at least one of the following: size, fluming rate or solids capacity.Solids capacity: MAX: 30,000 LB/H [13,500 KG/H]Required to enter at least one of the following: size, fluming rate or solids capacity.Spreader option: NONE- Not included *INCL*- included



Cooling Towers (CTW)

Steam Boilers (STB)

Heating Units (HU)

Refrigeration Units (RU)

Electrical Generators (EG)

Water Treatment Systems (WTS)

15 Utility Service Systems (G6)

15 Utility Service Systems (G6) 15-1

Cooling Towers (CTW)Description Type

Cooling tower includes fans, drivers, concrete basin 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]; Default: *15* DEG F [*8* DEG C]Approach gradient: Range: 5 - 22 DEG F [3 - 12 DEG C]; Default: *10* DEG F [*5* DEG C]Wet bulb temperature: Range: 60 - 82 DEG F [16 - 28 DEG C]; Default: *75* DEG F [*24* DEG C]Length each header: Default: *0* FEET [*0* M]

COOLING

15-2 15 Utility Service Systems (G6)

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.

Water flow rate: Min: 1,000 GPM [65 L/S]Temperature range: Range: 10 - 50 DEG F [6 - 27 DEG C]; Default: *15* DEG F [*8* DEG C]Approach gradient: Range: 5 - 22 DEG F [3 - 12 DEG C]; Default: *10* DEG F [*5* DEG C]Wet bulb temperature: Range: 60 - 82 DEG F [16 - 28 DEG C]; Default: *75* DEG F [*24* DEG C]Length each header: Default: *0* FEET [*0* M]

COOLING WP

Factory assembled cooling tower including fans, drivers and basins.

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];Default: *10* DEG F [*5* DEG C]Wet bulb temperature: Range: 60 - 82 DEG F [16 - 28 DEG C];Default: *75* DEG F [*24* DEG C]Number of cells: Default: *1*

PACKAGED


Steam Boilers (STB)Description Type

Packaged boiler unit includes forced draft fans, 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: Default: *CS* (Carbon steel)Boiler flow rate: Range: 10,000 - 800,000 LB/H [4,540 - 362,000 KG/H]Steam gauge pressure: 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 fuelOIL- Oil fuel

BOILER

Field erected boiler unit includes forced draft fans, 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: Default: *CS* (Carbon steel)Boiler flow rate: Range: 40,000 - 2,200,000 LB/H [18,2000 - 997,000 KG/H]Steam gauge pressure: Max: 1,000 PSIG [6,890 KPA]; Default: *400* PSIG [*2,700* KPA]Superheat: Max: 300 DEG F [165 DEG C]; Default: *100* DEG F [*55* DEG C]

STM BOILER


Heating Units (HU)

Description Type

Process heater type dowtherm unit to 40 MMBTU/H [11.5 MEGAW].

Material: Default: *CS*Duty: Max: 40 MMBTU/H [11.5 MEGAW]Design gauge pressure: Max: 6,000 PSIG [40,000 KPA];Default: *500* PSIG [*3,500* KPA]Design temperature: Max: 1,500 DEG F [815 DEG C];Default: *750* DEG F [*400* DEG C]

CYLINDER


Refrigeration Units (RU)Description Type

Centrifugal compression refrigeration unit produces 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: Default: *CS* (Carbon steel)Refrigeration capacity: Range: 50 - 3,000 TONS-REF [180 - 10,500 KW]Evaporator temperature: Range: -40 - 40 DEG F [-40 - 5 DEG C]

CENT COMPR

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.

Material: Default: *CS* (Carbon steel)Refrigeration capacity: Range: 4 - 500 TONS-REF [15 - 1,750 KW]Evaporator temperature: Range: -80 - 40 DEG F [-60 - 5 DEG C]

MECHANICAL


Electrical Generators (EG)Description Type

Portable stand-by diesel generator, skid-mounted to 800 KW.

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: Default: *CS* (Carbon steel)Output KW: Range: 10 - 800 KW

PORTABLE

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.

Used for the continuous generation of electrical power.

Material: Default: *CS* (Carbon steel)Output KVA: Range: for steam, 800 - 100,000 KVA; for gas,800 - 260,000 KVA.Driver type: *Steam*, Gas.

TURBO GEN


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.

Material: Default: *CS* (Carbon steel)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

DEMINERAL

Softening treatment system for boiler feedwater consists of hot lime process softener, filters, Zeolite softeners, associated piping and instruments.

Material: Default: *CS* (Carbon steel)Water flow rate: 10,000 - 50,000 GPH [38 - 189 M3/H]

SOFTENING

Aerators are used in aeration of effluent. The unit 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


AERATOR


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 aeratorAeration 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: Max: 3,600 RPM; Default: *1,800* RPMNumber of pontoons: Default: 3 for LSFLOT, 1 for HSFLOT, and none for LSFIXED.



Flares (FLR)

Stacks (STK)

16 Flares and Stacks (G6)

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 16 Flares and Stacks (G6)

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 (SELF-SUPP) 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


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 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 self-supporting 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 steelGas 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. Max: 96 INCHES [2,400 MM]Height Bottom section: For single diameter stacks, enter dimensions in bottom section data.Diameter Middle section: For single diameter stacks, enter dimensions in bottom section data. Max: 96 INCHES [2,400 MM]Height Middle section: For single diameter stacks, enter dimensions in bottom section data.Diameter Top section: For single diameter stacks, enter dimensions in bottom section data. Max: 96 INCHES [2,400 MM]


DERRICK


Flares (FLR) - continued

Description Type

DERRICK - continued

Height Top section: For single diameter stacks, enter dimensions in bottom section data.Gas temperature: Default: *100* DEG F [*40* DEG C]Molecular weight: Default: *40*Thickness Bottom section: For single diameter stacks, enter dimensions in bottom section data.Thickness Middle section: For single diameter stacks, enter dimensions in bottom section data.Thickness Top section: For single diameter stacks, enter dimensions in bottom 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 flareRadius 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, 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 - Continued on next page -

GUYED



Description Type

GUYED - continued

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. Max: 96 INCHES [2,400 MM]Height Bottom section: For single diameter stacks, enter dimensions in bottom section data.Diameter Middle section: For single diameter stacks, enter dimensions in bottom section data. Max: 96 INCHES [2,400 MM]Height Middle section: For single diameter stacks, enter dimensions in bottom section data.Diameter Top section: For single diameter stacks, enter dimensions in bottom section data. Max: 96 INCHES [2,400 MM]Height Top section: For single diameter stacks, enter dimensions in bottom section data.Gas temperature: Default: *100* DEG F [*40* DEG C]Molecular weight: Default: *40*Thickness Bottom section: For single diameter stacks, enter dimensions in bottom section data.Thickness Middle section: For single diameter stacks, enter dimensions in bottom section data.Thickness Top section: For single diameter stacks, enter dimensions in bottom section data.Percent sonic velocity at exit: Enter 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 flareRadius 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]



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.

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 steelGas 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. Max: 96 INCHES [2,400 MM]Height Bottom section: For single diameter stacks, enter dimensions in bottom section data.Diameter Middle section: For single diameter stacks, enter dimensions in bottom section data. Max: 96 INCHES [2,400 MM]Height Middle section: For single diameter stacks, enter dimensions in bottom section data.Diameter Top section: For single diameter stacks, enter dimensions in bottom section data. Max: 96 INCHES [2,400 MM]Height Top section: For single diameter stacks, enter dimensions in bottom section data.Gas temperature: Default: *100* DEG F [*40* DEG C]Molecular weight: Default: *40*Thickness Bottom section: For single diameter stacks, enter dimensions in bottom section data.Thickness Middle section: For single diameter stacks, enter dimensions in bottom section data.Thickness Top section: For single diameter stacks, enter dimensions in bottom section data.Percent sonic velocity at exit: Enter gas exit velocity as a percent of sonic velocity. Default: *20*. - Continued on next page -

SELF SUPP



Description Type

SELF SUPP - continued

Flare type: Default: *SMOKELESS* SMOKELESS- Standard smokeless flare AIR ASSIST- Air assisted smokeless flare NONSMOKE- Non-smokeless flareRadius 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]

Horizontal ground flare includes flare tip and 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 steelGas 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. Max: 96 INCHES [2,400 MM]Length Bottom section: For single diameter stacks, enter dimensions in bottom section data.Diameter Middle section: For single diameter stacks, enter dimensions in bottom section data. Max: 96 INCHES [2,400 MM]Length Middle section: For single diameter stacks, enter dimensions in bottom section data.Diameter Top section: For single diameter stacks, enter dimensions in bottom section data. Max: 96 INCHES [2,400 MM]


HORIZONTAL



Description Type

HORIZONTAL - continued

Length Top section: For single diameter stacks, enter dimensions in bottom section data.Gas temperature: Default: *100* DEG F [*40* DEG C]Molecular weight: Default: *40*Thickness Bottom section: For single diameter stacks, enter dimensions in bottom section data.Thickness Middle section: For single diameter stacks, enter dimensions in bottom section data.Thickness Top section: For single diameter stacks, enter dimensions in bottom section data.Percent sonic velocity at exit: Enter 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 flareRadius 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]

Recuperative thermal oxidizer for low concentration non-chlorinated waste gas.

Material: Default: *CS* (Carbon steel)Standard gas load rate: Low concentration non-chlorinated waste gas; burner, box, stack, exchanger blower. Max: 20,000 CFMGas heat content: Default: *13.00* BTU/CF [*484* KJ/M3]Gas oxygen content: Min: 0.0; Default: *14.00*

THRM OX LC



Stacks (STK)

Description Type

Vapor control flare for storage and loading. Includes stack, burners, seal drum, flare, sensors, etc.

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]

STORAGE

Description Type

Stack height to 200 FEET [60 M] and diameter to 60 INCHES [1500 MM].

Material: Default: *CS* CS- Carbon steel SS- Stainless steelHeight: Range: 30 - 200 FEET [10 - 60 M]Diameter: Range: 24 - 60 INCHES [600 - 1,500 MM]

STACK



Introduction to Plant Bulks

List of Plant Bulks

17 Introduction to Plant Bulks (G6)

17 Introduction to Plant Bulks (G6) 17-1

Introduction to Plant BulksPlant 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 BulksThe 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 17 Introduction to Plant Bulks (G6)

Chapter 18: Piping

Chapter 19: Civil

- 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 pipingAbove grade or buried pipingUtility pipe and utility stationsBuried concrete pipeRound duct with hangersSquare duct with hangersFluid heat tracing for equipmentFluid heat tracing for pipeSquare or rectangular laundersHalf round laundersCoating and wrapping of buried pipeHot tap of production pipe for branchPermanent scraper launcher and receiverPipe, valve and fittings at a well headHigh density polyethylene pipe, fusion bonded Sprinkler system (water / water+foam)Foam fire systemsStandpipe and hose fire systemsEmergency eyewash and shower unitsSanitary flow diversion panel

- 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 tankBelow grade concrete tankFoundations, slabs, other concrete itemsScaffold erection and dismantlingDrainage trench for paved areasTank containment - concrete paving, wallTank containment - dike and geomembraneAbove grade or buried yard pipingAbove grade or buried pipingHigh density polyethylene pipe, fusion bondedBuried concrete pipeBuildingOrganic, metallic, abrasion resist. liningPipe rackTee or bent type pipe sleepers


Chapter 20: Steel

Chapter 21: Instrumentation

- 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 structurePipe rackTee or bent type pipe sleepersMultiple-bay mill buildingElevated access platform - completeGallery for pipe, conveyor, personnelConveyor transfer towerSteel grate - less support structureSteel laddersStairs with grate, treads and handrailMiscellaneous steel itemsFabricated steel plate itemsSiding and roofing for steel structuresSanitary platform

- INST PANEL- INST TRAY- INST WIRE- PNU TUBING- THCPL WIRE- JUNC BOX- MULTI CONT- HL PIU- LL PIU- DATA HIWAY- OPER CENT

Instrument panel - analogInstrument cable trayInstrument electronic transmission wireInstrument pneumatic tubing runsThermocouple wire runsInstrument junction boxMultifunction controllersHigh energy level process interface unitLow energy level process interface unitData highway cableOperator 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

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

Electrical power cable run (3 or 4 wire)Electrical conduitElectrical cable trayElectrical tracing for equipmentElectrical tracing for pipeGround gridArea lighting on polesElectrical control cable runs (600 v)Group of anodes in deep wellIndividual galvanic anodeGroup of anodes in shallow surface bedPotential measurement test stationTransformer/rectifierSolar panel with storage batteriesEmergency light with batteryUnderground cable duct

Bus ductElectrical transformer: 1 or 2 tapOil circuit breakersDisconnect switchPower pole linesSteel for substation structureCurrent breaker: main, feeder, tieMotor control center Switch boardAC/DC TransformerPackage transformer with panelEmergency diesel generatorUninterrupted power supplyPower factor connection capacitor


Chapter 23: Insulation and Firepoofing

Chapter 24: Paint

- INSUL AREA- INSUL PIPE- FIREP AREA- FIREP SSTL

General area insulationPipe insulationGeneral area fireproofingStructural steel fireproofing

- PAINT AREA- PAINT PIPE- PAINT SSTL

General area paintingPipe paintingStructural steel painting



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)

18 Piping (G10) 1

Valve and Fitting Options for Installation Bulk Piping

Valve Trim Specifications

2 18 Piping (G10)

Piping Plant BulksPiping 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.

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: Enter either Custom Pipe Spec (see Design Basis) or 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]Design gauge pressure: 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 100 - Pipe scheduleXS - Extra-strong pipe 120 - Pipe scheduleXXS - Double extra-strong 140 - Pipe schedule5 - Pipe schedule 160 - Pipe schedule


YARD PIPE

18 Piping (G10) 3

Piping Plant Bulks - continued

Description Type

YARD PIPE - continued

10 - Pipe schedule 7G - SS gauge pipe only20 - Pipe schedule 10G- SS gauge pipe only30- Pipe schedule 11G - SS gauge pipe only40 - Pipe schedule 12G- SS gauge pipe only60 - Pipe schedule 14G- SS gauge pipe only80- Pipe scheduleFlange 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 WOGConfiguration: Default: *ABOVE* ABOVE- Above-grade BURIED- BuriedDepth 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.

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 tracerAC-E- Anti-condensation insulation/elec tracerFP-T- Freeze protection insulation/tube tracerFP-E- Freeze protection insulation/elec tracerFULL- Fully jacketed pipe (see illustration)EXPD- Exposed-weld jacketed pipe (see illustration)T-SP- Spiral traced/tube conn./no cementT-SPC- Spiral traced/tube conn./heat cementP-SP- Spiral traced/pipe conn./no cementP-SPC- Spiral traced/pipe conn./heat cementT-LO- Longit. traced/tube conn./no cementT-LOC- Longit. traced/tube conn./heat cementP-LO- Longit. traced/pipe conn./no cementP-LOC- Longit. traced/pipe conn./heat cementE-AMB- Electrical traced/ambient temp controlE-PRO- Electrical traced/process temp controlSTAND- Standard heat or cold insulation

Steam gauge pressure: 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* - Continued on next page -

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 1- Minimum 150 class fluid control valveControl 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

Above grade or buried piping

Pipe material: Enter either Custom Pipe Spec (see Design Basis) or 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]

PIPE

6 18 Piping (G10)


Description Type

PIPE - continued

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.Design gauge pressure: 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].Operating temperature: Default: same as design temperature.

- Continued on next page-

PIPE

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 scheduleXS- Extra-strong pipe120- Pipe scheduleXXS- Double extra-strong140- Pipe schedule5- Pipe schedule160- Pipe schedule10- Pipe schedule7G- SS gauge pipe only20- Pipe schedule10G- SS gauge pipe only30- Pipe schedule11G- SS gauge pipe only40- Pipe schedule12G- SS gauge pipe only60- Pipe schedule14G- SS gauge pipe only80- Pipe scheduleValves 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 pipeFlange 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-neckFlange class: Default: determined from custom spec or pipe material, temperature and pressure.150- Class 150300- Class 300600- Class 600900- Class 9001500- Class 15002500- Class 2500125- Class 125 WOG250- Class 250 WOGBend for elbow: Substitute pipe bends for any specified elbow (up to 12 INCH [300 MM] pipe only). *E*- Elbow B- Bend instead of elbow


8 18 Piping (G10)


Description Type

PIPE - continued

Branch for tee: Substitute fabricated branch nozzles for any specified tees. *T*-Tee B-Branch Pipe connector type: Default: see project design basisSW- 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 valvesWW- Weld pipe / weld valves; min: 2 INCHES (50 MM)VC- DI Victaulic couplingsVS- SS Victaulic couplingsPF- 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 fittingsControl 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 valvesControl valve minimum class: For fluid control valves only. Default: *3*. 3- Minimum 300 class fluid control valve 1- Minimum 150 class fluid control valveWeld X-ray: Default: see project design basisStress relief: C- Piping stress relief if code requires Y- Stress relieve all piping N- No piping stress relief requiredSpecial pipe description: Default: *NONE*


18 Piping (G10) 9


Description Type

PIPE - continued

STAND- Standard heat or cold insulationPPROT- 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 tracerAC-E- Anti-condensation insulation/elec tracerFP-T- Freeze protection insulation/tube tracerFP-E- Freeze protection insulation/elec tracerFULL- Fully jacketed pipe (see illustration)EXPD- Exposed-weld jacketed pipe (see illustration)T-SP- Spiral traced/tube conn./no cementT-SPC- Spiral traced/tube conn./heat cementP-SP- Spiral traced/pipe conn./no cementP-SPC- Spiral traced/pipe conn./heat cementT-LO- Longit. traced/tube conn./no cementT-LOC- Longit. traced/tube conn./heat cementP-LO- Longit. traced/pipe conn./no cementP-LOC- Longit. traced/pipe conn./heat cementE-AMB- Electrical traced/ambient temp controlE-PRO - Electrical traced/process temp controlE-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 cable5A 5 W/FT (16 W/M) Chemelex BTV2-CT cable8A 8 W/FT (26 W/M) Chemelex BTV2-CT cable10A 10 W/FT(33 W/M) Chemelex BTV2-CT cable5P 5 W/FT (16 W/M) Chemelex XTV2-CT cable10P 10 W/FT (33 W/M) Chemelex XTV2-CT cable15P 15 W/FT (49 W/M) Chemelex XTV2-CT cable20P 20 W/FT (65 W/M) Chemelex XTV2-CT cableM2 - 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]M6 - 600V, dual conductor MI cable, 1.15 OHM/FT [3.77 OHM/M]M8 - 600V, dual conductor MI cable, 0.505 OHM/FT [1.66 OHM/M]M10 - 600V, dual conductor MI cable, 0.2 OHM/FT [0.656 OHM/M]M12 - 600V, dual conductor MI cable, 0.1 OHM/FT [0.328 OHM/M]M14 - 600V, dual conductor MI cable, 0.0561 OHM/FT [0.184 OHM/M]M16 - 600V, dual conductor MI cable, 0.0281 OHM/FT [0.0922 OHM/M]M18 - 600V, dual conductor MI cable, 0.013 OHM/FT [0.042 OHM/M]M20 - 600V, dual conductor MI cable, 0.00516 OHM/FT [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 steam) 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 basisPipe 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: Default: see project design basis CA- Calcium silicate MW- Mineral wool FG- Foam-glassPersonnel 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 pipingB - Buried pipingDepth 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 rulesFitting 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.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 rulesFitting 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 - 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 pipingN- Do not use horizontal allowanceHorizontal 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 pipingN - Do not use vertical allowanceVertical 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 equipmentS- connected to shell of equipmentU- connected to tube side of equipmentJ- connected to jacket of equipmentB- connected to bottom of double diameter towerT- connected to top of double diameter towerSecondary 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 equipmentS- connected to shell of equipmentU- connected to tube side of equipmentJ- connected to jacket of equipmentB- connected to bottom of double diameter towerT- connected to top of double diameter tower

18 Piping (G10) 17


Jacket Pipe Illustrations

User an select jacketing for PIPE and YARD PIPE under Special Pipe Description.

18 18 Piping (G10)


Description Type

Utility service lines, stations: standard configurationUtility headers: runs of pipe providing up to 15 different services. Utility station: short runs of small-bore pipe providing local air, water, steam and condensate drain services.

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].Header diameter symbol: Diameter symbol defines size of any line not specified. See Utility Piping Services later in this chapter.L- Low/small diameterM- Medium diameterH- High/large diameterV- Very large diameterFirewater loop diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Firewater lateral diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Potable water header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set. Line will be insulated base on location: US - uninsulated, UK - insulated.Cooling water supply diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set. Line will be insulated base on location: US - uninsulated, UK - insulated.


UTIL PIPE

18 Piping (G10) 19


Description Type

UTIL PIPE - continued

Cool water return diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set. Line will be insulated base on location: US - uninsulated, UK - insulated.Low Pressure (LP) steam header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Medium Pressure (MP) steam header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.High Pressure (HP) steam header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Condensate return diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Plant air header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Instrument air header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Fuel gas header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Inert gas header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Chemical sewer diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.Flare header diameter: Default: determined by diameter symbol, enter 0.0 to delete if diameter symbol set.

Buried concrete pipe, manholes, elbows, tees: trench, backfill Includes trenching and backfilling.

Diameter: Range: 12 - 98 INCHES [300 - 2,450 MM]Number of manholes: Default: *0*Number of elbows: Default: *0*Number of tees: Default: *0*

RCON PIPE

20 18 Piping (G10)


Description Type

Process ductwork, roundStiffeners 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- AluminumDuct 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].Partical density: Density of concentrated particulates for duct classes 2, 3 and 4. Default: *25* PCF [*400* KG/M3].


DUCT RD

18 Piping (G10) 21


Description Type

DUCT RD - continued

Stiffener size: Default: size and spacing determined from duct pressure, dimensions and thickness.Stiffener spacing: Default: size and spacing determined from duct pressure, dimensions and thickness.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 elbows: Default: *0*Number of tees: Default: *0*Number of reducers: Default: *0*Number of dampers: Default: *0*Number of access doors: Default: *0*Number Flexible connection: Default: *0*

Process ductwork, square

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- AluminumDuct 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.


DUCT SQ

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: Default: size and spacing determined from duct pressure, dimensions and thickness.Stiffener spacing: Default: size and spacing determined from duct pressure, dimensions and thickness.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 elbows: Default: *0*Number of tees: Default: *0*Number of reducers: Default: *0*Number of dampers: Default: *0*Number of access doors: Default: *0*Number Flexible connection: Default: *0*

18 Piping (G10) 23


Description Type

Fluid heat tracing existing equipment

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 steelTracer 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 cementT-SPC- Traced: tube conn. - spiral tracer - with cementP-SP- Traced: pipe conn. - spiral tracer - no cementP-SPC- Traced: pipe conn. - spiral tracer - with cementDistance 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 mediumSteam gauge pressure: Default: *25* PSIG [*175* KPA].

EQPT TRACE

24 18 Piping (G10)


Description Type

Fluid heat tracing for existing pipe runs

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 steelTraced 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 specified elsewhere.Tracing symbol: T-SP- Traced: tube conn. - spiral tracer - no cementT-SPC- Traced: tube conn. - spiral tracer - with cementP-SP- Traced: pipe conn. - spiral tracer - no cementP-SPC- Traced: pipe conn. - spiral tracer - with cement T-LO- Traced: tube conn. - longit. tracer - no cementT-LOC- Traced: tube conn. - longit tracer - with cementP-LO- Traced: pipe conn. - longit tracer - no cementP-LOC- Traced pipe conn. - longit tracer - with cementDistance 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 mediumSteam guage pressure: Default *25* PSIG [*175* KPA]. (See “Trapping Distances” tables.)

PIPE TRACE

18 Piping (G10) 25


STEAM Tracing - Number of Tracers Per Line


Trapping Distance (Steam)

Traced Process Line Size

25 PSIG

[175 KPA]

150 PSIG

[1050 KPA]

200 PSIG

[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 INCHES50.80 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

-2

over 4.00 INCHES[over 101.60 MM]

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

-2

-3

Traced Process Line Size (INCHES)

No. of 0.5 INCH [12.7 MM] O.D. Tracers per Line

< 3 1

> to < 8 2

> 8 3

26 18 Piping (G10)


Trapping Distance (Steam) - continued

How Icarus Calculates Insulation Length on PipingAll 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 +

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

18 Piping (G10) 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 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

LAUNDER RD

Launders, square/rectangular, rubber lined 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

LAUNDER SQ

Coat and wrap pipe for burial: manual or machine Application may be by hand or machine.

Application Symbol: HAND- Manual MACH- Machine

COAT WRAP

Hot tap: production line to branch line Split tee or nipple, flange and valve provided; branch must be specified elsewhere. Available in Icarus 2000 and Icarus Process Evaluator only.

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


HOT TAP

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 receiverA pair (launcher and receiver) is provided for each item.Available in Icarus 2000 and Icarus Process Evaluator only.

Material: Default: *X52W* X52W- API5LLX-X52 welded X42W- API5LX-X42 welded X60W- API5LX-X60 welded X65W- API5LX-X65 welded GRBW- API5L - gr B/5LS welded X52S- API5LX-X52 seamless X42S- APIFLX-X42 seamless X60S- API5LX-X60 seamless X65S- API5LX-X65 seamless GRBS- API5L - gr B seamlessFlange 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

SCRAPER LR

18 Piping (G10) 35


Description Type

Pipe, valve, and fittings at well headStandard valve and fitting configuration plus 70 FEET [20 M] of pipe.Available in Icarus 2000 and Icarus Process Evaluator only.

Material: Default: *X52W* X52W- API5LLX-X52 welded X42W- API5LX-X42 welded X60W- API5LX-X60 welded X65W- API5LX-X65 welded GRBW- API5L - gr B/5LS welded X52S- API5LX-X52 seamless X42S- APIFLX-X42 seamless X60S- API5LX-X60 seamless X65S- API5LX-X65 seamless GRBS- API5L - gr B seamlessPipe diameter: Default: *8* INCHES DIAM [*200* MM DIAM]Type of well: Default: *PROD* PROD- Production well INJEC- Injection well

WELL HEAD

Sprinkler fire system (water / water+foam)

Pipe material: *A 53*, 304P, 316POutlet arrangement:*PLANE*- Outlet devices arranged over planar areaARRAY- Outlet devices arranged over equipment areaDiameter 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].


SPRNK

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 occupSystem 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 actuatorDetector 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 - Continued on next page -

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: 0Number of hydrants: Default: 0Foam concentration: Default: 3%; Max: 100%; for foam System type onlyFoam tank option:*NONE*- No foam storage tank requiredBALPR- Tank with balanced pressure proportioningPRTNK- Tank with pressure proportioningARPMP- Tank with around the pump proportioningTank design gauge pressure: Default: *15* PSIG [*100* KPA]; for foam systems onlyTank temperature: Default: *68* DEG F [*20* DEG C]; for foam systems onlyPipe sizing method:*HYDLC*- Hydraulic pressure drop calculationsPSCHD- Schedule of pipe sizes vs. number of sprinklers

Foam fire systems

Pipe material: *A 53*, 304P, 316P.Outlet arrangement:*PLANE*- Outlet devices arranged over planar areaARRAY- Outlet devices arranged over equipment areaDiameter 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.


FOAM

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 systemPipe system type: *DRFXP*- Dry pipe system WTFXP- Wet pipe system DLFXP- Deluge system PORT- Portable system with nozzleFoam delivery option: FCHMB- Foam chambers MONTR- Monitors *NOZLE*Nozzles HNDLN- Hand lines SPRKR- SprinklersApplication density: Volume of water/foam required per unit of area. Default based on hazard/class.Number of hose stations: Default: 0Number of hydrants: Default: 0Foam concentration: Default: 3.00%; Max: 100%Foam tank option:*NONE*- No foam storage tank requiredBALPR- Tank with balanced pressure proportioningPRTNK- Tank with pressure proportioningARPMP- Tank with around the pump proportioningTank design gauge pressure: Default: *15* PSIG [*100* KPA]Tank temperature: Default: *68* DEG F [*20* DEG C]

18 Piping (G10) 39


Description Type

Standpipe and hose fire systems

Pipe material: *A 53*, 304P, 316PLength: Area length for determining number of hosesWidth: Area width for determining number of hoses; default: same as lengthNumber of levels: Default: 1.00; number of levels or floors having the indicated dimensions.System type: *C-I*- Class I stand pipe and hose systemC-II- Class II stand pipe and hose systemC-III- Class III stand pipe and hose systemNumber of hoses: Default based on class and area dimensionsPipe system type:*DRAUT*- Automatic dry system; Class I onlyDRSMA- Semi-automatic dry system; Class I onlyDRMNL- Manual dry system; Class I onlyWTAUT- Automatic wet systemWTMNL- Manual wet systemMinimum 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

SPHOS

Emergency eyewash and shower units

Pipe material: *A 53*, 304P, 316PNumber of wash units: Default: 0Enter 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: 0Enter the number of full-body showers.Number of combined units: Default: 0


WSHWR

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: 12Enter 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 unitFACE- face wash unitCOMB- combination eye and face wash unitDrain requirement: *YES*, NO

High density polyethylene pipe, fusion bonded

Pipe length: Min: 1.0 FEET [0.35 M]Pipe diameter: 2-54 INCHES DIAM [50-1350 MM DIAM]Design gauge pressure: Default: based on SDR and temperatureTemperature: Default: 73 DEG F [23 DEG C]Configuration: *BURIED*, ABOVEDepth 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*

HDPE PIPE

Sanitary flow diversion 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 - Continued on next page -

FLO PANEL

18 Piping (G10) 41


Description Type

FLO PANEL - continued

Material: *304PS*- SS304, sanitary grade pipe material316PS- SS316, sanitary grafe pipe materialMaterial 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 panelSWALL- Single wall type panelNo. stations/panel: MIN: *2*; MAX: 8Proximity sensors:NO- No proximity sensors will be provided*YES*- Proximity sensors will be providedClamp connections: select clamp connection type for front (U-bend) side*CB*- Cherry-Burrel couplingsTC- Tri-Clover couplingsNo. of extra U-bends: Default: *0* Ferrules on outlet: *NO*- No ferrule will be providedYES- Ferrules will be providedClamp 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)

Pipe ScheduleUse 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.

INCHES MM

0.51 51

.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

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.

18 Piping (G10) 43

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)**0.5IF (Diameter > 4.0) THENDiameter = Diameter - 1.00ELSEDiameter = Diameter - 0.25

Gas Lines

Minimum Flowrate = 100000.0Maximum Flowrate = 1.0E07

Flowrate LBS/HRVelocity=Log-Log X1 = 1.0E05 X2 = 1.0E07

for velocity calculationsfor 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)**0.50IF (Diameter > 18.0) Use one pipe size smaller

Steam Lines

Minimum Flowrate = 10000.0Maximum Flowrate = 1.0E06

Flowrate LBS/HRVelocity = Log-Log X1 = 1.0E04 X2 = 1.0E06

for velocity equationsfor velocity equations

Velocity FPS Y1=20.0 Y2=100.0

TempSteam = 100.0*(Pressure+30.0)**0.25SpecificVolume = 0.596*(TempSteam+460.0)/(Pressure+15.0)Diameter = 0.226*(Flowrate*SpecificVolume/Velocity)**0.50IF (Diameter > 18.0) Use one pipe size smaller

44 18 Piping (G10)

Standard Equations for Pipe Diameter (Old) - continued

Relief Lines

SQ INCHES DIAM INCHES

0.1961.2872.8536.3816.026.0

1.02.03.04.06.08.0

18 Piping (G10) 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:

Parameter Equation Remarks

Pipe Velocity

Pressure Drop (psi per 100 ft.)

V = flow Velocity;Vmax = maximum velocity given below;

is the allowable maximum pressure

drop per 100ft, given below

Application Maximum Velocity

Maximum Pressure Drop Per 100 ft.

Liquid Lines

Gas Lines

Steam Lines

Centrifugal Pump Suction

PD & Gear Pump Suction

All Pump Discharge

Tower Reboiler

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)

Vmax = A/PlB

0.5

0.5

ft/s

ft/s

Table as a function of Pipe Diameter

ft/s

= 1 psi

= 0.224 + 0.00172 P + 0.0000034 P2

where P is the operating pressure in psia.

= 1 psi

= 1 psi

= 1 psi

= 3 psi

V Vmax≤

P 100⁄Δ PΔ max≤ PΔ max

Vmax 100 p1⁄=

Vmax 100 pv⁄=

Vmax 100 ps⁄=

Vmax 5=

Vmax 1.5=

Vmax 3=

PΔ max

PΔ max

PΔ max

PΔ max

PΔ max

PΔ max

46 18 Piping (G10)

Standard Equations for Pipe Diameter (NEW) - continued

Name Equation

Flare Stack inlet header

Pipe Diameter Liquid

Vapor**

Friction Factor Vapor/Liquid

Frictional pressure drop (psi per 100 ft) Vapor/Liquid

Vapor Density

* Sonic Velocity

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)

Vmax = A/PlB

f=2*[(8/NRE)12 + 1/(C1+C2)

1.5]0.0833

where:

C1={2.457*ln[1/((7NRE)0.9+(0.27*( /(d/12))))]}16

C2=(37530/NRE)16

(abs. roughness) = 0.00015ft (Commercial steel/wrought iron)

v (liquid velocity) = 0.4085*gpm/d2

v (vapor velocity) = 0.051076* flowrate*specificvolume/d2

(liquid density) = lb/ft3

(liquid viscosity) = cP*6.7197*10-4

d = pipe ID, inches

=((Pi+14.696)*MW)/(10.73*(Ti+460))

where:Pi=Operating Pressure, psig

Ti= Operating Temperature, oF

MW=Molecular Weight

Vmax 0.75=

ε

NREd 12⁄( )vρ

μ--------------------------=

ε

ρ

μ

ΔP100-------- 100 2fρv2( )

gcd12-----⎝ ⎠⎛ ⎞144

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

ρ

18 Piping (G10) 47

Standard Equations for Pipe Diameter (NEW) - continued

Name Equation

Vapor Viscosity

Pressure Drop

Steam

Friction Factor, Steam

=K*10-4*EXP(X* y)

where:

X=3.5+(986/Ti+460)+0.01*MW

y=2.4 – 0.2*X

, Standard density=(MW/28.97)*0.0764*

(520/14.696)*(Pi+14.696)/Ti+460)*1/62.428

where:

μg ρs

K9.4 0.02MW+( ) Ti 460+( )1.5

209 19MW Ti 460+( )+ +------------------------------------------------------------------------=

ρs

PΔ100--------- 100 3.36 6–×10( )f flowrate( )2

ρd5( )-----------------------------------------------------------------------------=

f 12Log ε d 12⁄( )⁄( )–

3.7 5.02 NRE⁄( )–----------------------------------------------⎝ ⎠⎛ ⎞ Log ε d 12⁄( )⁄( )

3.7 13 NRE⁄( )+----------------------------------------⎝ ⎠⎛ ⎞

--------------------------------------------------------------------------------------------------

⎝ ⎠⎜ ⎟⎜ ⎟⎜ ⎟⎛ ⎞ 2

=

NREd 12⁄( )vρ

μ--------------------------=

48 18 Piping (G10)

Maximum Flow Velocity as a function of Pipe Diameter for Pump Discharge (Fluid Specific Gravity = 1)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) 49

Utility Piping ServicesUtility 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 Nominal Pipe Diameter: INCHES [MM] Diameter Symbol

Symbol Type L M H V -

Water

F (b)F (b)PC

Firewater - loopFirewater - lateralPotable waterCooling 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]

excludedexcludedexcludedexcluded

Steam*

L (i)M (i)H (i)

Low pressure steamMedium pressure steamHigh pressure steam

3 [80]3 [80]3 [80]

4[100]4[100]4[100]

8[200]8[200]6[150]

12[300]12[300] 8 [200]

excludedexcludedexcluded

Air

PI

Plant airInstrument air

2 [50]2 [50]

3 [80]2 [50]

4[100] 3 [80]

6[150] [100]

excludedexcluded

Gas

FI

Fuel gasInert gas

2 [50]2 [50]

2 [50]2 [50]

4[100]4[100]

6[150]6[150]

excludedexcluded

Other

CS (b)FLUS

Chemical sewerFlare lineUtility station (see diagram)

8[200]10[250] 1 [25]

10[250]14[350]1 [25]

12[300]16[400] 1 [25]

14[350]24[600]1 [25]

excludedexcluded

*One condensate return line is provided upon selection of any combination of steam services.(b) Buried(i) Insulated

50 18 Piping (G10)

Utility Station Diagram

18 Piping (G10) 51

Default Piping MaterialsEquipment Fabrication Materials

Temperature Range*

F C

Piping Material Symbol

Questimate and Icarus Project Manager

All Materials all all A 106 (up to 2 INCHES [50 MM]A 53 (2 INCHES [50mm] and larger)

Icarus 2000 and Icarus Project Evaluation

All carbon and Low Alloy Steel

-425 to 051-50 to -21-20 to 650-20 to 650651 to 10001000 to 12001201 to 1500

-253 to -46-45 to -29-28 to 343-28 to 343344 to 537538 to 648649 to 815

304PA333AA 106 (up to 2 INCHES [50 MM]A 53 (2 INCHES [50 MM] and larger)A335CA335F304P

Clad Vessels Material corresponding to process-side cladding material.

Lined Vessels: Brick or monolithic lined

all all Carbon steel - see above

Lined Vessels: rubber lined all all RBLCS

Lined Vessels: organic (except rubber), glass, lead zinc lines

all all TFELS

High Alloy Steel (Stainless) -425 to 650651 to 1500

-252 to 343344 to 815

304P316P

Aluminum -425 to 650651 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 204CUCarbon Steel - see above

HASTELLOY all all HAST

INCONEL all all INCNL

KARBATE (graphite) all all TFELS

MONEL all all MONEL

Nickel all all N

Titanium all all TI

Expoxy/Polypropylene (PPL) all all TFELS

Wood all all 316P

The maximum temperature for any pipe material will not exceed the maximum temperature for the corresponding plate material listed in Chapter 28.

52 18 Piping (G10)

Pipe Materials - Ferrous MaterialsCarbon Steel

(COA 310 - 319)

API Pipe

(COA 310-319)

System Material Symbol

ASTM BS JIS DIN Composition Recommended Maximum Temperature Degrees*

F C

Length Type**

A 53 or CS A-53(B)

3601ERW410

G3454STPGG3452SGP

17172StE240.7

1100 593 1

GALV (B) ERW410 STPGG3452SGP

StE240.7 Galvanized CS 1100 593 1

A 106 or CS A - 106(B)

3602HFS410

G3456STPT

17175St45.8

1100 593 1

A33A A-333(6)

3603410LT50

G3460STPL380

SEQW-680TTSt35N

1100 593 1

* The maximum temperature for any pipe material will not exceed the maximum temperature for the corresponding plate material listed in Chapter 28.** See Length Types.



F C

Length Type**

GRBW*** 5L/5LS 3601ERW410

G3454STPG

17172StE240.7

1100 593 1

X42W 1100 593 1

X52W 1100 593 1

X60W 1100 593 1

X65W 1100 593 1

* The maximum temperature for any pipe material will not exceed the maximum temperature for the corresponding plate material listed in Chapter 28.** See Length Types.*** For GRBS (GR.B seamless), select GRBW (GR.B welded) as the system material symbol and then select “Seamless” in the Pipe Type Field.

18 Piping (G10) 53

Low and Intermediate Alloy Steel

(All COA 320-329, except A##C COA 310-319)



F C

Length Type**

A-335 3604 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 Min. Temp

A-333 3603 G3460 SEW680 F C

A33C (3) 503LT100

STPL450 10Ni14 3.5Ni -150 -101 1


Random lengthsassumed for pipeof different materi-als and diameters.

54 18 Piping (G10)

High Alloy Steel

(COA 320-329)



F C

Length Type**

304P A-312TP 304

3605304S18

G3459SUS304TP

2462X5CrNi1810

18Cr-8Ni 1500 815 1

304LP A312TP 304L

3605304S14

G3459SUS304LTP

2462X2CrNi1911

18Cr-8Ni 1500 815 1

316P A-312TP 316

3606316S18

G3459SUS316TP

2462X5CrNiMo17122

16Cr-12Ni-2Mo 1500 815 1

316LP A-312TP 316L

3605316S14

G3459SUS316LTP

2462X2CrNiMo17132

16Cr-12Ni-2Mo 1500 815 1

321P A-312TP 321

3605321S18

G3459SUS321TP

2462X6CrNiTi1810

18Cr-10Ni-Ti 1500 815 1

6MOP A-312TP 317L

3605316S22

G3459SUS317LTP-A

2463X2CrNiMo18143

20Cr-18Ni-6Mo 1382 750 1

Guage Pipe (Very Light Wall)

304PG A-312TP 304

3605304S18

G3459SUS304TP

2462X5CrNi1810

18Cr-8Ni 1500 815 2

316PG A-312TP 316

3605316S18

G3459SUS316TP

2462X5CrNiMo17122

16Cr-12Ni-2Mo 1500 815 2

Sanitary Pipe (Polished, Quick Disconnects)

304PS*** A-312TP 304

3605304S18

G3459SUS304TP

2462X5CrNi1810

18Cr-8Ni 1500 815 3

316PS*** A-312TP 316

3605316S18

G3459SUS316TP

2462X5CrNiMo17122

16Cr-12Ni-Mo 3

* The maximum temperature for any pipe material will not exceed the maximum temperature for the corresponding plate material listed in Chapter 28.** See Length Types.***<axo,i, 200 PSIG (1,375 KPA)

18 Piping (G10) 55

Pipe Materials - Non-Ferrous MaterialsNon-Ferrous Materials

(COA 330-339)



F C

Length Type**

AL B-241 1474 H4080 1746 AluminumU.S to 10 INCHES [250 MM]A96961 6061 A6061TU.S above 10 INCHES [250 MM] and all others

350 176 1

CU B-42C10200

2871C103

H3300C1020T

1754OF-Cu

Copper 400 204 3

N B-161N02200

3074NA11

H4552NNCT

17740Ni99.2

Nickel99Ni

600 315 3

MONEL B-165N04400

3074NA13

H4552NCuT

17751NiCu30Fe

Monel67Ni-30Cu

800 426 3

INCNL B-167N06600

Inconel72Ni-15Cr-8Fe

1200 648 3

TI B-337R50400

H4630TTP35

17850 Titanium 600 315 3

HAST B-619N10276

H4552NMCr

17751NiMo16Cr15

Hastelloy54Ni-16Mo-15Cr

1250 676 3

A 20 B-464N08020

Alloy 2035Ni-35Fe-20Cr-Cb

800 426 3

ZR B-658R60702

Zirconium99.2Zr

700 371 3


56 18 Piping (G10)

Plastic and Resin Materials(COA 350-359)

Material Class Pipe Material


Recommended Maximum

Temperature

DEG F DEG C

F CLength Type*

Plastics and Resins Fiberglass Reinforced **Epoxy Resin

Polyvinyl Chloride,Maximum 8 INCHES [200 MM}diameter

Chlorinated Polyvinyl Chloride, Maximum 8 INCHES [200 MM] diameter

FRP

PVC

CPVC

260

140

200

125

60

93

4

4

* See below for Length Types** Thickness/schedule not adjustable

Type Length

10 FEET

[3 M]

15 FEET

[4.6 M]

20 FEET

[6.1 M]

30 FEET

[9.1 M]

1 < = 1.5 INCHE > 1.5 INCHE

2 All D

3 All D

4 All D

5 All D

18 Piping (G10) 57

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.

Spool Types

Lined Steel


Recommended Maximum

Temperature

Degrees Degrees

F CSpool Type*

Remote shop fabricated carbon steel pipe and fittings, lined with:EpoxyGlassNatural rubber, (1/4 INCHES [6 MM] thickNitrile rubber (1/4 INCHES [6 MM] thickHypalon rubber (1/4 INCHES [6 MM] thick

Butyl rubber (1/4 INCHES [6 MM] thick)Neoprene rubber (1/4 INCHES [6 MM] thickEbonite (1/4 INCHES [6 MM] thickCementPolypropylene

Polyvinylidene Fluoride (KYNAR)Polyvinylidene Chloride (SARAN)Fluorinated Ethylene Propylene (FEP TEFLON)Polytetrafluoroethylene (TFE TEFLON)

EPLCSGSLCSRBLCSNITRLHYPLN

BUTYLNEPNEEBONTCMLCSPPLCS*

PVDF*PVDCFEPTFELS*

260450175175175

175175175

225

275175400450

125230808080

808080

110

13580200230

424

1

1341

Remote shop fabricated stainless steel pipe and fittings, lined with:

Polytetrafluoroethylene (TFE TEFLON)

TFESS* 450 230 1

* Can use bends up to 4 INCHES instead of elbows.

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]

58 18 Piping (G10)

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 TFELS (material)System generates: 10 sections 20 flangesSpool length = 20 FEET [6.1 M]

200 FEET [61 M] Yard Pipe 10 INCHES diameter TFELS (Material)User enters: 10 flangesSystem generates: 5 Sections 10 flangesSpool lengths = 40 FEET [12 M}

200 FEET Yard Pipe 10 INCHES diameter TFELS (Material)User enters: 8 flangesSystem 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.


18 Piping (G10) 59

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 =

60 18 Piping (G10)

18 Piping (G10) 61

62 18 Piping (G10)

18 Piping (G10) 63

Icarus’ Pipe Fabrication, Erection and Testing ProceduresCode of Account Icarus Operation What is Included

3X2 FIELD SHOP FAB(312-CS, 322-SS, etc.)

HANDLE AND WELD PREP OPER.

Shop handling for fabrication

Weld prep

Pre-heating

Unload from train/truck into shop storage’ procure material for favrication; place completed spools in temporary storage.

Prepare for welding (clean, pickle, etc.); smooth weld (deburr/grink), and clean-up

For temperatures up to 400F [204C]

CUTTING PIPEFlame cuttingMachine cutting

Flame cut pipe- plain endMachine cut pipe - plain end

BEVELING PIPEFlame beveling

Machine beveling

Flame bevel pipe for weldingMachine bevel pipe for welding

WELDING (shop)Butt weldRepari bad x-ray welds

Manual butt weldDig out & re-weld bad X-ray welds

FIELD SHOP X-RAY Radiographic inspection

FIELD SHOP STRESS RELIEF Local stress, relieving

TESTING, MISC. CLEANINGClean & polishOther testing

User specifiedUser specified

3X4 REMOTE SHOP FAB(3140CS, 324-SS, etc.)

[Operations same as Field Shop] [Cost accounted as material cost]

64 18 Piping (G10)

Icarus’ Pipe Fabrication, Erection and Testing Procedures - continued

Code of Account Icarus Operation What is Included

3X7 PIPE ERECTION(317-CS, 327-SS, etc.)

ERECT SHOP FAB PIPE 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 cuttingMachine cuttingFlame bevelingMachine bevelingButt weldRepair bad X-ray welds

Same items as Field Shop Fab Same items as Field Shop FabSame items as Field Shop FabSame items as Field Shop FabSame items as Field Shop FabSame items as Field Shop Fab

FIELD X-RAY Same items as Field Shop Fab

FIELD STRESS RELEIF 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 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) 65

Valve and Fitting Options for Installation Bulk PipingSelections 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 Icarus 2000 systems.

Description Symbol

For Standard Piping Materials (all available piping materialsexcept 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

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

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.

66 18 Piping (G10)

Valve and Fitting Options for Installation Bulk Piping - continued

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.

18 Piping (G10) 67

Valve Trim SpecificationsThe 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.

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.

Definition of Aspen Icarus Valve Trim SpecificationsAPI-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

68 18 Piping (G10)

18 Piping (G10) 69

70 18 Piping (G10)


Civil Plant Bulks

Foundation Types

Typical Structure Live Loads

Soil Types

Specifying Seismic Data

How Icarus Calculates Wind Load and Seismic Shear

Example of Equipment Foundation Design

Example of Pile Foundation for an Equipment

19 Civil (G8)

19 Civil (G8) 19-1

Civil Plant BulksCivil plant bulk items include concrete tanks, foundations and structures.

Description Type

Concrete tanks: above grade, circular/rectangular

Shape symbol: CYLIN- Cylindrical tankRECT- Rectangular tankInside 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.

ABVGR TANK

19-2 19 Civil (G8)

Civil Plant Bulks - continued

Description Type

Concrete tanks: below grade, circular/rectangular

Shape symbol: CYLIN- Cylindrical tank RECT- Rectangular tankInside 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.

BELGR TANK

Concrete foundations, structures: 18 types (see Foundation Types later in this chapter)

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 10, “Administrative Operations,” 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. - Continued on next page -

CONCRETE

19 Civil (G8) 19-3


1 Calculate foundation footprint surface area.

2 Convert to a square of equivalent size.

3 Excavated footprint = equivalent square + allowance [Width] for formwork.

4 Depth of footing [to the frostline] in your Project Civil Design Basis = 1 FOOT

5 Blinding slab covers the footprint of the equivalent-sized square.

6 User can specify the excavation slope in the project and area level civil specs. By default, Icarus calculates excavation slope based on soil type.

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- SealcoatGM- Standard geosynthetic membraneC1- Bentonite clay liner - 1 membraneC2- Bentonite clay liner - 2 membranes*NO*- No sealcoat or membrane linerSealcoat or liner area: Default 0.0 SYMembrane thickness: Default 0.060 INCHES [1.50 MM]; Min: 0.020 INCHES [0.500 MM]; Max: 0.120 [3.0 MM]

19-4 19 Civil (G8)


Description Type

Scaffold labor: erect, dismantle

Temporary tubular steel scaffold, rental excluded. Default plank area = L x W.

SCAFFOLD

Concrete drainage trench, grate cover

Average invert depth: Default: *18* INCHES [*450* MM]Trench width: Default: *12* INCHES [*300* MM]

TRENCH

Tank containment with concrete paving and surrounding wall with coating

Depth of paving: Default: *8* INCHES [*200* MM]Wall height: Default: *3* FEET [*0.900* M]Wall thickness: Default: *12* INCHES [*300* MM]Number of stairways: Access stairway over wall. Default: *2*.Sealcoat option: Default: *YES* YES- Concrete sealer coating required NO- No sealer coating

CONTAINMNT

Tank containment with diked area and geomembrane

Contained length: Length, width and depth of diked area.Contained width: Length, width and depth of diked area.


DIKE MEMBR

19 Civil (G8) 19-5


Description Type

DIKE MEMBR - continued

Contained depth: Length, width and depth of diked area. Default: *4* FEET [*1.20* 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]; Default: *0.060* INCHES [*1.50* 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

19-6 19 Civil (G8)


Description Type

Above grade or buried yard piping

See Chapter 18, “Piping”

YARD PIPE

Above grade or buried piping


PIPE

High density polyethylene pipe, fusion bonded


HDPE

Buried concrete pipeSee Chapter 18, “Piping”

RCON PIPE

Building

See Chapter 26, “Buildings”

BUILDING

Organic, metallic, abrasion resist. lining

Material:*EPLCS*- Epoxt resin liningASRSN- Asphalt resin liningPHRSN- Phenolic resin liningPVDF- Kynar sheet liningTFELS- Teflon sheet liningBUTYL - 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 impactCERMM- Ceramic liner, med. abrasion, light impactCERMH- Ceramic liner, hvy. abrasion, light impactCERMV- Ceramic liner, hvy. abrasion, heavy impactABRPL- 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

LINING

19 Civil (G8) 19-7


Description Type

Pipe rack

See Chapter 20, “Steel”

PIPE RACK

Tee or bent type pipe sleepers

See Chapter 20, “Steel”

PIPE SUPPT

Open Concrete Structure

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]


OPN CON ST

19-8 19 Civil (G8)


Description Type

OPN CON ST - continued

Structure Type: * PREC * - Precast concrete structure CONC - Cast-in-place concrete structureConcrete 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]Number of stairways: Default: 1 + 1 per 5000 SF [500 M2] of area per floorFloor slab percent of area: Default: 75Floor slab thickness: Concrete slab thickness. Default: If not specified, system calculates based on span and loading.Floor grate - percent of area: Default: 0Grating type: Default: grating type from area steel specsSiding per wall area: Default: 0Siding type: * CORR * - Corrugated siding NSUL - insulated sidingWind Force Adjustment: Additional adjustment for wind force specified in project civil design specs. Default: 1Seismic Force Adjustment: Additional adjustment for seismic force specified in project civil design specs. Default: 1

19 Civil (G8) 19-9

Foundation TypesType Symbol Type Description

1 OCT+PROJ Octagon Slabs and Piers with Projection.

Foundation Typical Application

2 OCTAGONL Octagon Slabs and Piers without Projection.


3 PAVING Area Paving.


4 MASSPOUR Mass Pours - Large Mats, Pile Caps, and Other Shapes - 25 CY [19 M3] minimum.


19-10 19 Civil (G8)

Foundation Types - continued

Type Symbol Type Description

5 SM BLOCK Small Blocks - Pumps, Compressors, 3 CY [2.3 M3] or less.


6 LG BLOCK Large Blocks - Large Compressors, Turbines 3-25 CY [2.3-1.9 M3].


7 PILE CAPS Pile Caps - 5 CY [3.8 M3] or less.


8 CONDUIT Conduit Envelope.


9 RING Circular Ring Foundation - For Large Tanks.


19 Civil (G8) 19-11



10 BASIN Basins.


11 EL SLAB Elevated Slab.


12 COLM/BM Columns and Beams.


13 WALL Wall and Wall Footings.


14 GRIND BM Grade Beam.


19-12 19 Civil (G8)



15 PIER Piers.


16 FOOTING Column Footings, Sleepers.


17 BOX Valve Boxes, Manholes etc.


18 SLAB GRB Slab on grade.


19 Civil (G8) 19-13

Typical Structure Live Loads

Soil Types

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 TypeSoil Type Symbol Soil Loading Soil Density

PSF 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

19-14 19 Civil (G8)

Specifying Seismic DataThere are three different ways to specify seismic data. The system actually uses acceleration (measured in g: 0.17 means 17% of "g") to get the seismic load. Therefore, the most accurate way of specifying your seismic design requirements is to specify the acceleration value to be designed for. Entering Mercalli Number or UBC Zone is less accurate because it forces the system to estimate Acceleration using the following table.

How Icarus Calculates Wind Load and Seismic Shear1) 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 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.

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

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

19 Civil (G8) 19-15

3) Seismic acceleration (g) and Seismic Force Adjustment (default=1.0)

Icarus use the input value of Peak Ground acceleration (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 * SesmicForceAdjustment.

Example of Equipment Foundation DesignVessel 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

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

19-16 19 Civil (G8)

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 EquipmentThis 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

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

19 Civil (G8) 19-17

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

19-18 19 Civil (G8)


Steel Plant Bulks

How ICARUS Generates the Number of Column Struts

20 Steel (G6)

20 Steel (G6) 20-1

Steel Plant BulksSteel 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.

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.


OPN STL ST

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.Number of stairways: Default: 1 + 1 per 5,000 SF [500 M2] of area per floor.Structural steel analysis:S- Simplified stress analysisF- 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% - Continued on next page -

20 Steel (G6) 20-3


Description Type

OPN STL ST - continued

Siding type: *CORR*- corrugated sidingINSUL- insulated sidingSlab 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, stairs, laddersIncludes 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 piperackStructural steel analysis: S- Simplified stress analysis F- 2D finite element rigid frame analysisMain bent spacing: Default: *20.0* FEETLongitudinal 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.


PIPE RACK

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 levelNumber of ladders: *1* per 80 FEET [25 M] of length; MIN: 2Number 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 30-7 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 StrutsSystem 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

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: Default: 24 FEET [7.2 M]Levels between top and bottom chord: Default: 0Height to bottom chord: Default: 20 FEET [6.0 M]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: 1Seismic Force Adjustment: Default: 1

PIPE TRUSS

20-10 20 Steel (G6)


Description Type

Pipe supports/sleepers: bent or tee, just above grade

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

PIPE SUPPT

20 Steel (G6) 20-11


Description Type

Multiple-bay steel mill building: structural steel, siding

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. Default: *20* FEET [*6.0* M].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 identical, adjacent bays.Number of bays 1st Section: First bay type, describes one or more identical, adjacent bays. Default: *1*


MILL BLDG

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 identical, adjacent bays.2nd Section bay height: Second bay type, describes one or more identical, adjacent bays.Number of bays 2nd Section: Second bay type, describes one or more identical, adjacent bays. Default: *1*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 identical, adjacent bays. Default: *100*3rd Section bay width: Third bay type, describes one or more identical, adjacent bays.3rd Section bay height: Third bay type, describes one or more identical, adjacent bays.Number of bays 3rd Section: Third bay type, describes one or more identical, adjacent bays. Default: *1*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 more identical, adjacent bays. Default: *100*

Elevated access platforms: columns/beams, rail, grate, ladder

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.

PLATFORM

20 Steel (G6) 20-13


Description Type

Steel gallery structure for pipe, conveyors, walkways

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].


GALLERY

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- EnclosedTower 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]Grating: See “Grating Types” later in this chapter.

Conveyor transfer tower, square cross-section

Steel tower only; conveyors, hoppers and chutes must be specified elsewhere.

Grating: See “Grating Types” later in this chapter.

TRNS TOWER

Steel grate, less support steel

Grating: Default: *CS*. See “Grating Types” later in this chapter.

GRATE

Steel ladders Ladders greater than 10 FEET [3 M] are automatically caged.

Ladder Type: Default: *CAGED* CAGED- Caged ladder NONE- Ladder without cage

LADDER

Steel stairs, with grate treads, handrail STAIR

20 Steel (G6) 20-15


Description Type

Columns, beams, bracing, brackets 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

MISC STEEL

Fabricated, lined, stiffened plate items for chutes, boxes, etc.

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- SS316Plate 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 thickness Type 2: Lining type 2: thickness may not be specified for ceramic linings; Default: *1.0* INCHES [*25* MM].Lining per plate area Type 2: Lining type 2; Default: *0.0*Lining material Type 2: Lining type 2. See “Abrasion Resistant Linings; Replaceable” in Chapter 28.Lining thickness Type 3: Lining type 3: thickness may not be specified for ceramic linings; Default: *1.0* INCHES [*25* MM].Lining per plate area Type 3: Lining type 3; Default: *0.0*Lining material Type 3: Lining type 3. See “Abrasion Resistant Linings; Replaceable” in Chapter 28.

FABR PLATE

20-16 20 Steel (G6)


Description Type

Siding and roofing for steel structures

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

SIDING

Sanitary platform for equipment access

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*


SAN PLATFM

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 plateNumber of stairways: *1.00*Number of ladders: *0*Number of columnsLength of handrail and toeplate: FEET [M]

Grating Types

FG Fibergrate

S2 1/8 IN [3 MM] SS slipnot plate



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



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

20-18 20 Steel (G6)


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 Instrumentation (G10) 21-1

Instrumentation Plant BulksDescription 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- FiberglassCable Size: *14*, 12, 10 AWG; *1.5*, 2.5, 4.0 MM2.Rigid conduit, galvanized steel, couplings, fittings and seals

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- FiberglassConduit diameter: Range: 0.5 - 6.0 INCHES [15 - 150 MM]Number of elbows: Default: *0*Number of fittings: Default: *0*Number of conduit seals: Default: *0*

CONDUIT

Instrument panel, electronic/pneumatic

Panel type: ELC- Electronic panel PNU- Pneumatic panel E/P- Combined electronic/pneumatic

INST PANEL

21-2 21 Instrumentation (G10)

Instrument cable tray

Tray width: Range: 6 - 36 INCHES [150 - 910 MM]; Default: *18* INCHES [*450* MM]

INST TRAY

Electronic signal wire: wire, armored wire, wire in conduit

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

INST WIRE

Instrument pneumatic multi-tube bundle runs

Number of tubes per bundle: Range: 7, 12, or 19

PNU TUBING

Description Type


Instrumentation Plant Bulks - continued

Description Type

Thermocouple wire: wire, armored wire, wire in conduit

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

THCPL WIRE

Instrument junction boxes: electronic, pneumatic, thermocouple

Junction box type: EL50- Electronic - 50 conductorEL36- Electronic - 36 conductorEL24- Electronic - 24 conductorEL20- Electronic - 20 conductorEL16- Electronic - 16 conductorEL12- Electronic - 12 conductorEL6- Electronic - 6 conductorEL4- Electronic - 4 conductorPL4 - 4 Drop pluggable brick (Fieldbus only)PL4S - 4 Drop pluggable brick with short circuit protection (Fieldbus only)PL6 - 6 Drop pluggable brick (Fieldbus only)PL6S - 6 Drop pluggable brick with short circuit protection (Fieldbus only)PL8 - 8 Drop pluggable brick (Fieldbus only)PL8S - 8 Drop pluggable brick with short circuit protection (Fieldbus only)


JUNC BOX



Description Type

JUNC BOX - continued

PN19- Pneumatic - 19 tubesPN12- Pneumatic - 12 tubesPN7- Pneumatic - 7 tubesTC50- Thermocouple - 50 conductorTC36- Thermocouple - 36 conductorTC24- Thermocouple - 24 conductorTC20- Thermocouple - 20 conductorTC16- Thermocouple - 16 conductorTC12- Thermocouple - 12 conductorTC4- Thermocouple - 4 conductorSRSC- 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

Operator center type: Universal operator center or local center for one data hiway. Default: *UNIV*UNIV- Universal centerLOCAL- Local centerNumber of operator display units: Number of operator CRT (Cathode-Ray Tube Terminals), includes keyboardsNumber 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.


OPER CENT



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

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.

MULTI CONT



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.




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:

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 redundancyNumber 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*

Signal Type No. Input Signals per Card

No. Output Signals per Card

Analog 8 4

Digital 16 8



Description Type

High energy level process interface units: Indicator, switch, alarm circuits

Number of digital input cards: Enter number of input cards required.Number of digital output cards: Enter number of output cards required.

HL PIU

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.

Material selection: Default: *COAX* COAX- Coax cable FIBER- Fiber optic cableNumber of terminations: Min: 1; Default: *2*Enclosure type: Default: *NONE* NONE- None COND- Conduit

DATA HIWAY


Sensor Loop Descriptions

Pressure (p)

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 Signal Type: e = electronic, p = pneumatic.

Sensor Type Symbol

Loop Description Process Variable

Panel Action (1)

Instrument Location (2)

Signal Type (3)

1 Pressure Gauge, field mounted:

Sensor element types(default = ST):pipe fittings to process (ST),gauge valves to process (FT)draft gauge (DG)

P I LC none

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 IICRCR1R2R3

LPorCC

e

4 Pressure Switch:field mounted, via pipe and tubing.*NS*- No chemical sealCS- With chemical seal

P A LPorCC

e

6 Additional Control Valve:secondary control valve for adding to another control loop.

P IC LPorCC

Pore


Differential Pressure (DP)




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

1 Differential Pressure Gauge:connected to process via pipe and tubing.

DP l LC none

2 Differential Pressure Transmitter:connected to process via pipe and tubing.Sensor element types:transmitter without seal (TN)transmitter with seal (TS)standard or mircoprocessor

DP A LPorCC

por e

4 Differential Pressure Switch:connected to process via pipe and tubing.*NS*- No chemical sealCS- With chemical seal

DP A LPorCC

e

6 Additional Control Valve:secondary control valve for adding to another control loop

DP lC LPorCC

por e


Temperature (T)




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

1 Temperature indicatorSensor element types:TM- Dial thermometer withthermowellTC- 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 thermowellSensor element types (default = FS):FS- Filled systemTC- ThermocoupleRT- Resistance temperatureWB- Wet bulb temperatureSM- Surface mounted

T llICRCR1R2R3

LPor CC

pore

4 Temperature Switch: with thermowell, field-mounted

T A LPorCC

e

6 Additional Control Valvesecondary control valvefor adding to another control loop

T lC LPorCC

pore


Flow (F)




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

1 Flow Indicator F l LC none

2 Flow Transmitter:

Sensor element types (default = OP):OP- Orifice plate and DP transmitterOS- Orifice plate, DP transmitterand chemical seals VX- Vortex meterMG- Magnetic meter (standardor microprocessor)MS- Mass flow meterNS- No sensing element, transmitter loop only (NS)UM- Ultrasonic meterTM- Turbine meterMR - Meter run with orifice plateRS- Meter run with orifice plateand chemical seals

F llCRCR1R2R3

lPorCC

eor p

3 Flow Controller: orificeplate, field-mounted, connected to process via pipe, valves, tubing

F lC LC p

4 Flow Switch with orifice plate:Sensor element types (default FS):FS- Flow switch (FS),TS- Flow sensing and totalizing switch

F A LPorCC

e


F C LPorCC

pore


Level (L)




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

1 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

L l LC none

3 Level Controller:displacement type

L lC LC p

2 Level Transmitter:Sensor element types (default = DS):DS- Displacement typeDP- Differential pressure(standard or micro-processor)RS- DP with chemical sealsTF- Tape/floatUL- Single point Ultrasonic levelNL- Nuclear levelRD- Radar type

L llCRCR1R2R3

LPorCC

eorp

4 Level Switch:Sensor element types (default (DS):DS- Displacement level switch-fluidsPD- Paddle type level switch-solidsVS- Vibrating (tuning fork) switchCD- Conductivity (max/min) detection switchCS- Capacitive type switch



Analyzers (A)

1 For panel action, panel option and control valve option, refer to the applicable section later in this chapter. Instrument Location:


LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

2 Analyzers:Sensor element types (default PH):PH- pH indicating transmitter OR- ORP (Oxidation Reduction Potential) (Redox) transmitter O2- Oxygen analyzer (up to 4 samples)BT- BTU transmitterCS- Consistency analyzerPL- Gas detection% LEL (incl. electronics, rack)HD- Gas detection H2S (incl. electronics, rackC2- C02 (without sample conditioning system)VS- Viscosity (w/o sample conditioning system)CL- Color (without sample conditioning system)FP- Flame point (w/o sample conditioning system)CP- Cloud pointSD- Smoke densityFL- Flash pointSG- Specific gravity (liquid) HV- Heating value (incl. sampleconditioning)GC- Gas chromatograph (1 sample point, 6 comp.)HC- H2 and hydrocarbons (w/o sample probe)HS- H2S analyzerH2- Hydrocarbon in waterHR- H2S/S02 ratioSO- Sulphur in oil

A llCRCR2R3

LPorCC

e

6 Additional Control Valve:secondary control valve for adding to another control loop.

A lC LPorCC

pore


Speed (S)




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

2 Speed Indicating Transmitter:electronic,non-contact type

S llCRCR1R2R3

LPorCC

e

4 Speed Switch: S A LPorCC

e


Motion (X): Axial, Radial, Vibration




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

2 Motion Transmitter - non contact type, (default AX):Radial (RD)

X llCRCR1R2R3

LPorCC

e

4 Vibration Switch;vibrating read type

X A LPorCC

e


Position (PN)




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

2 Position Transmitter,(default VP):Variable position (VP):On/Off positions (NF)

PN llCRCR1R2R3

LPorCC

eorp

4 Position Switch PN A LPorCC

e


Weight (W)




LP= local panel



Electrical Conductivity (C)




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

2 Load Cells;Sensing element options(Default = 4C):3 cell configuration (3C)4 cell configuration (4C)6 cell configuration (6C)

W llCRCR1R2R3

LPorCC

e

Sensor Type Symbol


Panel Action (1)


Signal Type (3)

2 Conductivity Transmitter: C llCRCR1R2R3

LPorCC

e


Hand (Manual Activation) (H)




LP= local panel



Field Mounted Solenoid (SL)




LP= local panel



Sensor Type Symbol


Panel Action (1)


Signal Type (3)

3 Hand Regulator:field-mounted (pneumatic)

H lC LC p

6 Manual Controller:panel-mounted, no input signal, output signal only

H lC LPorCC

eorp

4 Manual switch: panel-mounted (front of panel)

H S LPorCC

e

Sensor Type Symbol


Panel Action (1)


Signal Type (3)

6 Solenoid: Field-mounted SL none LPorCC

e


Instrument Hookup


Panel Action Descriptions

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.

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

R1R2R3

Recorder (LP or CC):panel-mounted, one penpanel-mounted, two penspanel-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)

ClJlJR

Thermocouple-based Temperature Indicator, panel mounted (LP or CC):complete with back-of-panel mounted EMF convertermulti-pointThermocouple-based Temperature Recorder, multi-point, panel mounted (LP or CC)


Panel Option Descriptions

Fisher Control Valve Information

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

Control Valve Type

Size Range Body Type Actuator Positioner

Globe < = 4 INCHES6 - 8 INCHES

CEED

585657

3611JP3582

Ball all sizes V100 1052 3610J

Butterfly all sizes 8532 1052 3610J


Control Valve Options

Fluid positioning control valves may be specified as line size or reduced size. The default size reductions are as follows:

Type Definition

STD

GLP 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]

Line size Control valve0.5 - 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.

Standard positioning - type varies with size:

Type Size

Globe 0.5 - 4 INCH [12 - 100 MM]

Ball 6 - 12 INCH [150 - 300 MM]

Butterfly > 12 INCH [>300 MM]


Control Valve Configurations


Air Supply PipingFeed

Drop


Remote Control Type

Transmitter 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

Type Definition

S Standard

M Microprocessor (Smart)


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/Electricl Pneumatic Instrumentation



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 Electrical (G13) 22-1

Electrical Plant BulksElectrical plant bulks are divided into two categories, general and substation plant bulks. A description of each follows.

General Electrical Plant BulksGeneral electrical plant bulks include cables, trays, grounding, lighting and tracing.

Description Type

Material:

ARMOR- Armored multi-core cableW-C- Single wires in conduit, includes conduitW-NC - Single wires in conduit (less conduit)W-TR- Single wires in tray (less tray)M-C- Multi-core in conduit, includes conduitM-NC- Multi-core in conduit (less conduit)M-TR- Multi-core cable in tray (less tray)LARM- Lead covered armored cableRated voltage: 600- 600 V at 60 HZ5000- 5000 V at 60 HZ15000- 15000 V at 60 HZ600- 600 V at 50 HZ3300- 3300 V at 50 HZ1000- 11000 at 50 HZCable 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 trenchingConduit material: Default: *GALV* GALV- Galvanized rigid steel conduit EMT- Electrical mechanical tubing AL- Aluminum 1PVC- PVC plastic conduit PBON- PVC coated rigid steel (plasti-bond) PVCA- PVC coated aluminum FRE- Fiberglass

ELEC CABLE

22-2 22 Electrical (G13)

Electric Plant Bulks - General Electrical Plant Bulks - continued

Description Type

Electrical control cable runs (LV)

Material: ARMOR- Armored multi-core cableW-C- Single wires in conduit, includes conduitW-NC- Single wires in conduit (less conduit)W-TR- Single wires in tray (less tray)M-C- Multi-core in conduit, includes conduitM-NC- Multi-core in conduit (less conduit)M-TR- Multi-core cable in tray (less tray)LARM - Lead covered armored cableLength of cable run: Default: US: multi-core cable in conduit, else multi-core cable in tray w/o trayCable placement: Default: Project/Area Design Basis ABOVE - Above ground cable/wire BELOW - Buried cable/wire with trenching NOTRN - Buried cable/wire without trenchingNumber of conductors: Range: 1 - 37

CTRL CABLE

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- FiberglassCable Size: *14*, 12, 10 AWG; *1.5*, 2.5, 4.0 MM2.Rigid conduit, galvanized steel, couplings, fittings and seals


CONDUIT



Description Type

CONDUIT - continued.

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- FiberglassConduit diameter: Range: 0.5 - 6.0 INCHES [15 - 150 MM]Number of elbows: Default: *0*Number of fittings: Default: *0*Number of conduit seals: Default: *0*

Electrical cable tray

Material: *GALV*, FBRGL, SS, ALTray 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

ELEC TRAY

Electrical tracing of existing equipment Electrical tracing of equipment; item of equipment and its insulation are assumed specified elsewhere in the project.

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 cable5A- 5 W/FT [16 W/M] Chemelex BTV2-CT cable8A- 8 W/FT [26 W/M] Chemelex BTV2-CT cable10A- 10 W/FT [33 W/M] Chemelex BTV2-CT cable5P- 5 W/FT [16 W/M] Chemelex XTV2-CT cable10P- 10 W/FT [33 W/M] Chemelex XTV2-CT cable15P- 15 W/FT [49 W/M] Chemelex XTV2-CT cable20P- 20 W/FT [65 W/M] Chemelex XTV2-CT cable40M - 40 W/FT [131 W/M] 300 Volt MI cable


EQPT TRACE



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]M6 - 600V, dual conductor MI cable, 1.15 OHM/FT [3.77 OHM/M]M8 - 600V, dual conductor MI cable, 0.505 OHM/FT [1.66 OHM/M]M10 - 600V, dual conductor MI cable, 0.2 OHM/FT [0.656 OHM/M]M12 - 600V, dual conductor MI cable, 0.1 OHM/FT [0.328 OHM/M]M14 - 600V, dual conductor MI cable, 0.0561 OHM/FT [0.184 OHM/M]M16 - 600V, dual conductor MI cable, 0.0281 OHM/FT [0.0922 OHM/M]M18 - 600V, dual conductor MI cable, 0.013 OHM/FT [0.042 OHM/M]M20 - 600V, dual conductor MI cable, 0.00516 OHM/FT [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 controlSingle thermostat, control of electrical tracer based upon low ambient temperature specified for General Area Specifications.E-PRO- Electric tracing/process temperature controlMultiple thermostated circuits, control of electrical tracer based upon low ambient temperature specified for General Area Specifications.

Electrical tracing of existing piping run

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 specified elsewhere.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.


PIPE TRACE



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.3A- 3 W/FT [10 W/M] Chemelex BTV2-CT cable5A- 5 W/FT [16 W/M] Chemelex BTV2-CT cable8A- 8 W/FT [26 W/M] Chemelex BTV2-CT cable10A- 10 W/FT [33 W/M] Chemelex BTV2-CT cable 5P- 5 W/FT [16 W/M] Chemelex XTV2-CT cable10P- 10 W/FT [33 W/M] Chemelex XTV2-CT cable15P- 15 W/FT [49 W/M] Chemelex XTV2-CT cable20P- 20 W/FT [65 W/M] Chemelex XTV2-CT cable40P- 40M W/FT [131 W/M] 300 volt MI cableM2 - 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]M6 - 600V, dual conductor MI cable, 1.15 OHM/FT [3.77 OHM/M]M8 - 600V, dual conductor MI cable, 0.505 OHM/FT [1.66 OHM/M]M10 - 600V, dual conductor MI cable, 0.2 OHM/FT [0.656 OHM/M]M12 - 600V, dual conductor MI cable, 0.1 OHM/FT [0.328 OHM/M]M14 - 600V, dual conductor MI cable, 0.0561 OHM/FT [0.184 OHM/M]M16 - 600V, dual conductor MI cable, 0.0281 OHM/FT [0.0922 OHM/M]M18 - 600V, dual conductor MI cable, 0.013 OHM/FT [0.042 OHM/M]M20 - 600V, dual conductor MI cable, 0.00516 OHM/FT [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 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.




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

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:

GRND GRID



Description Type

Area lighting: includes poles, lights and cable

Flood: 400 - 1000 W; Default: *400*Other: 100 - 400 W; Default: *175*

Fixture type: Default: Mercury vapor/explosion proofFL1- Fluorescent - 1 bulbFL2- Fluorescent - 2 bulbsFL1E- Fluorescent - 1 bulb, explosion proofFL2E- Fluorescent - 1 bulbs, explosion proofMVPE - Mercury vapor/explosion proofMVPV- Mercury vapor/vaportiteMVCE - Mercury vapor/ceiling/explosion proofMVCV - Mercury vapor/ceiling vaportiteMVF- Mercury vapor/floodSVPE-Sodium vapor/explosion proofSVPV- Sodium vapor/vaportiteSVCE- Sodium vapor/ceiling/explosion proofSVCV- Sodium vapor/ceiling/vaportiteSVF- Sodium vapor/floodINPE- Incandescent/explosion proofINPV- Incandescent/vaportiteINCE- Incandescent/ceiling/explosion proofINCV- Incandescent/ceiling/vaportiteMHV- Mercury halide floodElectrical 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 WSupport type: See illustrations on following page.*PENDT*- Pendant supportBRAKT- Bracket supportSTAND- Stand and support armPOLE- Pole support (see height entry below)


AREA LIGHT



Description Type

AREA LIGHT - continued

Number of poles: Default: *0*.Pole height: Default: *20* FEET [*6.0* M].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 system3- 3 conductor system4- 4 conductor systemCable size: Default: US: *12 AWG*, else: 2.5 MM2.14- 14 AWG - US only12- 12 AWG - US only10- 10 AWG - US only1.5- 1.5 MM2 - other bases2.5- 2.5 MM2 - other bases4- 4 MM2 - other basesCable placement: Default: Project/Area Design BasisABOVE - Above ground cable/wireBELOW - Buried cable/wire with trenchingNOTRN - Buried cable/wire without trenchingElectrical cable type:ARMOR- Armored multi-core cableW-C- Single wires in conduit, includes conduitW-NC- Single wires in conduit (less conduit)W-TR- Single wires in tray (less tray)M-C- Multi-core in conduit, includes conduitM-NC- Multi-core in conduit (less conduit)M-TR- Multi-core cable in tray (less tray)




AREA LIGHT - continued

STAND Support Type STAND Support Type with Mast

POLE Support Type BRAKT and PENDT Support Types



Description Type

Group of anodes in deep well A group of anodes in a deep well with connecting leads to an adjacent 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

DEEP ANODE

Individual galvanic anode

An individual galvanic anode for road crossings, etc.Length per cable run: Default: *40* FEET [*12* M]

GALV ANODE

Group of anodes in shallow surface bed

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 backfillNumber of anodes per bed: *10*Spacing: Anode spacing is the center-to-center distance. Default: *8* FEET [*2.5* M]

SURF ANODE

Potential measurement test station

Number of test stations: Enter number of test stations per location.

POT TEST

Transformer/rectifier

480 V/60 HZ [415 V/50 HZ] 3 phase inputD.C. Output: 50 V/50 A or 100 V/100 A

Power pole line must be specified separately.Anode capacity:50:50A / 50V150:150A / 100V Length per cable run: Default: *500* FEET [*150* M]

RECTIFIER



Description Type

Solar panel with storage batteries Solar panels, adjacent storage batteries, control center, supporting structure, fencing and cable to a junction box.

Length per cable run: Default: *500* FEET [*150* M]

SOLAR PANL

Emergency light with battery

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, STDRNumber of light bulbs: *1*, 2

EMER LIGHT

Underground cable duct

Buried depth: Default: *40* INCHES [*1000* MM]Cable duct width: Default: *72* INCHES [*1800* MM]Cable duct type: *TILE*, ENVEL, CONC, PRCST

CABLE DUCT

Lighting panelboard and distribution board

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.

PANEL BRD

Tracing panelboard for electrical heat tracing

Panelboard for electrical heat tracing circuits.Panelboard size: 12-36

TRACE PANL



Description Type

Electrical heat tracing controller - single and multi-point

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

TRACE CNTR

Single/Multi-point Controller

Tracing control points: Default: *0*, Maximum 20Relay type: EMR - Electromechanical relaySSR - Solid state relayDefault: *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 PanelboardTracing control points: Only 10 control points allowedPanelboard size: *24*, 30 and 42Relay type: EMR - Electromechanical relay SSR - Solid state relay Default: *EMR*


Substation Electrical Plant BulksSubstation electrical plant bulks include transformers, breakers, transmission lines and bus.

Description Type

Bus duct

Continuous Current: Max: 3,000 ALength 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

BUS DUCT

Electrical transformer: 1 or 2 tap Rated load: Range: 10 - 100,000 KVATransformer type: *DRY*, OIL

TRANSFORM

Oil circuit breakers

Rated voltage: Range: 11 - 400 KVContinuous Current: Max: 5 KA [5000 A]

OIL C BRKR

Disconnect switches

Rated voltage: Range: 4 - 230 KV

DISCNCT SW

Overhead transmission line: cables, structures, guys, grounds

See “Schematic of Project Site Transmission Line Hook-Up”

Wire size: See “Wire Sizes” later in this chapter.

POLE LINE

Steel for substation structure SUBSTN STL


Electrical Plant Bulks - Substation Electrical Plant Bulks - continued

Description Type

Circuit breakers: main, feeder, tie-breakers

Continuous current: Max: 3,000 ARated voltage: through the maximum HV.Interrupt capacity: LV: 25 - 70 MVA; MV: 250 - 350 MVA; HV: 500 - 1000 MVACircuit breaker type: *AIR*, SF6, VACBreaker location: Default: *FEED* FEED- Feeder breaker MAIN- Main breaker TIE- Tie breaker

BREAKER

Motor control center

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).

MCC


Electrical Plant Bulks - Substation Electrical Plant Bulks - continued

Description Type

Switch board

Continuous current: 600-4000 ARated voltage: 3-13.8 KV

Switchboard type:VCB- Vacuum circuit breakerVCS1- Vacuum circuit breaker 1 unit stackVCS2- Vacuum circuit breaker 2 unit stackVCS3- Vacuum circuit breaker 3 unit stackShort circuit current: *25*-40 KA

SWITCH BRD

AC/DC Transformer

Rating: 30-300 ampere-hours

AC DC TRAN

Package transformer with panel

Rated load: 50-800 KVATransformer primary voltage: 3000-13800 VNumber of phases: 1 or *3*

PKG TRANSF

Emergency diesel generator

Power output: 5 - 1500 KVA

EM PWR SET

Uninterrupted power supply

Rated load: 2-300 KVA.UPS type: *STD*, MULT.

UPS

Power factor connection capacitor

Capacity: 24-2500 KVAR.Voltage: LV (low voltage), MV (medium voltage).

PF CORRECT


Schematic of Transmission Line


Substation Schematics


Electrical & Control Hook-Ups for Electric Motors

Motor Control CenterThe 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.


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 3-space starters.

Motor Size

HP KW

Voltage 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


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.

Medium Voltage (MV) and Low Voltage (LV) Motor Control Centers (MCC):


Power Distribution Network


Wire SizesWires sizes must be chosen from one of the following tables.

UK, EU, and JP Country Bases

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 2000

-------- (AWG) --- ----- (KCMIL) -----

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

6 95 400 1000

120

150

---------------------- (MM2) -------------------------


Electrical Class/DivisionNational Electrical Code (NEC)

+ Indicates cable type consistent with electrical class and division.

- Indicates cable type inconsistent with electrical class and division.

Electrical Class and Division Symbol Single Core or Multi-Core Wire In Tray

Single Core or Multi-Core Wire In Conduit

Armor-ed Cable

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. - + -


International Electrical Code (IEC)

+ Indicates cable type consistent with electrical class and division.

- Indicates cable type inconsistent with electrical class and division.

Electrical Zone Single Core or Multi-Core Wire In Tray

Single Core or Multi-Core Wire In Conduit

Armored Cable

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 + + +



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 Insulation and Fireproofing (G8) 23-1

Insulation Plant BulksDescription Type

Fireproofing for existing surface area

General fireproofing specified as a surface area to be covered.

Material: *MAGN*- Magnesium oxychloride CONC- ConcreteFire resistance rating: Range: 2 - 4The thickness changes according to the Firepr. Rating-Hours: For magnesium oxychlor fireproofing:2 hours- 9/16 INCHES [14 MM]3 hours- 7/8 INCHES [22 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]4 hours- 3 1/2 INCHES [88 MM]

FIREP AREA

Fireproofing for existing structural steel

Material:*MAGN*- Magnesium oxychlorideCONC- ConcreteFire resistance rating: Range: 2 - 4The thickness changes according to the Firepr. Rating-Hours: For magnesium oxychlor fireproofing:2 hours- 9/16 INCHES [14 MM]3 hours- 7/8 INCHES [22 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]4 hours- 3 1/2 INCHES [88 MM]

FIREP SSTL

General area insulation.

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


INSUL AREA

23-2 23 Insulation and Fireproofing (G8)

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

Material: *CASIL*- Calcium silicate MWOOL- Mineral wool FOAM- Foam glassTemperature: Temperature for FOAM only, provides cold (default) or hot insulation.Jacket type: AL- Aluminum jacket SS- Stainless steel jacket CS- Painted carbon steel jacket

INSUL PIPE

Packed bulk insulation

Material: *PERL*- Perlite bulk insulation VERM- Vermiculite bulk insulation RWOOL- Rockwool bulk insulation

INSUL BULK

Cable Tray fireproofing

Fire resistance rating: Range: 2 - 4

FIREP TRAY


Insulation MaterialsNote 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.

Fireproofing MaterialsNote 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 Maximum Thickness

INCHES MM

Temperature Range

DEG F 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

Foam glass 10.0 300.0 -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

Description Rating (hours)

Thickness

INCHES MM

Fireproofing Symbol

Magnesium oxychloride

0 0 0 MAGN

2 14

3 22

4 30

Concrete 0 0 0 CONC

2 64

3 3 76

4 89

Pyrocrete 1 19 PYRO

2 1 25

3 32

4 38

916------

1 416------

1 316------

112---

112---

34---

114---

112---


Insulation Schedules - System Default Tables

Hot Insulation - Light Schedule (L): I-P Units

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.

NominalPipe Diameter

Insulation Thickness - INCHES

1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6

Inches 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


Hot Insulation - Medium Schedule (M): I-P Units

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:







1 1.5 2 2.5 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


Hot Insulation - Heavy Schedule (H): I-P Units

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:





Nominal

Pipe Diameter


1.5 2 2.5 3 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 1413 2000

28 150 194 367 594 872 1243 1796

30 150 306 502 784 1092 1585

36 150 306 502 784 1092 1585


Cold Insulation - 1 to 5.5 INCH Thicknesses

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:







1 1.5 2 2.5 3 3.5 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


Cold Insulation - 6 to 10 INCH Thicknesses

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.


To use the table:





Nominal

Pipe Diameter


6 6.5 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 -459

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


Hot Insulation - Light Schedule (L): Metric Units

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:


2 Read across line to locate the operating temperature (degrees C).




Insulation Thickness - MM

25 38 50 63 75 88 100 113 125 138 150

MM 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


Hot Insulation - Medium Schedule (M): Metric Units

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:







25 38 50 63 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


Hot Insulation - Heavy Schedule (H): Metric Units

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:




4 For large diameter pipe, equipment, or other large flat surfaces, use thicknesses in the last line in the table



38 50 63 75 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 1093

250 65 158 281 462 635 857 1093

300 65 125 237 407 572 777 1006 1093

350 65 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: 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 10 degrees C or colder.


To use the table:







25 38 50 63 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


Cold Insulation - 178 to 254 Thicknesses

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 10 degrees C or colder.


To use the table:







175 188 200 213 225 238 250


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


Customizing Insulation SpecificationsIn 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 V7.1\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 IPM (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.


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:

• Unit of Measurement option fields at the top of the file

Diameter UnitsSection

Overall Units Section


• 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.


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


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 IPM, 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, IPM: C:/Aspen Tech/Aspen Icarus xxx/Data/PIDS

Project Directory (activation for a specific project only):

Aspen Capital Cost Estimator, IPM: 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.



Introduction to Paint

Paint Plant Bulks

How Icarus Systems Paint Equipment

24 Paint (G6)

24 Paint (G6) 24-1

Introduction to PaintIcarus 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 BulksDescription 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

24-2 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)


Introduction to Site Development

Demolition

Drainage

Earthwork

General

Excavation

Fencing

Landscaping

Roads-Slabs-Paving

Piling

Railroads

25 Site Development (G6)

25 Site Development (G6) 25-1

Introduction to Site DevelopmentSite 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 ItemsWithin 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 25 Site Development (G6)

development work items are presented to accommodate particular, well-defined 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.

DemolitionDescription Type

Demolish building w/disposal, no salvage

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.

DEMOLITION

Demolish building w/disposal and salvage Demolition of individual structures with separation of reusable materials for specified frame type. Loading and hauling waste material is included. Dump charge not included.

DISPOSAL

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


DrainageDescription Type

Catch basin, manhole

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.

BASINS

Pump and hose for open excavations

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.

DEWATERING

Drainage piping

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.

DRAINS

Septic tank and drain field

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.

SEPTIC TNK

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.

SUBDRAIN

Sump pit

Construction of sump pits including excavation and gravel bottom. Option of wood lining to a depth of 4 FEET [1.25 M].

SUMP PIT

Cased water supply well with pump

Domestic water wells drilled and cased. Includes down-hole pump, surface grouting, and utility runs, if specified. Does not include plumbing fixtures and connections.

WATER WELL


Drainage - continued

Description Type

Wellpoints with header and pump

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].

WELLPOINTS

9 Dewatering wells with pump

Dewatering wells; 2 INCH [50 MM] diameter bore with steel casing. Includes 2 INCH [50 MM] centrifugal pump per well for a specified period.

WELLS

10 Lump sum quotation - drainage

Enter Total Cost or Mat’l and MH. See code of accounts (Civil only).

DRAINAGE


Earthwork

GeneralDescription Type

Test borings with engineer’s reportIncludes field stake-out and elevations, 2.5 INCH [65 MM] auger holes with samples of earth, drawings and professional engineer’s (P.E.) report.

BORINGS

Clear brush - manual or dozer Brush clearing by hand with saw and rake (HAND) or by dozer with ball and chain (MACH).

BRUSH

Clearing and grubbing Mechanized clearing and grubbing.

OptionIncludes removal of trees toLIGHT 6 INCH [150 MM] diameterMEDIUM 10 INCH [250 MM] diameterHEAVY 16 INCH [400 MM] diameter

Includes on-site cutting, chipping and stump removal.

CLEAR GRUB

Dike construction including stabilizingConstruction 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 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.

GUNITE

Pond with bedding, lining, fencing-no pipeSpecify 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 stabilizationErosion protection and soil stabilization by spraying with asphalt.

STABILIZE

Lump sum quotation - earthwork Enter Total Cost or Mat’l and MH.See code of accounts (Civil only).

EARTHWORK


ExcavationDescription Type

Backfill and compact excavation Backfilling of trenches or footings. Fill material is assumed to be stockpiled locally, with no hauling. For numerous small items, man-hours 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.

BACKFILL

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 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.

COMPACT

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. Excavation by hand of trenches or pits, in sand, earth, or clay. Man-hours 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.

HAND EXCV

Truck haul-disposal or purchased fill 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].

HAULING


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 excavationsMax 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:

• 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).

SHORING

Excavation with stockpile or disposalThe 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.

SITE EXCVN


Excavation - continued

Description Type

Strip and stockpile soil - no hauling

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.

STRIP SOIL

Machine excavation, no backfill/shoring, etc.

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.

STRUC EXC

Ditching no backfill/shoring, etc.

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.

TRENCH EXC


FencingDescription Type

Barbed wire topping for fence No. of sides = wire on one or both sides of fence;No. of strands = no. each sideInstallation of barbed wire on chain link, mesh, or security fence. Two or three-strand galvanized or aluminum wire on either 1 or 2 sides.

BARBED

Boundary or Perimeter fencing in which the user can specify both fence and gates has been added.

BOUNDARY

Chain link fence with concrete footing

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.

CHAIN LINK

Wood fencing Permanent wood fencing of cedar picket, redwood basket-weave, or oak rustic rail with appropriate gates.

FENCE WOOD

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 brick8 INCH[200 MM] concrete block18 INCH[450 MM] decorative random stone8 INCH[200 MM] concrete.

FS WALL

Industrial gate for fence

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.

GATES

Wire mesh fencing

Galvanized steel mesh fencing and gates with posts on 5 FEET [1.5 M] centers. No bracing or concrete.

MESH

Heavy duty security fencing

Heavy duty security fence, security grade, set in concrete and trussed and braced.

SECURITY


LandscapingDescription Type

Mesh or netting erosion control Erosion control by placing and securing either jute mesh, plastic netting, polypropylene mesh, or tobacco netting.

EROSION

Placing peat or wood chip mulch Placing a 2 INCH [50 MM] deep layer of either wood chips or peat moss as mulch.

MULCH

Planting trees or shrubs 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.

PLANTING

Fine grade, seed, lime, fertilize Fine grading, seeding, liming, fertilization, and final watering.

SEEDING

Furnish, place sod on prepared area Furnish, place, and water sod (1 INCH [25 MM) deep) on pregraded area.

SODDING

Polybor chlorate soil sterilization Sterilization of cleared areas using polybor chlorate.

STERILIZE

Furnish, place and fine grade topsoil Furnish, place and fine-grade topsoil.

TOPSOIL

Lump sum quotation - landscaping Enter Total Cost or Mat’l and MH. See code of accounts (Civil only).

LANDSCAPE


Roads - Slabs - PavingDescription Type

Paving - asphalt base and wearing courses 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.

ASPHALT

Grade and compact base for paving Grade and compact areas to correct elevation to plus or minus 0.1 FEET [0.03 M].

BASE PREP

Concrete paving - no base preparation

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.

CONC PAVNG

Slipformed or manual cross gutter 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.

CROSS GUTT

Slipformed or manual placed 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.

CURB


Slipformed or manual curb and gutter Monolithic concrete curbing (kerbing) and gutter. Optional forming, pouring, and expansion joints on 30 FEET [9 M] centers or slipform by machine, if specified.

CURB GUTT

Concrete canal or gutter

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.

CANALGUTTR

Description Type


Roads - Slabs - Paving - continued

Description Type

Coal tar pitch emulsion (2 coats)

Application of sealcoating. Includes cleaning and preparing the existing surface and applying two coats of coal tar pitch emulsion.

SEALCOAT

Sidewalk base and paving

Installation of concrete or asphalt sidewalks or pavements with an option of a bank run gravel base.

SIDEWALKS

Gravel base course - no base prep

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.

SUBPAVING

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.

TAR CHIP

Parking Area

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.

PARKING

Lump sum quotation - paving/roads


PAVING

Main, secondary and minor Roads

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.

ROAD

Site Preparation for paving has been added. This includes Grubbing and cleaning, Hand and Machine Excavation, Fill of Subgrade and Compaction.

SITEPREP


PilingDescription Type

Drilled bell-type 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 soilsCLAY Wet, unstable soilsROCK Soft, weathered rock.

CAISSON

Driven pipe piles

Driving set pipe piles of selected diameter with an option of concrete filling. Equipment rental includes rental of drilling equipment.

PIPE

Drilled and cast-in-place concrete piles 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.

POURED

Driven precast concrete piles 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

PRECAST

Driven Raymond step-taper piles

Driving Raymond step-taper piles. Piles furnished and installed on a subcontract basis by Raymond International, Inc. Testing not included.

RAYMOND


Piling - continued

Description Type

Driven steel H-PILES 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).

STEEL H

Driven wood piles 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.

WOOD

Lump sum quotation - piling Enter Total Cost or Mat’l MH. See code of accounts (Civil only).

PILING


Railroads Description Type

Bumper at siding end

Installation of bumpers on a siding end. Heavy duty bumpers available as an option.

BUMPER

Single line siding crossing

Single line siding crossing including special track mat, timber, and crossing signal installed on level grade.

CROSSING

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

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.

SIDING HVY

Crossing signal with barrier, etc.

Track crossing signal with road barrier and flashing light.

SIGNAL

Wheel stops on siding

Installation of wheel stops on a yard siding.

STOPS

#8 turnout, switch-hitting, etc.

Installation of #8 turnouts, including rails, plates, bars, frogs, switch-points, timbers and ballast.

TURNOUT

Lump sum quotation - railroads

Enter Total Cost or Mat’l MH. See code of accounts (Civil only).

RAILROADS



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 Buildings (G6) 26-1

Introduction to BuildingsBuilding 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 BuildingA 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 2.Select the ‘—’ in Total cost adjust., then enter your unit costs for each of the five general categories.

3 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 super-structure 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.


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: 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.


Building Types and Defaults

S

HO

PO

FFIC

EC

OM

PR

CA

FE

WA

RE

CO

NTR

LG

AR

AG

ELA

BC

LO

SED

SA

NTR

YEX

IST

SH

ELL

WA

GE

YEA

R

ELE

CTRIC

AL

UN

IT L

OAD

45

42

0.5

40.5

51

11

1

SU

BSTRU

CTU

RE T

OTA

L0.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

019.1

21998

SU

BSTRU

CTU

RE T

OTA

L-

Fram

e-

Floor

- Roof

- Sta

irs

- Ext

ernal

Wal

ls-

Ext

ernal

Doors

& W

indow

s-

Ext

ernal

Doors

& W

indow

s

21.0

50.0

00.0

00.0

00.0

00.0

00.0

00.0

0

31.1

70.0

00.0

00.0

00.0

00.0

00.0

00.0

0

24.8

80.0

00.0

00.0

00.0

00.0

00.0

00.0

0

26.8

80.0

00.0

00.0

00.0

00.0

00.0

00.0

0

18.6

90.0

00.0

00.0

00.0

00.0

00.0

00.0

0

31.5

60.0

00.0

00.0

00.0

00.0

00.0

00.0

0

19.6

90.0

00.0

00.0

00.0

00.0

00.0

00.0

0

32.0

90.0

00.0

00.0

00.0

00.0

00.0

00.0

0

21.0

50.0

00.0

00.0

00.0

00.0

00.0

00.0

0

30.5

90.0

00.0

00.0

00.0

00.0

00.0

00.0

0

21.0

50.0

00.0

00.0

00.0

00.0

00.0

00.0

0

21.0

50.0

00.0

00.0

00.0

00.0

00.0

00.0

0

19.1

219.1

219.1

219.1

219.1

219.1

219.1

219.1

2

1998

1998

1998

1998

1998

1998

1998

1998

INTERN

AL

FIN

ISH

TO

TAL

- W

all Fi

nis

hes

- Fl

oor

Finis

hes

- Cei

ling F

inis

hes

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

0.0

00.0

00.0

00.0

0

19.1

219.1

219.1

219.1

2

1998

1998

1998

1998

FITT

ING

& F

URN

ISH

ING

TO

TAL

12.7

115.2

112.1

715.2

112.1

718.2

512.1

748.6

712.1

717.6

912.1

712.1

718.6

41998

SERVIC

E T

OTA

L-

Air C

onditio

nin

g-

Lighting a

nd E

lect

rica

l-

Hea

ting/V

entila

tion

- Pl

um

bin

g &

Fix

ture

s-

Fire

Pro

tect

ion

- Li

ft I

nst

alla

tion

- Sec

urity

Inst

alla

tion

- Spec

ial In

stal

lation

- Build

ers

Work

0.0

04.4

05.4

72.7

83.7

91.8

70.0

00.0

00.0

00.0

0

0.0

06.9

58.1

13.0

05.1

01.8

70.0

00.0

00.0

00.0

0

0.0

04.4

08.1

12.7

83.6

71.8

70.0

00.0

00.0

00.0

0

0.0

06.9

55.6

83.0

05.1

01.3

70.0

00.0

00.0

00.0

0

0.0

04.4

03.1

92.7

83.6

71.8

70.0

00.0

00.0

00.0

0

0.0

07.4

18.1

13.0

05.1

01.8

70.0

00.0

00.0

00.0

0

0.0

04.4

05.6

82.7

83.6

71.8

70.0

00.0

00.0

00.0

0

0.0

07.4

18.1

13.0

05.6

01.8

70.0

00.0

00.0

00.0

0

0.0

04.4

05.6

82.7

84.5

11.3

70.0

00.0

00.0

00.0

00

0.0

06.9

58.1

13.0

05.1

01.8

70.0

00.0

00.0

00.0

0

0.0

04.4

05.6

82.7

84.5

11.3

70.0

00.0

00.0

00.0

0

0.0

04.4

05.6

82.7

84.5

11.3

70.0

00.0

00.0

00.0

0

21.3

320.7

722.5

921.6

420.3

121.3

622.5

922.5

918.6

418.6

4

1998

1998

1998

1998

1998

1998

1998

1998

1998

1998

OVERH

EAD

AN

D P

RO

FIT

0.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00.0

00

1998


Default floor Heights/Levels

Building Construction Range Adjustment

Building Type Type Symbol Height per Floor or Level

FEET M

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

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

Adjustment Symbol

Construction Type

Frame Roof Walls Floors Finishes

L Pre-Fabricated Light Steel Light Steel Transite or metal sheet

Concrete Minimum

M Pre-fabricated Medium steel frame and trusses

Concrete Concrete walls or good brick

Concrete Average

H Custom designed

Heavy steel, heavy sidings

Concrete Face brick on concrete block

Concrete Expensive


Calculating Building Costs and LaborWhen 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.


Figure 1


Figure 2



Introduction

Quoted Equipment

User Libraries

27 Quoted Equipment and Libraries (G6)

27 Quoted Equipment and Libraries (G6) 27-1

IntroductionThere are two methods for specifying specialty items or items not included in system:

• Quoted equipment

• User libraries

Quoted EquipmentQuoted 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 LibrariesUser 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)


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 - Carbon Steel

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 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

Lining Materials

Brick: Acid-Resistant Applied Over Membrane-Lined Carbon Steel

Brick: Firebrick

Monolithic Lining

Abrasion Resistant Linings: Replaceable

Linings: Organic, Glass, Metallic

Casting Materials

Packing Materials

28-2 28 Material Selections (G10)

ASME Design Code - Plate Materials

ASME Ferrous Plate Materials - Carbon Steel

na = Material not selectable for vacuum design

ASTM Spec

(Grade)

Description and Nominal Composition

System Material

Internal Pressure Maximum Temp.

F C

External Pressure Maximum Temp.

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)

Low and intermediate strength carbon steel plates for pressure vessels

A 285 or A 285 C or CS

900 482 900 482

A-299 Carbon-manganese-silicon 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 pressure vessels for intermediate and higher temperature service: C-Si

A 515 1000 537 900 482

A-516(70)

Carbon steel plates for pressure vessels for moderate and lower temperature service - C-Si

A 516 1000 537 900 482

A-537 Carbon steel plates for pressure vessels for low temperature serviceC-Mn-Si

A 537 1292 700 300 148


ASME Ferrous Plate Materials - Heat Treated Steel


ASTM Spec

(Grade)


System Material


F C


F C

A-353 Nine percent nickel alloy steel plates, double normalized and tempered for pressure vessels:9Ni

A353 250 121 900 484

A-553

(Type 1)

Eight and nine percent nickel alloy steel plates, quenched and tempered, for pressure vessels:9Ni

A553 250 121 900 484

A-517

(A)(B)(E)(F)

High strength alloy steel plates, quenched and tempered, for pressure vessels:

Cr-Mn-SiCr-Mn-SiCr-Mn-SiCr-Mn-Si

A517AA517BA517EA517F

650650650650

343343343343

650650650650

343343343343


ASME Ferrous Plate Materials - Low Alloy Steel

- continued on next page -

ASTM Spec

(Grade)


System Material


F C


F C

A-202

(A)(B)

Chromium-manganese-silicon alloy steel plates for pressure vessels

A202AA 202

or A202B

10001000

537537

900900

482482

A-203

(A)(B)(D)(E)

Nickel alloy steel plates for pressure vessels:2.5Ni2.5Ni3.5Ni3.5Ni

A203AA203BA203DA203E

1000100010001000

537537537537

900900900900

482482482482

A-204

(A)(B)(C)

Molybdenum alloy steel plates for pressure vessels:C-.5MoC-.5MoC-.5Mo

A204AA204BA 204

or A204C

100010001000

537537537

900900900

482482482

A-302

(A)(B)

(C)(D)

Manganese-molybdenum and manganese-molybdenum-nickel alloy steel plates for pressure vessels:Mn-.5MoMn-.5Mo

Mn-.5Mo-NiMn-.5Mo-Ni

A302AA 302

orA302BA302CA302D

10001000

10001000

537537

537537

900900

900900

482482

482482


ASME Ferrous Plate Materials - Low Alloy Steel - continued


ASTM Spec

(Grade)


System Material


F C


F C

A-387

(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)

Pressure vessel plates, alloy steel, chromium-molybdenum:

.5Cr-.5Mo

.5Cr-.5Mo1Cr-.5Mo1Cr-.5Mo1.25Cr-.5Mo-Si1.25Cr-.5Mo-Si2.25Cr-1Mo2.25Cr-1Mo3Cr-1Mo3Cr-1Mo5Cr-.5Mo5Cr-.5Mo

A387AA387GA387BA387HA387CA387JA387DA387KA387EA387LA387FA387M

100010001200120012001200120012001200120012001200

537537648648648648648648648648648648

900900900900900900900900900900900900

482482482482482482482482482482482482

A-533

(A CL 1)(B CL 1)(C CL 1)

Manganese-molybdenum and manganese-molybdenum-nickel alloy steel plates, quenched and tempered, for pressure vessels:C-Mn-MoC-Mn-Mo-NiC-Mn-Mo-Ni

A533AA533BA533C

1000800800

537426426

650650650

343343343


ASME Ferrous Plate Materials - High Alloy Steel


ASTM Spec

(Grade)


System Material


F C


F C

A-240 Chromium and chromium-nickel stainless steel plate, sheet, and strip for fusion-welded unfired pressure vessels:

(304L) 8Cr - 8Ni 304L 800 426 800 426

(304) 18Cr - 8Ni SS304 (or SS)

1500 815 1200 648

(316L) 16Cr - 12Ni - 2Mo 316L 850 454 800 426

(316) 16Cr - 12Ni - 2Mo SS316 1500 815 1200 648

(316Ti) 16Cr - 12Ni - 2Mo-Ti 316TI 1500 815 1200 648

(317) 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 600 315 400 204

(410) 13Cr SS410 1200 648 900 482

(430) 17Cr SS430 1200 648 1200 648


ASME Non-Ferrous Plate Materials

na = material not selectable for vacuum design

ASTM Spec

(Grade)


System Material


F C


F C

B-209

(1100)(3003)(5052)(5083)(5086)(6061)

Aluminum-alloy sheet and plate:

AlAlAlAlAlAl

A1100A3003A5052A5083A5086A6061

400400400150150204

2042042046666204

400400400150150400

2042042046666204

B-171

(464)

Copper and copper alloys - Naval brass

CA464 400 204 350 177

B-11

(110)

Copper plates for locomotive fireboxes

Cu CU orCA110

400 204 150 66

B-96

(655)

Copper-silicon alloy plate and sheet for pressure vessels:

Cu - Zn CA655 350 176 350 176

B-152

(122)

Copper sheet, strip, plate, and rolled bar:

Cu CA122 400 204 150 66

B-171

(715)

Copper-nickel alloy plate and sheet for pressure vessels:

Cu - Ni 70/30 CA715 700 371 700 371


ASME Non-Ferrous Plate Materials - continued


ASTM Spec

(Grade)


System Material


F C


F C

B-333(B)

Hastelloy:Ni - Mo HAST or

HASTB800 426 800 426

B-575(C-276)

Hastelloy:Ni - Mo - Cr HASTC 1000 537 1000 537

B-409

(800)

Specification for nickel-iron-chromium alloy plate, sheet, and strip:

Ni - Fe - Cr I800 1500 815 800 426

B-424

(825)

Nickel-iron-chromium-molybdenum-copper alloy plate, sheet, and strip:

Ni - Fe - Cr - Mo - Cu I825 1000 537 700 371

B-463

(20Cb)

Carpenter 20 alloy plate, sheet and strip:

Cr-Ni-Fe-Mo-Cu-Cb C 20 800 426 800 426

B-168

(600)

Nickel-chromium-iron alloy plate, sheet, and strip,

Inconel:Ni - Cr - Fe

INCNLorI600

1200 648 800 426

B-162

(200)

(201)

Nickel plate, sheet, and strip:

Ni

Ni-Low C

NI orNI200NI201

6006001200

315315648

6006001000

315315537

B-127

(400)

Nickel-copper alloy plate, sheet, and strip:Ni - Cu MONEL

orM400

900 482 800 426

B-265

(1)(2)

Titanium and titanium alloy strip, sheet, and plate:

TiTi

TI35ATl orTI50A

600600

600

315315

315

600600

600

315315

315


ASME Design Code - Clad Plate Materials

* 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.

Material Classification Description*

Grade System Material

Symbol

Vessel Base (Backing Material)**ASTM A-285ASTM A-285 A-204 A-515 A-516 A-387 A-387 A-387 A-387 A-387 A-387

CBC707012 CL 112 CL 211 CL 111 CL 222 CL 122 CL 2

A285CA204BA204CA 515A 516A387BA387HA387CA387JA387DA387K

Cladding Material (Process Side)Stainless steel type 304

304L316316L321347410430

SS304304LSS316316LSS321SS347SS410SS430

Nickel alloy 200201

NI200NI201

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


ASME Design Code - Tube Materials

ASME Ferrous Tube Materials - Carbon SteelASTM Spec

(Grade)


System MaterialSymbol


F C


F C

System Default Tubesheet Material (Plate)

A-179 Seamless cold-drawnlow-carbon steel heat exchanger and condenser tubes.

CS (seamless)A - 179

900900

482482

900900

482482

A285CA285C

A-192 Seamless carbon steel boiler tubes for high-pressure service A 192 100

0537 900 482 A 515

A-210

(A-1)

(C)

Seamless medium carbon steel boiler and superheater tubes

A210A

A210C

1000

1000

537

537

900

900

482

482

A515

A515

A-214 Electric-resistance-welded carbon steel heat exchanger and condenser tubes

CS (welded)A 214

1000

1000

537

537

900

900

482

482

A515

A515

A-334

(1)(6)

Seamless carbon steel tubes for low temperature service A334A

A334B650650

343343

650650

343343

A 442A 442


ASME Ferrous Tube Materials - Low Alloy Steel ASTM Spec

(Grade)




F C


F C


A-199

(T11)(T22)(T21)(T5)

Seamless cold-drawn intermediate alloy steel heat exchanger and condenser tubes:

1.25Cr - .5Mo - Si2.5Cr - 1Mo3Cr - .9Mo5Cr - .5Mo

A199CA199DA199EA199F

1200120012001200

648648648648

900900900900

482482482482


A-209

(T1)(T1A)(T1B)

Seamless carbon-molybdenum alloy steel boiler and superheater tubes:

C - .5MoC - .5MoC - .5Mo

A 209A209AA209B

100010001000

537537537

900900900

482482482

A 204A 204A 204

A-213

(T2)(T12)(T11)(T22)(T21)(T5)

Seamless ferritic and austenitic alloy steel boiler, superheater, and heat exchanger tubes:.5Cr - .5Mo1Cr - .5Mo1.25Cr - .5Mo - Si2.25Cr - 1Mo3Cr - .9Mo5Cr - .5Mo

A213AA213BA213CA213DA213EA213F

100012001200120012001200

537648648648648648

900900900900900900

482482482482482482



ASME Ferrous Tube Materials - High Alloy SteelASTM Spec

(Grade)


System Material

Symbol

Internal Pressure Maximum

Temp.

F C

External Pressure Maximum

Temp.

F C


A-213

TP304

TP304LTP316

TP316LTP321TP347

Seamless Ferritic and austenitic alloy steel boiler, superheater, and heat exchanger tubes:18Cr - 8Ni

18Cr - 8Ni16Cr - 12Ni - 2Mo

16Cr - 12Ni - 2Mo18Cr - 10Ni - Ti18Cr - 10Ni - Cb

304S (or SS)304LS316S

316LS321S347S

1500

8001500

85015001500

815

426815

454815815

1000

8001000

85010001000

537

426537

454537537

SS304

304LSS316

316LSS321SS347

A-249

TP304TP304LTP316

TP316LTP321TP347

Welded austenitic steel boiler superheater, heat exchanger, and condenser tubes:18Cr - 8Ni18Cr - 8Ni16Cr - 12Ni - 2Mo

16Cr - 12Ni - 2Mo18Cr - 10Ni - Ti18Cr - 10Ni - Ti

18Cr - 8Ni304LW316W

316LW321W347W

15008001500

85015001500

815426815

454815815

100010001000

81510001000

537426537

426537537

SS304SS304SS316

316LSS321SS347

A-268

TP410

TP410

Seamless tubes13CWelded tubes13C

410S

410W

1200

1200

-648

648

900

900

482

482

SS410

SS410

A-789(S31803)

Welded duplex austenitic steel tubes:

22Cr - 5Ni - 3Mo 2205W 600 315 400 204 S2205


ASME Non-Ferrous Tube MaterialsASTM Spec

(Grade)


System Material

Symbol


Temp.

F C


Temp.

F C


B-111

(122)(687)(706)(715)

(443)(444)(445)

Seamless copper and copper alloy tubes for use in surface condensers, evaporators and heat exchangers:

CuCu - AlCu - Ni 90/10Cu - Ni 70/30Admiralty Brass

CA122CA687CA706CA715

CA443CA444CA445

400450600700

450450450

204232315371

232232232

150150150100

350350350

66666637

176176176

A285CA285CA285CA285C

A285CA285CA285C

B-163

(200)(201)

Seamless cold-drawn nickel tubes for general corrosive service:

NiNi-Low C

NI200NI201

6001200

315648

6001000

315537

NI200NI201

B-163(400)

MonelNi - Cu MONEL 800 426 800 426 MONEL

B-163(600)

InconelNi - Cr - Fe INCNL

orI600

1200 648 1000 537 INCNL

B-163(800)(825)

IncoloyNi - Fe - CrNi - Fe - Cr - Mo - Cu

I800I825

15001000

815537

1000700

537371

I800I825

B-619(B)

(C-276)

HastelloyNi - Mo

Ni - Mo - Cr

HAST orHASTBHASTC

800

1000

426

537

800

800

426

426

HASTB

HASTC

B-468(20Cb)

Carpenter 20Cr - Ni - Fe - Mo - Cu - Cb

C 20 800 426 800 426 C 20

B-338(2)

TitaniumTi TI50A 600 315 600 315 TI50A


BS Design Code - Plate Materials

BS Ferrous Plate Materials - Carbon Steel


BS* or ASTM Spec and

(Grade)




F C


F C

A-36 (Structural steel) A 36 650 343 - -

A-283

154-430*

Low and intermediate strength carbonsteel plates of structural quality

A 283C 622 327 na na

A-285

151-400*161-400*


A 285 orA 285C or CS

752 400 752 400

A-299

164-400*

Carbon-manganese-silicon steel plates for pressure vessels:C - Mn - Si A 299 752 400 752 400

A-455

225-460*


A 455 752 400 752 400

A-515

224-460*

Carbon steel plates for pressure vessels for intermediate and higher temperature service:C - Si A 515 752 400 725 400

A-516

224-490*

Carbon steel plates for pressure vessels for moderate and lower temperature service:C - Si A 516 725 400 725 400


BS Ferrous Plate Materials - Heat Treated Steel



(Grade)




F C


F C

A-353

510N*

Nine percent nickel alloy steel plates, double normalized and tempered for pressure vessels:

9Ni A 353 250 121 na na

A-553

510*

Eight and nine percent nickel alloy steel plate, quenched and tempered, for pressure vessels:9Ni A 553 250 121 na na

A-517

(A)(B)(E)(F)


Cr - Mn - Si Cr - Mn - Si Cr - Mn - Si Cr - Mn - Si

A517AA517BA517EA517F

650650650650

343 343 343 343

650650650650

343 343 343 343


BS Ferrous Plate Materials - Low Alloy Steel BS* or ASTM Spec and

(Grade)




F C


F C

A-202

(A)(B)

Chromium-manganese-silicon alloy steel plates for pressure vessels A202A

A 202orA202B

10001000

537537

900900

482482

A-203

(A)(B)(E)503*

Nickel alloy steel plates for pressure vessels:

2.5Ni2.5Ni3.5Ni3.5Ni

A203AA203BA203EA203D

100010001000122

53753753750

900900900122

48248248250

A-204

(C)

240*261*

Molybdenum alloy steel plates for pressure vessels:

C - .5Mo

C - .5MoC - .5Mo

A 204

A204CA204AA204B

1000

752752

537

400400

900

752752

482

400400

A-302

(A)(B)

(C)(D)

Manganese-molybdenum and manganese-molybdenum-nickel alloy steel plates for pressure vessels:Mn - .5MoMn - .5Mo

Mn - .5Mo - NiMn - .5Mo - Ni

A302AA 302orA302BA302CA302D

10001000

10001000

537537

537537

900900

900900

482482

482482


BS Ferrous Plate Materials - Low Alloy Steel (continued)



(Grade)




F C


F C

A-387

(2 CL 1)(2 CL 2)

620*(12 CL 2)

621*(11 CL 2)

622-515*(22 CL 2)

(21 CL 1)(21 CL 2)

(5 CL 1)(5 CL 2)

Pressure vessel plates, alloy steel, chromium-molybdenum:.5Cr - .5Mo.5Cr - .5Mo

1Cr - .5Mo 1Cr - .5Mo

1.25Cr - .5Mo - Si1.25Cr - .5Mo - Si

2.25Cr - 1Mo2.25Cr - 1Mo

3Cr - 1Mo3Cr - 1Mo

5Cr - .5Mo5Cr - .5Mo

A387AA387G

A387BA387H

A387CA387J

A387DA387K

A387EA387L

A387FA387M

842842

842896

842896

842896

896896

896896

450450

450480

450480

450480

480480

480480

842842

842896

842896

842896

896896

896896

450450

450480

450480

450480

480480

480480

A-533

(A CL 1)(B CL 1)(C CL 1)

Manganese-molybdenum and manganese-molybdenum-nickel alloy steel plates, quenched and tempered, for pressure vessels:C - Mn - MoC - Mn - Mo - NiC - Mn - Mo - Ni

A533AA533BA533C

1000800800

537426426

650650650

343343343


BS Ferrous Plate Materials - High Alloy SteelBS* or ASTM Spec and

(Grade)




F C


F C

A-240

(317)(348)

318-S13*

Chromium and chromium-nickel stainless steel plate, sheet, and strip for fusion-welded unfired pressure vessels:18Cr - 10Ni - 3Mo18Cr - 10Ni - Cb

Duplex22Cr - 5Ni - 3Mo

SS317SS348

S2205

12921292

600

700700

315

12001200

400

648648

204

(410)(430)

304-S31*304-S11*316-S31*

316-S11*320-517*321-S31*347-S31*

13Cr17Cr

18Cr - 8Ni18Cr - 8Ni16Cr - 12Ni - 2Mo

16Cr - 12Ni - 2Mo16Cr - 12Ni - 2Mo - Ti18Cr - 10Ni - Ti18Cr - 10Ni - Cb

SS410SS430

SS304304L

SS316

316L316TISS321SS321

12001200

12927521292

752129212921292

648648

700400700

400700700700

9001200

12007521200

752120012001200

482648

648400648

400648648648


BS Non-Ferrous Plate Materials



(Grade)




F C


F C

1470*

(1100)*(3003)*(5052)*(5083)*(5086)*(6061)*


AlAlAlAlAlAl

A1100 A3003A5052 A5083A5086A6061

400400400150 150 400

20420420466 66 204

na na na na na na

na na na na na na

B-171

(464)


CA464 400 204 200 93

B-11(110)

Copper plates for locomotive fireboxes:Cu CU or

CA110400 204 150 66

B-96

(655)


Cu - Zn CA655 350 176 200 93

B-152

(122)


Cu CA122 400 204 150 66

B-171

(715)


Cu - Ni 70/30 CA715 700 371 200 93


BS Non-Ferrous Plate Materials (continued)



(Grade)




F C


F C

B-333(B)


HASTB800 426 800 426

B-575(C-276)


B-409

(800)


Ni - Fe - Cr I800 1292 700 800 426

B-424

NA15*


Ni-Fe-Cr-Mo-Cu I825 500 260 400 204

B-463

(20Cb)

Carpenter 20 alloy plate, sheet and strip:Cr - Ni - Fe - Mo - Cu - Cb

C 20 800 426 800 426

B-168

(600)

Nickel-chromium-iron alloy plate, sheet, and strip:

Ni-Cr-Fe INCNLorI600

1200 648 800 426

B-162

(200)(201)

Nickel plate, sheet, and strip:

NiNi-Low C

NI orNI200NI201

6006001200

315315648

600600800

315315426

B-127

(400)

Nickel-copper alloy plate, sheet, and strip:Ni - Cu MONEL

orM400

900 482 800 426

B-265

(1)(2)

Titanium and titanium alloy strip, sheet,TiTi

TI35ATI orTI50A

600600600

315315315

na600600

na315315


BS Design Code - Clad Plate Materials

* See Plate Materials (BS 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.

Material Classification 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

Cladding Material (Process Side)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

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


BS Design Code - Tube Materials

BS Ferrous Tube Materials - Carbon Steel BS*

or ASTM Spec and

(Grade)


System Material

Symbol


F C


F C


A-179

320*

Seamless cold-drawn low-carbon steel heat exchanger and condenser tubes

A 179 752 400 752 400 A285C

A-192

410*

Seamless carbon steel boiler tubes for high-pressure service

A 192 752 400 752 400 A 515

A-210

(A-1)(C)


A210AA210C

10001000

537537

900900

482482

A 515A 515

A-214

360*

Electric-resistance-welded carbon steel heat exchanger and condenser tubes

A 214 842 450 842 450 A 515

A-334

410-LT50*(6)


A334B122650

50 343

122650

50 343

A 442A 442


BS Ferrous Tube Materials - Low Alloy SteelBS*

or ASTM Spec and

(Grade)




F C


F C


A-199

(T11)(T22)(T21)(T5)




1022102210221022

550550550550

900900900900

482482482482


A-209

(T1)245-450*(T1B)


C - .5MoC - .5MoC - .5Mo

A 209A209AA209B

10007521000

537400537

900752900

482400482

A 204A 204A 204

A-213

(T2)(T21)

620-460*620-460*622-490*625-450*

Seamless ferritic and austenitic alloy steel boiler, superheater, and heat exchanger tubes:

.5Cr - .5Mo3Cr - .9Mo

1Cr - .5Mo1.25Cr - .5Mo - Si2.25Cr - 1Mo5Cr - .5Mo

A213AA213E

A213BA213CA213DA213F

10001022

1022102210221022

537550

550550550550

900900

900900900900

482482

482482482482

A387AA387E

A387BA387CA387DA387F


BS Ferrous Tube Materials - High Alloy SteelBS* or ASTM Spec and

(Grade)




F C


F C


A-213

304-S18*304-S14*316-S18*

316-S14*321-S18*347-S18*

Seamless Ferritic and austenitic alloy steel boiler, superheater, and heat exchanger tubes:18Cr - 8Ni18Cr - 8Ni16Cr - 12Ni - 2Mo


304S304LS316S

316LS321S347S

842752842

842842842

450400450

450450450

842752842

800842842

450400450

426450450

SS304304LSS316

316LSS321SS347

A-249

304-S25*304-S22*316-S26*

316-S22*321-S22*347-S17*

Welded austenitic steel boiler superheater, heat exchanger,and condenser tubes:

18Cr - 8Ni18Cr - 8Ni16Cr - 12Ni - 2Mo


304W304LW316W

316LW321W347W

842752842

842842842

450400450

450450450

842752842

800842842

450400450

426450450

SS304304LSS316

316LSS321SS347

A-268TP410

TP410

Seamless tubes13 CrWelded tubes13 Cr

410S

410W

752

752

400

400

752

752

400

400

SS410

SS410

A-789

(S31803)

Welded duplex austenitic steel tubes:22Cr - 5Ni - 3Mo

2205W 600 315 400 204 S2205


BS Non-Ferrous Tube MaterialsBS*or ASTM Spec and

(Grade)




F C


F C


B-111

(122)(687)(708)(715)


CuCu - AlCu - Ni 90/10Cu - Ni 70/30


400450600700

204230315371

150200150200

66936693


(443)(444)(445)

Admiralty Brass CA443CA444CA445

450450450

232232232

200200200

939393

A285CA285CA285C

B-163

(200)(201)


NiNi - Low C

NI200NI201

6001200

315648

600800

315426

NI200NI201

B-163(400)

Monel (Seamless)Ni - Cu MONEL 900 482 800 426 MONEL

B-163(600)

Inconel (Welded)Ni - Cr - Fe INCNL

orI600

1200 648 800 426 INCNL

B-163 (800)(825)

IncoloyNi - Fe - Cr (Welded)Ni - Fe - Cr - Mo- Cu (Seamless)

I800I825

12921000

700537

800500

426260

I800I825

B-619(B)

(C-276)

Hastelloy (Welded)Ni - Mo

Ni - Mo - Cr

HAST orHASTBHASTC

800

1202

426

650

800

800

426

426

HASTB

HASTC

B-468(20Cb)

Carpenter 20 (Welded)Cr - Ni - Fe - Mo- Cu - Cb

C 20 800 426 800 426 C 20

B-338(2)

Titanium (Welded)Ti

TI50A 600 315 600 315 TI50A


JIS Design Code - Plate Materials

JIS Ferrous Plate Materials - Carbon Steel


JIS*or ASTM Spec and

(Grade)



Internal Pressure Maximum Degrees

F C

External Pressure Temp. Degrees

F C

G-3101*SS400*

(structural steel)A 36 650 343 - -

G-3106*

SM520C*

Low and intermediate strength carbon steel plates of structural quality A 283 C 662 350 na na

G-3115*

SPV355*

Low and intermediate strength steel plates for pressure vessels

A 285 orA 285C orCS

662 350 662 350

G-3115*

SPV450*

Carbon-manganese-silicon steel plates for pressure vessels:

C - Mn - Si A 299 662 350 662 350

A-455

(A)


A 455 650 343 650 343

G-3118*

SGV480*

Carbon steel plates for pressure vessels for intermediate and higher temperature service

C - Si A 515 662 350 662 350

G-3126*

SLA360*

Carbon steel plates for pressure vessels for moderate and lower temperature service:

C - Si A 516 662 350 662 350


JIS Ferrous Plate Materials - Heat Treated Steel



(Grade)




F C


F C

G-3127*

SL9N520*

Nine percent nickel alloy steel plates, double normalized and tempered for pressure vessels:

9Ni A 353 392 200 na na

G-3127*

SL9N590*

Eight and nine percent nickel alloy steel plate, quenched and tempered, for pressure vessels:

9Ni A 553 392 200 na na

A-517

(A)(B)(E)(E)


Cr - Mn - SiCr - Mn - SiCr - Mn - SiCr - Mn - Si

A517AA517BA517EA517E

650650650650

343343343343

650650650650

343343343343


JIS Ferrous Plate Materials - Low Alloy Steel JIS*or ASTM Spec and

(Grade)




F C


F C

A-202

(A)(B)

Chromium-manganese-silicon alloy steel plates for pressure vessels A202A

A 202 orA202B

10001000

537537

900900

482482

G-3127*

SL2N255*(B)SL3N255*SL3N275*

Nickel alloy steel plates for pressure vessels:

2.5Ni2.5Ni3.5Ni3.5Ni


3921000392392

200537200200

392900122392

20048250200

G-3103*

SB450M*SB480M*(C)

Molybdenum alloy steel plates for pressure vessels:C - .5MoC - .5MoC - .5Mo

A204AA204BA204 orA204C

102210221000

550550537

752752900

400400482

G-3119*

SBV1A*SBV1B*

SBV2*SBV2*

Manganese-molybdenum and manganese-molybdenum-nickel alloy steel plates for pressure vessels:

Mn - .5MoMn - .5Mo

Mn - .5Mo - NiMn - .5Mo - Ni


A302AA 302 or A302BA302CA302D

9771022

10221022

525550

550550

900900

900900

482482

482482



G-4109*

SCMV1(A)*SCMV1(N)*

SCMV2(A)*SCMV2(N)*

SCMV3(A)*SCMV3(N)*

SCMV4(A)*SCMV4(N)*

SCMV5(A)*SCMV5(N)*

SCMV6(A)*SCMV6(N)*


.5Cr - .5Mo

.5Cr - .5Mo

1Cr - .5Mo1Cr - .5Mo

1.25Cr - .5Mo - Si1.25Cr - .5Mo - Si

2.25Cr - 1Mo2.25Cr - 1Mo

3Cr - 1Mo3Cr - 1Mo

5Cr - .5MoCr - .5Mo

A387AA387G

A387BA387H

A387CA387J

A387DA387K

A387EA387L

A387FA387M

10221022

11571157

11571157

10671067

11571157

11571157

550550

625625

625625

575575

625625

625625

900900

842842

896896

896896

896896

896896

482482

450450

480480

480480

480480

480480

G-3120*

SQV1A*SQV2A*SQV3A*

Manganese-molybdenum and manganese-molybdenum-nickel alloy steel plates, quenched and tempered, for pressure vessels:

C - Mn - MoC - Mn - Mo-NiC - Mn - Mo-Ni

A533AA533BA533C

1022797797

550425425

nanana

nanana


(Grade)




F C


F C


JIS Ferrous Plate Materials - High Alloy Steel JIS*or ASTM Spec and

(Grade)




F C


F C

G-4303*G-4304*G-4305*

SUS304L*SUS304*

SUS316L*SUS316*SUS316*

SUS317*SUS321*SUS347*(348)

(2205)

Chromium and chromium-nickel stainless steel plate, sheet, and strip for fusion-welded unfired pressure vessels:

18Cr - 8Ni18Cr - 8Ni

16Cr - 12Ni - 2Mo16Cr - 12Ni - 2Mo16Cr - 12Ni - 2Mo-Ti

18Cr - 10Ni - 3Mo18Cr - 10Ni - Ti18Cr - 10Ni - Cb18Cr - 10Ni - Cb

Duplex 22Cr - 5Ni - 3Mo

304LSS304

316LSS316SS316TI

SS317SS321SS347SS348

S2205

7971472

84214721472

1472147214721500

600

425800

450800800

800800800815

315

7521200

75212001200

1200120012001200

400

400648

400648648

648648648648

204

SUS410*SUS430*

13Cr17Cr

SS410SS430

12021202

650650

9001200

482648


JIS Non-Ferrous Plate Materials



(Grade)




F C


F C

H-4000*A1100P*A3003P*A5052P*A5083P*A5086P*A6061P*

Aluminum-alloy sheet and plate:Al Al Al Al Al Al

A1100A3003A5052A5083A5086A6061

392392392150150392

2002002006666200

nananananana

nananananana

H-3100*C4640P*


CA464 392 200 350 177

H3100*

C1100P*

Copper plates for locomotive fireboxes:

Cu CU orCA110

392 200 150 66

B-96

(B55)


Cu - Zn CA655 350 176 350 176

H-3100*

C1220P*


Cu CA122 392 200 150 66

H-3100*

C7150P*


Cu - Ni 70/30 CA715 662 350 662 350


JIS Non-Ferrous Plate Materials - continued



(Grade)




F C


F C

B-333(B)


HASTB800 426 800 426

B-575(C-276)


G-4902*

NCF800*

Specification for nickel-iron- chromium alloy plate, sheet, and strip:

Ni - Fe - Cr I800 1472 800 1000 537

B-424

(825)


Ni - Fe - Cr - Mo - Cu I825 1000 537 700 371

B-463

(20Cb)

Carpenter 20 alloy plate, sheet and strip:

Cr - Ni - Fe - Mo - Cu - Cb C 20 800 426 800 426

G-4902*

NCF600*

Nickel-chromium-iron alloy plate, sheet, and strip,

Inconel: Ni - Cr - Fe INCNLorI600

1202 650 1000 537

B-162(200)

(201)

Nickel plate, sheet, and strip:Ni

Ni-Low C

NI orNI200NI201

6006001200

315315648

6006001000

315315537

H-4551*

NCuP*

Nickel-copper alloy plate, sheet, and strip:

Ni - Cu MONELorM400

932 500 800 426

H-4600*

TP28*TP35*

Titanium and titanium alloy strip, sheet, and plate:

TiTi

TI35ATI orTI50A

662662662

350350350

na600600

na315315


JIS Design Code - Clad Plate Materials

* See Plate Materials (JIS 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.

Material Classification Description Grade System Material Symbol

Vessel Base (Backing Material)**SPV350SB480M

SGV480

SLA360SCMV2(A)SCMV2(A)SCMV3(A)SCMV3(A)SCMV4(A)SCMV4(A)

ASTM A-285 A-204 A-204 A-515

A-516 A-387 A-387 A-387 A-387 A-387 A-387

CBC70

7012 CL 112 CL 211 CL 111 CL 222 CL 122 CL 2

A285CA204BA204CA 515

A 516A387BA387HA387CA387JA387DA387K

Cladding Material (Process Side)Stainless steel type SUS304 SUS304L SUS316 SUS316L SUS321 SUS321 SUS321 SUS430Nickel alloy

Monel NCUPInconel NCF600Ni-Fe-CRNi-Fe-Cr-Mo-CuCarpenter 20TitaniumHastelloy BHastelloy C

304 304L 316316L321347410 430200201

400

60080082520 CB2BC-276

SS304304LSS316316LSS321SS347SS410SS430NI200NI201

MONEL

INCNLI800I825C 20TiHASTBHASTC


JIS Design Code - Tube Materials

JIS Ferrous Tube Materials - Carbon SteelJIS*

or ASTM Spec and

(Grade)


System Material

Symbol


F C


F C


G-3461*

STB340*


A 179 1022 550 752 400 A285C

A-192 Seamless carbon steel boiler tubes for high-pressure service

A 192 1000 537 900 482 A 515

G-3461*

STB510*STB410*

Seamless medium carbon steel boiler and superheater tubes A210A

A210C10221022

550550

900900

482482

A 515A 515

G-3461*

STB340*


A 214 1022 550 900 482 A 515

G-3464*

(1)STBL380*

Seamless carbon steel tubes for low temperature service

A334AA334B

650392

343200

650392

343200

A 442A 442


JIS Ferrous Tube Materials - Low Alloy SteelJIS*

or ASTM Spec and

(Grade)


System Material

Symbol


F C


F C


G-3462*

STBA23*STBA24*(T21)STBA25*

G-3462*

STBA12*STBA13*(T1B)




C - .5MoC - .5MoC - .5Mo


A 209A209AA209B

1202120212001202

102210221000

650650648650

550550537

900900900900

900900900

482482482482

482482482


A 204A 204A 204

G-3462*

STBA20*STBA20*(T11)(T22)(T21)(T5)


.5Cr - .5Mo1Cr - .5Mo1.25Cr - .5Mo - Si2.25Cr - 1Mo3Cr - .9Mo5Cr - .5Mo

A213AA213BA213CA213DA213E A213F

102212021200120012001200

550650648648648648

900900900900900900

482482482482482483



JIS Ferrous Tube Materials - High Alloy Steel JIS*

or ASTM Spec and

(Grade)


System Material

Symbol


F C


F C


G-3463*

SUS304TB*SUS304LTB*SUS316TB*

Seamless Ferritic and austenitic alloy steel boiler, superheater, and heat exchanger tubes:18Cr - 8Ni18Cr - 8Ni16Cr - 12Ni - 2Mo

304S304LS316S

14727971472

800425800

842752842

450450450

SS304304LSS316

SUS316LTB*SUS321TB* SUS347TB*


316LS321S347S

84214721472

450800800

842842842

450400450

316LSS321SS347

G-3463*

SUS304TB*SUS304LTB*SUS316TB*

SUS316LTB*SUS321TB*SUS347TB*

Welded austenitic steel boiler superheater, heat exchanger, and condenser tubes:

18Cr - 8Ni18Cr - 8Ni16Cr - 12Ni - 2Mo


304W304LW316W

316LW321W347W

14727971472

84214721472

800425800

450800800

842752842

842842842

450400450

450450450

SS304304LSS316

316LSS321SS347

A-268TP 410

TP 410

Seamless tubes13Cr

Welded tubes13Cr

410S

410W

752

752

400

400

752

752

400

400

SS410

SS410

A-789

(S31803)


22Cr - 5Ni - 3Mo 2205W 600 315 400 204 S2205


JIS Non-Ferrous Tube MaterialsJIS*or ASTM Spec and

(Grade)




F C


F C


H-3300*

C1220T*C6871T*C7060T*C7150T*


CuCu - AlCu - Ni 90/10Cu - Ni 70/30


392392572662

200200300350

150150150700

666666371


C4430T*(444)(445)

Admiralty Brass CA443CA444CA445

437450450

225232232

350350350

176176176

A285CA285CA285C

B-163

(200)(201)


NiNi-Low C

NI200NI201

6001200

315648

6001000

315537

NI200NI201

H-4552*NCuT*

MonelNi - Cu MONEL 887 475 752 400 MONEL

G-4904*NCF600TB*

InconelNi - Cr - Fe INCNL

orI600

1202 650 1000 537 INCNL

G-4904*NCF800TB*NCF825TB*

IncoloyNi - Fe - CrNi - Fe - Cr - Mo - Cu

I800I825

14721000

800537

1000700

537371

I8001825

B-619(B)

(C-276)

HastelloyNi - Mo

Ni - Mo - Cr

HAST orHASTBHASTC

800

1000

426

537

800

1000

426

537

HASTB

HASTC

B-468(20Cb)


C 20 800 426 800 426 C 20

H-4650*TB35*

TitaniumTi TI50A 662 350 600 315 TI50A


DIN Design Code - Plate Materials

DIN Ferrous Plate Materials - Carbon Steel


DIN*or ASTM Spec and

(Grade)




F C


F C

DIN EN 10025-91*S235JRG1*

(structural steel) A 36 650 343 - -

DIN EN 10025-91*

S235JRG2*


A 283C 662 350 na na

DIN 17155*

HII*

Low and intermediate strength steel plates for pressure vessels A 285 or

A 285C orCS

1022 550 896 480

DIN 17102*

St E 355*

Carbon-manganese-silicon steel plates for pressure vessels:

C - Mn - Si A 299 662 350 662 350

A-455

(A)

Pressure vessel plates, carbon steel, high strength manganese A 455 650 343 650 343

DIN 17155* Carbon steel plates for pressure vessels for intermediate and higher temperature service:

19Mn5* A 515 662 350 662 350

DIN 17102*

SIE315*

Carbon steel plates for pressure vessels for moderate and lower temperature service:

C - Si A 516 662 350 662 350


DIN Ferrous Plate Materials - Heat Treated Steel


DIN*

or ASTM Spec and

(Grade)


System Material

Symbol


F C


F C

SEW 680* Nine percent nickel alloy steel plates, double normalized and tempered for pressure vessels:

X8Ni9*

A 353

392 200 na na

SEW 680* Eight and nine percent nickel alloy steel plate, quenched and tempered, for pressure vessels:

X8Ni9* A 553 392 200 na na

A-517

(A)(B)(E)(F)


Cr - Mn - SiCr - Mn - SiCr - Mn - SiCr - Mn - Si

A517AA517BA517EA517E

650650650650

343343343343

650650650650

343343343343


DIN Ferrous Plate Materials - Low Alloy SteelDIN*or

ASTM Spec and

(Grade)


System Material

Symbol


F C


F C

A 202

(A)(B)

Chromium-manganese-silicon alloy steel plates for pressure vessels

A202AA 202 orA202B

10001000

537537

900900

482482

SEW 680*

(D)(E)

Nickel alloy steel plates for pressure vessels:14Ni6*10Ni14*3.5Ni3.5Ni


3921000392392

200537200200

392900122392

20048250200

DIN 17155*

(B)(C)

Molybdenum alloy steel plates for pressure vessels:

15Mo3*C - .5MoC - .5Mo

A204AA204BA 204 orA204C

102210221000

550550537

752752900

400400482

VdTUV Wbl.376 WB35*VdTUV Wbl.377 WB36*

VdTUV Wbl.378*VdTUV Wbl384 WB34*

Manganese-molybdenum and manganese-molybdenum-nickel alloy steel plates for pressure vessels:

17Mn Mo V64*15Ni Cu Mo Nb5*

12Mn Ni Mo55*13Mn Ni Mo54*

A302A

A 302 or A302B

A302C

A302D

9771022

10221022

525550

550550

900900

900900

482482

482482



(A)(G)

DIN 17155*DIN 17155*

(C)(J)

DIN 17155*VdTUV Wbl.404*

VdTUV Wbl.007*VdTUV Wbl.007*

(F)(M)


.5Cr - .5Mo

.5Cr - .5Mo

13Cr Mo44*13Cr Mo44*

1.25Cr - .5Mo - Si1.25Cr - .5Mo - Si

10Cr Mo910*12Cr Mo910*

12Cr Mo195*12Cr Mo195*

5Cr - .5MoCr - .5Mo

A387AA387G

A387BA387H

A387CA387J

A387DA387K

A387EA387L

A387FA387M

10221022

11571157

11571157

10671067

11571157

11571157

550550

500625

625625

500575

625625

625625

900900

842842

896896

896896

896896

896896

482482

450450

480480

480480

480480

480480

SEW 640*

(A)

Manganese-molybdenum and manganese-molybdenum-nickel alloy steel plates, quenched and tempered, for pressure vessels:C - Mn - Mo20 Mn Mo Ni55*12 Mn Ni Mo55*

A533AA533BA533C

1022797797

550425425

nanana

nanana

DIN*or

ASTM Spec and

(Grade)


System Material

Symbol


F C


F C


DIN Ferrous Plate Materials - High Alloy SteelDIN*

or ASTM Spec and

(Grade)


System Material

Symbol


F C


F C

DIN 17440*

(348)

(2205)


X2 Cr Ni1911*X5 Cr Ni1810*

X2 Cr Ni Mo17132*X5 Cr Ni Mo17122*X6 Cr Ni Mo Ti 17122*

X2 Cr Ni Mo18164*X6 Cr Ni Ti1810*X6 Cr Ni Nb1810*

Duplex22Cr - 5Ni - 3Mo

304LSS304

316LSS316316TI

SS317SS321SS347SS348

S2205

7971472

84214721472

1472147214721500

600

425800

450800800

800800800815

315

7521200

75212001200

1200120012001200

400

400648

400648648

648648648648

204

DIN 17440*

X10 Cr13*X6 Cr17*

SS410SS430

12021202

650650

9001200

482648


DIN Non-Ferrous Plate Materials


DIN*or ASTM Spec and (Grade)

Description and Nominal Compostion



F C


F C

DIN 1745A1100P*


AlAl Mn Cu*Al Mg 2.5*Al Mg 4.5* Mn*Al Mg 4 Mn*Al Mg 7.5 Si Cu*

A1100A3003A5052A5083A5086A6061

392392392150150392

2002002006666200

nananananana

nananananana

DIN 17660* Copper and copper alloys - Naval brassCu Zn38 Sn1* CA464 392 200 350 177

DIN 1787* Copper plates for locomotive fireboxes:E Cu58* orE Cu59*

CU orCA110

392 200 150 66

B-96

(655)

Copper-silicon alloy plate and sheet for pressure vessels:Cu - Zn CA655 350 176 350 176

DIN 1787* Copper sheet, strip, plate, and rolled bar:SF-Cu CA122 392 200 150 66

DIN 17664* Copper-nickel alloy plate and sheet for pressure vessels:Cu Ni 30 Mn1 Fe* CA715 662 350 662 350

B-333(B)


HASTB800 426 800 426

B-575(C-276)



DIN Non-Ferrous Plate Materials -continued


DIN*or ASTM Spec and (Grade)




F C


F C

VdTUV Wbl.412*

NCF800*


X10 Ni Cr Al Ti 3220* I800 1472 800 1000 537

B-424

(825)


Ni - Fe - Cr - Mo - Cu I825 1000 537 700 371

B-463

(20Cb)

Carpenter 20 alloy plate, sheet and strip:Cr - Ni - Fe - Mo - Cu - Cb C 20 800 426 800 426

VdTUV Wbl.305* Nickel-chromium-iron alloy plate, sheet, and strip, Inconel: Ni Cr15 Fe INCNL

orI600

1202 650 1000 537

B-162

(200)

(201)

Nickel plate, sheet, and strip:Ni

Ni-Low C

NI orNI200NI201

6006001200

315315648

600]6001000

315315537

DIN 17750* Nickel-copper alloy plate, sheet, and strip:Ni Cu 30 Fe F45* MONEL

orM400

932 500 800 426

DIN 17860*

3.7025.10*3.7035.10*

Titanium and titanium alloy strip, sheet, and plate:TiTi

TI35ATI orTI50A

662662662

350350350

na600600

na315315


DIN Design Code - Clad Plate Materials

* See Plate Materials (German 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.

Material Classification Description Grade System Material Symbol

Vessel Base (Backing Material)**

DIN 17102A-204 (B)

DIN 17155DIN 17102DIN 17155DIN 17155A-387 (C)A-387DIN 17155DIN 17155

St E 355ASTM A-204ASTM A -204 19 Mn5 SIE 315 13Cr Mo44 13Cr Mo44ASTM A-387ASTM A-387 10Cr Mo 910 10Cr Mo 910

CBC707012 CL 112 CL 211 CL 111 CL 222 CL 122 CL 2

A285CA204BA204CA 515A 516A387BA387HA387CA387JA387DA387K

Cladding Material (Process Side)Stainless steel type 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*

Nickel alloy

Monel NCUP

VdTUV Wbl.305* Ni Cr15 Fe

Ni-Fe-Cr

Ni-Fe-Cr-Mo-Cu

Carpenter 20

Titanium

Hastelloy BHastelloy C

304304L316316L321347410430

200201

400

600

800

825

20Cb

2

BC-276

SS304304LSS316316LSS321SS347SS410SS430

NI200NI201

MONEL

INCNL

I800

I825

C 20

Ti

HASTBHASTC


DIN Design Code - Tube Materials

DIN Ferrous Tube Materials - Carbon SteelDIN*

or ASTM Spec and

(Grade)


System Material

Symbol


F C


F C


DIN 2391*

St 35GBKNBK*


A 179 1022 550 752 400 A285C

DIN 1629*

St 37.0*

Seamless carbon steel boiler tubes for high-pressure service A 192 1000 537 900 482 A 515

DIN 1629*

St 44.0*St 52.0*

Seamless medium carbon steel boiler and superheater tubes A210A

A210C10221022

550550

900900

482482

A 515A 515

DIN 2393*

St 37-2 NBK*


A 214 1022 550 900 482 A 515

SEW 680*

TTSt 35N*(B)


A334B650392

343200

650392

343200

A 442A 442


DIN Ferrous Tube Material - Low Alloy SteelDIN*or ASTM Spec and

(Grade)




F C


F C


DIN 17175* DIN 17175*(T21)VdTUV007*

DIN 17175*(T1A)(T1B)


13Cr Mo44*10Cr Mo910*3Cr - .9Mo12Cr Mo195G


15 Mo3*C - .5MoC - .5Mo


A 209A209AA209B

1202120212001202

102210221000

650650648650

550550537

900900900900

900900900

482482482482

482482482


A 204A 204A 204

(T2)DIN17175*DIN17175*DIN17175*(T21)VdTUV007*


.5Cr - .5Mo13Cr Mo44*13Cr Mo44*10Cr Mo910*3Cr -.9Mo12Cr Mo195G*


102212021200120012001200

550650648648648648

900900900900900900

482482482482482482



DIN Ferrous Tube Materials - High Alloy SteelDIN*or ASTM Spec and

(Grade)




F C


F C


DIN 17458* Seamless Ferritic and austenitic alloy steel boiler, superheater, and heat exchanger tubes:

X5Cr Ni1810*X2Cr Ni1911*X5Cr Ni Mo17122*

304S304LS316S

14727971472

800425800

842752842

450400450

SS304304LSS316

X2Cr Ni Mo18143*X6Cr Ni Ti1810*X6Cr Ni Nb1810*X10 Cr13*

316LS321S347S410S

84214721472752

450800800400

842842842752

450450450400

316LSS321SS347SS410

DIN 17457* Welded austenitic steel boiler superheater, heat exchanger, and condenser tubes:

X5Cr Ni1810*X2Cr Ni1911*X5Cr Ni Mo17122*

X2Cr Ni Mo18143*X6Cr Ni Ti1810*X6 Cr Ni Nb 1810*X10 Cr 13*

304W304LW316W

316LW321W347W410W

14727971472

84214721472752

800425800

450800800400

842752842

842842842752

450400450

450450450400

SS304304LSS316

316LSS321SS347SS410

A-789

(S31803)

Welded duplex austenitic steel tubes:22Cr - 5Ni - 3Mo 2205W 600 315 400 204 S2205


DIN Non-Ferrous Tube MaterialsDIN*or ASTM Spec and

(Grade)




F C


F C


DIN 1787*DIN 1785*DIN 17664*DIN 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 BrassCu Zn28 Sn1*


CA443CA444CA445

392392572662

437450450

200200300350

225232232

150150150700

350350350

666666371

176176176


A285CA285CA285C

DIN 17752*(201)


LC Ni 99F34*Ni-Low C

NI200NI201

6001200

315648

6001000

315537

NI200NI201

DIN 17751* MonelNi Cu30 Fe F45 MONEL 887 475 752 400 MONEL

VdTUV Wbl.305*

InconelNi Cr15 Fe* INCNL

orI600

1202 650 1000 537 INCNL

VdTUV Wbl.412

VdTUv Wbl.432*

IncoloyX10 Ni Cr Al Ti 3220*Ni Cr21 Mo*

I800

I825

1472

1000

800

537

1000

700

537

371

I800

I825

B-619(B)

(C-276)

HastelloyNi - Mo

Ni - Mo - Cr

HAST orHASTBHASTC

800

1000

426

537

800

1000

426

537

HASTB

HASTC

B-468(20Cb)


C 20 800 426 800 426 C 20

B-338(2)

TitaniumTi T150A 662 350 600 315 T150A


EN 13445 Design Code - Plate Materials

EN Ferrous Plate Materials - Carbon Steel EN or ASTM Specification


System Material


F C


F C

EN 10028-2 P235GH 1.0345 N


A 36 752 400 752 400

EN 10028-2 P235GH 1.0345 N


A 285 or A 285 C or CS

752 400 752 400

EN 10028-2 P235GH 1.0345 N

Carbon-manganese-silicon steel plates for plates for pressure vessels

A 299 752 400 752 400

EN 10028-2 P235GH 1.0345 N


A 455 752 400 752 400

EN 10028-3 P355NH 1.0565 n

Carbon steel plates for pressure vessels for intermediate and higher temperature service: C-Si

A 515 752 400 752 400

EN 10028-3 P355NH 1.0565

Carbon steel plates for pressure vessels for moderate and lower temperature service - C-Si

A 516 752 400 752 400

EN 10028-2 P235GH 1.0345 N

Carbon steel plates for pressure vessels for low temperature serviceC-Mn-Si

A 537 752 400 752 400


EN Ferrous Plate Materials - Low Alloy SteelEN or ASTM Specification


System Material


F C


F C

Manganese - molybdenum and manganese-molybdenum-nickel alloy steel plates for pressure vessels:

EN 10028-2 16Mo3 1.5415 N

Mn - .5Mo A302A 932 500 932 500

EN 10028-2 16Mo3 1.5415 N

Mn - .5Mo A302B 932 500 932 500

Pressure vessel plates, ally steel. chromium - molybdenum:

EN 10028-6 P460QH 1.8871 QT

.5Cr - .5Mo A387A 572 300 572 300

EN 10028-6 P460QH 1.8871 QT

.5Cr - .5Mo A387G 572 300 572 300

EN 10028-2 13CrMo4-5 1.7335 NT

.1Cr - .5Mo A387B 932 500 932 500

EN 10028-2 13CrMo4-5 1.7335 NT

.1Cr - .5Mo A387H 932 500 932 500


EN 10028-2 10CrMo9-10 1.7380 NT

2.25Cr - .1Mo A387D 932 500 932 500

EN 10028-2 10CrMo9-10 1.7380 NT

2.25Cr - .1Mo A553K 932 500 932 500

EN or ASTM Specification


System Material


F C


F C


EN Ferrous Plate Materials - High Alloy Steel EN or ASTM Specification


System Material


F C


F C


EN 10028-7 X2CrNi 18-10 1.4301AT

18Cr -8Ni 340L 1022 550 1022 550

EN 10028-7 X2CrNi 18-10 1.4301AT

18Cr -8Ni SS304 1022 550 1022 550

EN 10028-7X5CrNiMo 17-12-21.4401 AT

16Cr - 12Ni - 2Mo 316L 1022 550 1022 550

EN 10028-7X5CrNiMo 17-12-21.4401 AT

16Cr - 12Ni - 2Mo SS316 1022 550 1022 550

EN 10028-7X6CrNiTi18-101.4541 AT

18Cr - 10Ni - Ti SS321 1022 550 1022 550

EN 10028-7X6CrNiNb18-101.4550 AT

18Cr - 10Ni - Cb SS347 1022 550 1022 550


EN 10028-7X6CrNiNb18-101.4550 AT

18Cr - 10Ni - Cb SS348 1022 550 1022 550

EN 10028-7X2CrNiMoN22-5-31.4462 AT

22Cr - 5Ni - 3Mo (Duplex)

S2205 482 250 482 250



System Material


F C


F C


EN 13445 Design Code - Tube Materials

EN Ferrous Tube Materials - Carbon SteelEN or ASTM Specification




F C


F C


EN 10216-2 P235GH 1.0345 N

Seamless cold-drawnlow-carbon steel heat exchanger and condenser tubes.

A-179 842 450 842 450 A 516

EN 10216-2 P235GH 1.0345 N

Seamless carbon steel boiler tubes for high-pressure service

A-192 842 450 842 450 A 516

EN 10216-2 P235GH 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

EN 10216-2 P235GH 1.0345 N

Seamless carbon steel tubes for low temperature service

A-334 842 450 842 450 A 516


EN Ferrous Tube Materials - Low Alloy Steel EN or ASTM Specification




F C


F C



EN 10216-2 X11CrMo51.7362 I

1.25Cr - .5 Mo - Si A-199C 932 500 932 500 A387C

EN 10216-2 10CrMo9-101.7380 NT or QT

3Cr-.9Mo A199E 932 500 932 500 A387E


EN 10216-2 14MoV6-31.7715 NT or QT

.5Cr - .5Mo A213A 1022 550 1022 550 A387A

EN 10216-2 13CrMo4-51.7335 NT or QT

1Cr - .5Mo A213B 932 500 932 500 A387B

EN 10216-2 10CrMo9-101.7380 NT or QT

2.25Cr - 1Mo A213D 932 500 932 500 A387D

EN 10216-2 X11CrMo51.7362 I

5Cr - .5Mo A213F 932 500 932 500 A387F


EN Ferrous Tube Materials - High Alloy SteelEN or ASTM Specification


System Material

Symbol


Temp.

F C


Temp.

F C


Seamless Ferritic and austenitic alloy steel boiler, superheater, and heat exchanger tubes:

EN 10216-5X5CrNi18-101.4301 AT

18Cr - 8Ni 304S 1022 550 1022 550 SS304

EN 10216-5X5CrNi 19-111.4306 AT

18Cr - 8Ni 304LS 1022 550 1022 550 304L

EN 10216-5X5CrNiMo17-12-21.4401 AT

16Cr - 12Ni - 2Mo 316S 1022 550 1022 550 SS316

EN 10216-5X2CrNiMo17-12-21.4404 AT

16Cr - 12Ni - 2Mo 316LS 1022 550 1022 550 316L

EN 10216-5X6CrNiTi 18-101.4541 AT

18Cr - 10Ni - Ti 321S 1022 550 1022 550 SS321

EN 10216-5X6CrNiNb18-101.4550 AT

18Cr - 10Ni - Cb 347S 1022 550 1022 550 SS347


Welded austenitic steel boiler superheater, heat exchanger, and condenser tubes:

EN 10217-7X5CrNi18-101.4301 AT

18Cr - 8Ni 304W 1022 550 1022 550 SS304

EN 10217-7X2CrNi19-111.4306 AT

18Cr - 8Ni 304LW 1022 550 1022 550 304L

EN 10217-7X5CrNiMo17-12-21.4401 AT

16Cr - 12Ni - 2Mo 316W 1022 550 1022 550 SS316

EN 10217-7X5CrNiMo17-12-21.4404 AT

16Cr - 12Ni - 2Mo 316LW 1022 550 1022 550 316L

EN 10217-7X6CrNiTi18-101.4541 AT

18Cr - 10Ni - Ti 321W 1022 550 1022 550 SS321



System Material

Symbol


Temp.

F C


Temp.

F C



EN 10217-7X6CrNiNb18-101.4550 AT

18Cr - 10Ni - Cb 347W 1022 550 1022 550 SS347

EN 10217-7X2CrNiMolN22-5-31.4462 AT


22Cr - 5Ni - 3Mo 2205W 482 250 482 250 S2205



System Material

Symbol


Temp.

F C


Temp.

F C



Lining Materials

Brick: Acid-Resistant Applied Over Membrane-Lined Carbon Steel

Brick: Firebrick

Lining Material Description Inches MM System Material Symbol

Red shale brick 2.54.58.0

62112200

25RSB45RSB80RSB

Fireclay, 30 percent alumina 2.54.59.0

62112225

25AFC45AFC45AFC

Lining Material Description Inches MM System Material Symbol

Insulating firebrick 2.54.59.0

62112225

25IFB45IFB90IFB

60 percent alumina firebrick 2.54.59.0

62112225

25FB645FB690FB6

90 percent alumina firebrick 2.54.59.0

62112225

25FB945FB990FB9


Monolithic Lining

Abrasion Resistant Linings; ReplaceableOnly for use with:

• equipment items – water cyclones and linings

• plant bulk items – steel fabricated plate

Lining Material Description System Material Symbol

Applied to surface with anchors on 12 INCH [300 MM] centers 50 percent alumina refractory gunning mix 90 percent alumina refractory gunning mix 90 percent alumina castable refractory

GUNA5GUNA9CASA9

Applied to bare surface 50 percent alumina refractory gunning mix 90 percent alumina refractory gunning mix 90 percent alumina castable refractory

GUN50GUN90CAS90

Applied over wire mesh reinforcement

Gunite GUNIT

Lining Material Description System Material Symbol

Replaceable ceramic liner backed with urethane elastomer for light abrasion and light impact

CERML

Replaceable ceramic liner backed with urethane elastomer for medium abrasion and light impact

CERMM

Replaceable ceramic liner backed with urethane elastomer for heavy abrasion and light impact

CERMH

Replaceable ceramic liner backed with urethane elastomer for heavy abrasion and heavy impact

CERMV

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 otherwise specified)

LS304

Replaceable SS316 plate lining (1 INCH [25 MM] thick unless otherwise specified)

LS316


Linings: Organic, Glass, MetallicLining Material Description 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


Casting MaterialsMaterial Classification Casting Material Description System Material

Symbol

Aluminum Alloys Aluminum AL

Iron and Steel Alloys Low-Alloy Steel Grade BLow-Alloy Steel Grade ELow-Alloy Steel Grade CLow-Alloy Steel

Carbon SteelLow-Alloy Steel Grade BLow-Alloy Steel Grade ALow-Alloy Steel Grade BLow-Alloy Steel Grade C

Low-Alloy Steel Grade DLow-Alloy Steel Grade ECarbon Steel Grade 60Carbon SteelCarbon Steel Grade 70

Carbon Steel Grade 70Low-Alloy Steel Grade 1ALow-Alloy Steel Grade 1BLow-Alloy Steel Grade 1C9 Percent Nickel SteelCarbon Steel

Cast Iron

A203BA203EA 204A 283

A 299A 302A387AA387BA387C

A387DA387EA 442A 455A 515

A 516A533AA533BA533CA 553A285Sor CSCI

Stainless Steel Alloys Type 304 Stainless Steel

Type 304L Stainless SteelType 316 Stainless Steel

Type 316L Stainless SteelType 321 Stainless SteelType 347 Stainless SteelType 410 Stainless SteelType 430 Stainless Steel

- continued next page -

SS304 or SS304LSS316

316LSS321SS347SS410SS430


Other Alloys NickelInconel MonelTitaniumCarpenter 20

NIINCNLMONELTIC 20

Other Materials Available Only On Pumps Where Designated

SS304 Impeller, CS CasingSS316 Impeller, CS CasingGoulds Alloy 20High Nickel AlloyHigh Nickel Alloy

Cast Steel

304SF316SFGAL20ISO BISO CCASTS

Material Classification Casting Material Description System Material Symbol


Packing Materials Packing Type Size

Inches MM

Packing Material Packing Type Symbol

Activated carbon - - Carbon ACT-C

Alumina - - Alumina ALMNA

Berl saddles 0.50.751.01.5

15202540

Ceramic 0.5CBS.75CBS1.0CBS1.5CBS

Berl saddles 0.50.751.01.5

15202540

Porcelain 0.5PBS.75PBS1.0PBS1.5PBS

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 0.51.01.52.0

15254050

Ceramic 0.5CIS1.0CIS1.5CIS2.0CIS

INTALOX saddles 0.51.01.52.0

15254050

Porcelain 0.5PIS1.0PIS1.5PIS2.0PIS

Pall rings 0.51.01.52.0

15254050

Polypropylene 0.5PPR1.0PPR1.5PPR2.0PPR

Pall rings 0.51.01.52.0

15254050

Stainless steel 0.5SPR1.0SPR1.5SPR2.0SPR

Raschig rings 0.50.751.01.52.03.0

152025405075

Ceramic


0.5CRR.75CRR1.0CRR1.5CRR2.0CRR3.0CRR


Raschig rings 1.01.52.03.0

25405075

Porcelain 1.0PRR1.5PRR2.0PRR3.0PRR


25405075

Stainless steel 1.0SRR1.5SRR2.0SRR3.0SRR


25405075

Carbon steel 1.0FRR1.5FRR2.0FRR3.0FRR

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 1.02.03.0

255075

Ceramic 1.0CCR2.0CCR3.0CCR

Cascade rings 1.02.03.0

255075

Polypropylene 1.0PCR2.0PCR3.0PCR

Cascade rings 1.01.52.03.04.0

25405075100

Stainless steel 1.0SCR1.5SCR2.0SCR3.0SCR4.0SCR

Steel structured packing 45° angle of vertical orientation

107766235

350250205115

410S Stainless steel M107YAM76YAM62YAM35YA


107766235

350250205115

304 Stainless steel M107YBM76YBM62YBM35YB


107766235

350250205115

316L Stainless steel

- continued on next page -

M107YCM76YCM62YCM35YC

Packing Type Size

Inches MM




7635

250115

410S Stainless steel M76XAM35XA


7635

250115

304 Stainless steel M76XBM35XB


7635

250115

316L Stainless steel M76XCM35XC

Packing Type Size

Inches MM




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 Units of Measure (G6) 29-1

Introduction to Units of MeasureIcarus 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 CautionAll 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:

• 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.

29-2 29 Units of Measure (G6)

• 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 ExampleThe 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 CautionThe 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 trial of consequences of redefinitions of the units of measure is one expectedly difficult to backtrack, especially if that variable affects size selection of materials in a non-standard way.


Units of MeasureType No.

Inch/Pound

Description Symbol

Conversion Metric

Description Symbol

Length

01 Inches INCHES x 25.4 = Millimeters MM

02 Feet FEET x 0.3048 = Meters M

03 Miles (statute) MILES x 1.60934 = Kilometers KM

04 Mesh MESH x 1.0000 = Mesh MESH

Area

05 Square feet SF x 0.092903 = Square meters

M2

06 Square yards SY x 0.836127 = Square meters

M2

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

Mass

12 Pounds LBS x 0.45359 =Kilograms KG

13 Tons (2000 pounds)

TONS x 0.907185 = 1000 Kilograms

TON

Mass per Length

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


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) per square inch, gauge

PSIG x 6.894757 = Kilopascals (1000 newtons per square meter)

KPA

19 Inches of mercury

IN HG x 3.38638 = Kilopascals (1000 newtons per square meter)

KPA

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) per square foot (loading)

PSF x 0.0478802 = Kilonewtons per square meter (1 newton = 1 KG mass under 1 meter/sec2 acceleration)

KN/M2

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(HZ is frequently used to refer to local power frequency)

x 1.0000 = Hertz HZ

Type No.

Inch/Pound

Description Symbol

Conversion Metric

Description Symbol


Flow Rates

26 Cubic feet per minute

CFM x 1.69901 = Cubic meters per hour

M3/H

27 Cubic feet per hour

CFH x 0.028317 = Cubic meters per hour

M3/H

28 Cubic feet per minute per square foot of surface

CFM/SF 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 (short tons, no unit for long tons)

TPH 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 Kilovolt-amperes (1000V-A)

KVA x 1.0 = Kilovolt-amperes

KVA

Power

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

Type No.

Inch/Pound

Description Symbol

Conversion Metric

Description Symbol


Miscellaneous Useful Constants1 Gravitational Constant:

° Inch-Pound 32.174 lb-ft/lb(force)-sec2

° Metric 9.80665 kg-m/kg(force)-sec2

2 Absolute temperatures:

° Rankine DEG R = 459.67 + DEG F

° Kelvin DEG K = 273.15 + DEG C

3 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

43 Millions of BTU per hour

MMBTU/H x 0.293071 = Megawatts MEGAW

44 BTU per hour per square foot

BTU/H/SF x 3.15460 = Watts per square meter

W/M2

45 BTU per pound BTU/LB x 2.32601 = Kilojoules per kilogram

KJ/KG

Viscosity

46 Centipoise CPOISE x 1.0 = Millipascal-seconds

MPA-S

47 Centistoke CSTOKE x 1.0 = Millimeters squared per second

MM2/S

Angular

na Degrees DEGREE x 1.0 = Degrees DEGREE

Other

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 size (diameter and thickness)

INCH not applicable size

Nominal pipe size (diameter and thickness)

MM

na Driver power HP not applicable Driver power KW

Type No.

Inch/Pound

Description Symbol

Conversion Metric

Description Symbol


Project Specifications and their Use of Units of Measure

Special Units of MeasureUnit 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 UnitsUnit of Measure Name for: INCHES (INCH-POUND) or MM (METRIC)

Use to specify:

• 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 diameterUnit of Measure Name for: FEET (INCH-POUND) or M (METRIC)

Use to specify:

• Vessel size

° span, length, height, diameter,

° tube length

• Fluid head- pumpsUnit 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, tubularUnit 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 screenUnit of Measure Name for: SY (INCH-POUND) or M2 (METRIC)

Use to specify:


Volume UnitsUnit of Measure Name for: CF (INCH-POUND) or M3 (METRIC)

Use to specify:

• Centrifuges - capacity


• 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:


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:

• Foundation formwork (shuttering)


Mass and Unit MassUnit 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


Pressure UnitsUnit 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:

• Civil - soil bearing capacity


Velocity and Flow Rate UnitsUnit of Measure Name for: FPM (INCH-POUND) or M/H (METRIC)

Use to specify:

• Conveyors, belt speedUnit of Measure Name for: MPH (INCH-POUND) or KM/H (METRIC)

Use to specify:

• Wind velocityUnit of Measure Name for: RPM (INCH-POUND) or RPM (METRIC)

Use to specify:

• Agitators, agitated tanks

• Motors

• BlendersUnit 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 pumpsUnit of Measure Name for: CFH (INCH-POUND) or M3/H (METRIC)

Use to specify:

• FeedersUnit of Measure Name for: CFM/SF (INCH-POUND) or M3/H/M2 (METRIC)

Use to specify:

• Dust collectorsUnit 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 systemsUnit of Measure Name for: GPH (INCH-POUND) or M3/H (METRIC)

Use to specify:

• Water treatment systems


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 evaporatorsUnit of Measure Name for: TPH (INCH-POUND) or TON/H (METRIC)

Use to specify:

• Conveyors

• Bucket conveyors

• Crushers

• Feeders

• Filters

• MillsUnit of Measure Name for: TPD (INCH-POUND) or TON/H (METRIC)

Use to specify:

• Crystallizers

• Feeder, vibrating

• Mills

Electrical UnitsUnit 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:



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


Power UnitsUnit 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 UnitsUnit 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:

• Pumps, gear



US Country Base

UK Country Base

JP Country Base

EU Country Base

ME Country Base

30 Field Manpower Titles and Wage Rates (G13)

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 BaseCraft Code

US Craft Name Unloaded Wage Rate

($/MH)

Aspen In-Plant Cost Estimator Loaded Wage

Rate ($/MH) 1

51 Laborer 16.70 36.50

52

53 *Millwright 30.80 67.20

54 Rigger 28.80 62.70

55

56 Light Vehicle Driver 18.30 39.90

57 Heavy Vehicle Driver 20.30 44.40

58

59 Oiler 27.70 60.50

60 Mechanic 27.70 60.50

61

62 Light Equipment Oper 27.70 60.50

63 Medium Equipment Oper 28.80 62.70

64 Heavy Equipment Oper 29.80 65.00

65

66 *Pipefitter 29.30 63.90

67 *Pipe Welder 33.90 74.00

68

69 Cement Finisher 24.60 53.80

70 Carpenter 23.90 52.20

71 Bricklayer 25.70 56.00

72 Ironworker - Rebar 27.70 60.50

73

74 Ironworker - Structural 28.80 62.70

75 Welder - Structural 29.80 65.00

76

77 Welder - Special 30.30 66.10

78 *Welder - Fabricator 27.70 60.50

79 *Boilermaker 27.50 60.10

80

81 *Instrument Fitter 30.80 67.20

82

83 *Electrician - Line 30.80 67.20

84 *Electrician - Wiring 28.80 62.70

85

30-2 30 Field Manpower Titles and Wage Rates (G13)

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 2009) = 2010.

86 *Sheetmetal Worker 26.30 57.40

87 Insulator 21.10 45.90

88

89 Painter 21.10 45.90

90

91

92

93

94

95

96

97

98 Craft Helper 18.50 40.30

99 Foreman ** **

Craft Code

US Craft Name Unloaded Wage Rate

($/MH)


Rate ($/MH) 1


UK Country Base ***

Craft Code

UK Craft Name Unloaded Wage Rate (PS/MH)


Rate (PS/MH) 1

51 Laborer 13.00 28.50

52

53 *Fitter/Millwright 16.90 37.10

54 Rigger 16.90 37.10

55



58

59

60 Plant Fitter 16.90 37.10

61




65

66 *Plater/Pipefitter 16.90 37.10

67 *Welder 17.20 37.80

68


70 Joiner 17.10 37.50


72 Steel Fixer 15.10 33.30

73

74 Steel Erector 16.90 37.10


76




80


82

83 *Electrical Technician 18.60 40.90

84 *Electrician 16.90 37.10

85


87 Insulator 16.90 37.10

88



* Principal Crafts.


*** Wage Rate Basis: National Agreement for the Engineering Construction Industry, 2008-2009 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 2009) = 4290

Note: PS indicates Pounds Sterling

89 Painter 15.10 33.30

90

91

92

93

94

95

96

97

98 Craftsman’s Mate 13.80 30.40

99 Foreman ** **

Craft Code

UK Craft Name Unloaded Wage Rate (PS/MH)


Rate (PS/MH) 1


JP Country BaseCraft Code

JP Craft Name Unloaded Wage Rate (KY/MH)


Rate (KY/MH) 1

51 Laborer 1.60 3.40

52

53 *Millwright 2.10 4.30

54 Rigger 2.10 4.30

55



58

59 Oiler 1.90 4.10

60 Mechanic 2.20 4.50

61




65

66 *Pipefitter 2.70 5.60

67 *Pipe Welder 2.80 5.80

68


70 Carpenter 2.30 4.90



73

74 Ironworker - Structural 2.40 4.90


76




80


82

83 *Electrician - Line 2.50 5.30

84 *Electrician - Wiring 2.50 5.30

85


87 Insulator 2.10 4.50

88



* Principal Crafts.


Base Construction Index Value (1Q 2009 = 1150).

Note: KY indicates thousand Yen.

89 Painter 2.20 4.60

90

91

92

93

94

95

96

97

98 Craft Helper 1.70 3.60

99 Foreman ** **

Craft Code

JP Craft Name Unloaded Wage Rate (KY/MH)


Rate (KY/MH) 1


EU Country BaseCraft Code

EU Craft Name Unloaded Wage Rate (EUR/MH)


Rate (EUR/MH) 1

51 Laborer 18.00 42.80

52

53 *Millwright 23.40 55.60

54 Rigger 23.40 55.60

55

56 Driver: Light 20.90 49.60

57 Driver: Heavy 20.90 49.60

58

59 Oiler

60 Mechanic 23.40 55.60

61

62 EquipOp: Light 20.90 49.60

63 EquipOp: Medium 21.10 50.20

64 EquipOp: Heavy 23.40 55.60

65

66 *Pipefitter 23.40 55.60

67 *Pipe Welder 23.80 56.40

68


70 Carpenter 23.60 55.90



73

74 Ironworker: Struct 23.40 55.60

75 Welder: Struct 23.40 55.60

76

77 Welder: Special 24.00 57.00

78 *Welder: Fabr 24.00 57.00


80

81 *Instru.Fitter 23.40 55.60

82

83 *Electr: Line 23.60 55.90

84 *Electr: Wire 23.40 55.60

85


87 Insulator 23.40 55.60

88



* Principal Crafts.



89 Painter 20.90 49.60

90

91

92

93

94

95

96

97

98 Helper 19.20 45.50

99 Foreman ** **

Craft Code

EU Craft Name Unloaded Wage Rate (EUR/MH)


Rate (EUR/MH) 1


ME Country BaseNote: SAR = Saudi Arabian Riyals

Craft Code

ME Craft Name Unloaded Wage Rate (SAR/MH)


Rate (SAR/MH) 1

51 Laborer 18.00 45.00

52

53 *Millwright 23.00 57.50

54 Rigger 23.00 57.50

55

56 Driver: Light 19.60 49.00

57 Driver: Heavy 19.60 49.00

58

59 Oiler 23.00 57.50

60 Mechanic 34.00 85.00

61

62 EquipOp: Light 18.00 45.00

63 EquipOp: Medium 20.70 51.80

64 EquipOp: Heavy 23.80 59.50

65

66 *Pipefitter 23.00 57.50

67 *Pipe Welder 34.00 85.00

68


70 Carpenter 19.00 47.50



73

74 Ironworker: Struct 21.00 52.50

75 Welder: Struct 21.00 52.50

76

77 Welder: Special 21.00 52.50

78 *Welder: Fabr 22.00 55.00


80

81 *Instru.Fitter 23.00 57.50

82

83 *Electr: Line 23.00 57.50

84 *Electr: Wire 23.00 57.50

85


87 Insulator 22.50 56.30



* Principal Crafts.



88

89 Painter 20.00 50.00

90

91

92

93

94

95

96

97

98 Helper 15.50 38.80

99

Craft Code

ME Craft Name Unloaded Wage Rate (SAR/MH)


Rate (SAR/MH) 1



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 Engineering (G13) 31-1

Design and Construction Engineering Disciplines and Wage Rates

US Country BaseNote: $ indicates US dollars

No. Design* Discipline $/MH No. Construction** Discipline

$/MH

Basic Engineering: Home Office

01 Project Engineering 65.80 01 Project Management 65.40

02 Process Engineering 57.90 02 Cost Accounting 44.00

03 Piping Design 57.30 03 Construction Dept. 38.90

04 Instrument Design 56.70 04 Planning, Scheduling 49.90

05 Mechanical Design 57.30 05 Tools, Equipment 39.40

06 Electrical Design 57.10 06 Industrial Relations 39.50

07 Civil Design 54.00 07 Subcontract Admin. 39.60

08 Piping Drafting 46.90 08 Support, Clerical 24.00

09 Instrument Drafting 47.00 Field Office:

10 Mechanical Drafting 43.70 01 Project Constrn. Supt. 53.10

11 Electrical Drafting 46.20 02 Area Superintendents 42.90

12 Civil Drafting 44.60 Field Superintendents:

13 General Drafting 38.30 03 Piping 40.10

14 Planning, Scheduling 51.00 04 Instrumentation 40.10

15 Cost Estimating 53.20 05 Electrical 40.10

16 Support, Clerical 24.00 06 Civil 40.10

Detail Engineering: 07 Mechanical 40.10

01 Project Engineering 65.80 08 QC&A, Inspection 39.40

02 Process Engineering 57.90 09 Subcontract Admin 41.20

03 Piping Design 57.30 10 Cost Engineering 44.00

04 Instrument Design 56.70 11 Field Engineering 43.90

05 Mechanical Design 57.30 12 Planning, Scheduling 49.90

06 Electrical Design 57.10 13 Safety & Medical 38.60

07 Civil Design 54.00 14 Field Accounting 35.70

08 Piping Drafting 46.90 15 Materials Control 40.40

09 Instrument Drafting 47.00 16 General Drafting 38.50

10 Mechanical Drafting 43.70 17 Support, Clerical 20.40

11 Electrical Drafting 46.20 Construction Management (Home):

12 Civil Drafting 44.60 01 Project Management 65.40

31-2 31 Engineering (G13)

13 General Drafting 38.30 02 Cost Accounting 44.00

14 Planning, Scheduling 51.00 03 Construction Dept. 38.90

15 Cost Estimating 53.20 04 Subcon. Admin. (Field)

39.60

16 Support, Clerical 24.00 05 Construction Manager 70.70

17 Model Building 33.00 06 Area Managers 41.90

Procurement: 07 Subcon. Coordinator 39.60

01 Procurement 42.40 08 Field Inspector 40.40

02 Support, Clerical 24.00 09 Cost Engineering 43.80

Eng'g Management: 10 Field Engineering 41.20

01 Project Engineering 79.40 11 Planning, Scheduling 46.80

12 Safety & Medical 36.30

* These rates are the current (1Q 2009) System base values, which are escalated by the Design Engineering Index specified by the user in the Indexing/Escalation data.

Base Design Engineering Index = 1620

13 Support, Clerical 24.00

Start-up, Commissioning:

01 Commissioning Staff 50.30

02 Start-up Staff 40.90

03 Performance Testing 40.90

** These rates are the current (1Q 2009) System base values, which are escalated by the Construction Management Index specified by the user in the Indexing/Escalation data.

Base Construction Management Index = 1660

No. Design* Discipline $/MH No. Construction** Discipline

$/MH


UK Country BaseNote: PS indicates Pounds Sterling

No. Design* Discipline PS/MH No. Construction** Discipline

PS/MH

Basic Engineering: Home Office:












12 Civil Drafting 20.60 Field Superintendents







02 Process Engineering 29.90 09 Subcontract Admin. 25.60













15 Cost Estimating 20.60 04 Subcon. Admin. (Field) 26.80









Note: PS indicates Pounds Sterling* These rates are the current (1Q 2009) System base values, which are escalated by the Design Engineering Index specified by the user in the Indexing/Escalation data.










No. Design* Discipline PS/MH No. Construction** Discipline

PS/MH


JP Country BaseNote: KY indicates thousand Yen

No. Design* Discipline KY/MH No. Construction** Discipline

KY/MH


















Detail Engineering: 07 QC&A, Inspection 3.7

01 Project Engineering 4.6 08 Mechanical 3.7























Note: KY indicates thousand YEN

* These rates are the current (1Q 2009) System base values, which are escalated by the Design Engineering Index specified by the user in the Indexing/Escalation data.Base Design Engineering Index = 1900









No. Design* Discipline KY/MH No. Construction** Discipline

KY/MH


EU Country BaseNote: EUR indicates Euros

No. Design* Discipline EUR/MH No. Construction** Discipline

EUR/MH


















Detail Engineering: 07 QC&A, Inspection 30.00

01 Project Engineering 48.80 08 Mechanical 30.00


















01 Procurement 01 08 Field Inspector 31.10





* These rates are the current (1Q 2009) System base values, which are escalated by the Design Engineering Index specified by the user in the Indexing/Escalation data.Base Design Engineering Index = 1790









No. Design* Discipline EUR/MH No. Construction** Discipline

EUR/MH


ME Country BaseNote: SAR indicates Saudi Arabian Rials

No. Design* Discipline SAR/MH

No. Construction** Discipline

SAR/MH

Basic Engineering: Home Office



















02 Process Engineering 245.00 09 Subcontract Admin 65.00













15 Cost Estimating 170.00 04 Subcon. Admin. (Field)

65.00



07 Subcon. Coordinator 65.00


Procurement: 08 Field Inspector 178.50

01 Procurement 135.00 09 Cost Engineering 170.00

02 Support, Clerical 65.00 10 Field Engineering 52.00

Eng'g Management: 11 Planning, Scheduling 170.00

01 Project Engineering 310.00 12 Safety & Medical 65.00

* These rates are the current (1Q 2009) System base values.







** These rates are the current (1Q 2009) System base values..


No. Design* Discipline SAR/MH

No. Construction** Discipline

SAR/MH


Engineering Expenses and Indirects (Aspen Capital Cost Estimator and Aspen Process Economic Analyzer )US Country BasePhase % Eng'ng Manpower

Expense Rate ($/MH)*

Payroll Business

Cost Indirects

Basic Engineering 5.00 25 75

Detail Engineering 3.90 25 75

Procurement 8.90 25 75

Engineering Management

0.00 25 75

($/MH)**

Home Office Construction Services

3.60 25 75

Field Office Supervision 0.00 25 75

Construction Management

0.00 25 75

Start-up, Commissioning

0.00 25 75

UK Country BasePhase % Eng'ng Manpower

Expense Rate (PS/MH)*

Payroll Business

Cost Indirects





0.00 40 90

(PS/MH)**


2.70 40 90



0.00 40 90


0.00 40 90


Engineering Expenses and Indirects - continued

Japan Country BasePhase % Eng'ng Manpower

Expense Rate (KY/MH)*

Payroll Business Cost Indirects





0.00 25 75

(KY/MH)**


0.36 25 75



0.00 25 75


0.00 25 75



*These rates are the current (1Q 2009) 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 2009) System base values, which are escalated by the Construction Management Index specified by the user in the Indexing/Escalation data.

EU Country BasePhase % Eng'ng Manpower

Expense Rate (EUR/MH)*

Payroll Business Cost Indirects





0.00 40 90

(EUR/MH)**


4.20 40 90



0.00 40 90


0.00 40 90



*These rates are the current (1Q 2009) 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 2009) System base values, which are escalated by the Construction Management Index specified by the user in the Indexing/Escalation data.

Base Design Engineering Index = 1620 (US), 4450 (UK), 1900 (JP), 1790 (EU), 1580 (ME)

Base Construction Management Index = 1660 (US), 4190 (UK), 1780 (JP), 1720 (EU), 1580 (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

ME Country BasePhase % Eng'ng Manpower

Expense Rate (SAR/MH)*

Payroll Business

Cost Indirects





0.00 25 75

(SAR/MH)**


15.40 25 75



0.00 25 75


0.00 25 75



These four line items collectively comprise engineering expenses. They result from a fixed percentage split of this expense by phase. Multiply the Total Man-hours for the phase by this rate to calculate the total expenses. The system then allocates these to various categories by percentage as follows:

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:

• 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 includes rent, heat, electricity and other operating expenses not specifically covered in other engineering accounts.

Basic Detail Procure Home

Reproduction 23% 30% 14% 42%

Communications 3% 4% 12% 8%

Travel 17% 12% 50% 50%

Computation 57% 54% 24% 0%


Standard Engineering Drawing Types (Aspen Capital Cost Estimator and Aspen Process Economic Analyzer)Basic Engin -eering

Detailed Engineering

Drawing No.

Description Drawing No. Description

1 Process Flow Diagrams 1 Piping Arrangements (Plans & Elevns.)

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

User-specified Drawings

Up to nine user-specified drawings (or other tasks, such as models) may be added to the system drawings by using a drawing number from the range 91-99. Note: Only the drawing numbers shown in this table and 91-99 are accepted.

19 Lighting Drawings

20 Grounding Drawings

21 Electrical Tracing Drawings

23 Equipment Foundation Drawings

24 Steelwork Foundation Drawings

25 Area Paving Drawings

26 Misc. Concrete, Supports, Etc.


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

Basic Engin -eering

Detailed Engineering



Introduction to Construction Equipment Rental

Construction Equipment

32 Construction Equipment(G4)

32 Construction Equipment(G4) 32-1

Introduction to Construction Equipment RentalAn 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.

Construction Equipment(Aspen Capital Cost Estimator, Aspen Process Economic Analyzer , Aspen In-Plant Cost Estimator) Rental days and monthly rates may be adjusted for construction equipment items.

Equip No. Equipment Class Description

Size

Metric Units I-P Units

21 AUTOMOTIVE 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


32-2 32 Construction Equipment(G4)



51 TRUCK OFF-ROAD FLATBED 6 TONS - 6 X 6 6 TON - 6 X 6

56 TRUCK A-FRAME 4 X 4 4 X 4

57 TRUCK LUBE/GREASE

58 TRUCK FUEL/WATER 5000 GALLONS 18 M3

61 TRUCK POWERLINE, BUCKET INSULATED INSULATED

62 TRUCK CHERRY PICKER NON-INSULATED NON-INSULATED

66 TRUCK DUMP TRUCK 6 CY 5 M3




71 TRUCK FORKLIFT 2 TONS 2 TON

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

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


CAT988 6.00 CY CAT988 4.5 M3


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


Size



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 1200 MM

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


CAT631C 21-30 CY

CAT631C 16-23 M3


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







111 EARTHMOVING BACKHOE CRAWLER HYDR

.50 CY .40 M3


.75 CY .60 M3


1.0 CY 75 M3


1.5 CY 1.1 M3


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 IN

CRAWLER MTD

122 DRILLING TRACK DRILL,SWG BOOM

4.5 INCHES 115 MM

123 DRILLING TWIN ROCK DRILL SUSP. VERTICAL SUSP. VERTICAL

124 DRILLING AUGER,FLATBED-MOUNTD

2.5 TONS,OFFROAD

2 TON, OFFROAD


Size



125 DRILLING DRILL QUAD,SWG BOOM

4.5 INCHES 115 MM

126 COMPACTION ROLLER SELF-PROPELLD

VIBR DRUM 7 TONS

VIB DRUM 6.5 TON


9 WHEEL 15 TONS 9 WHEEL 14 TON


SMOOTH 10 TONS

SMOOTH 9 TON

131 COMPACTION ROLLER,TOWED, 1 DRUM

SHEEPSFT 40X60 IN

SHEEPSFT 1 X1.5 M

132 COMPACTION ROLLER,TOWED, 1 DRUM

VIBRATNG 30X54 IN

VIBRG.8 X1.4 M

133 COMPACTION ROLLER, MANUAL GUIDE

VIB DRUM 1.0 TONS

VIB DRUM 1 TON

134 COMPACTION RAMMER, HANDHELD 350-700SPM, 130 350-700SPM, 60 KG

136 TRACTOR TRUCK TRACTOR 20 TONS 4X2 18 TON 4X2



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 15 TONS 15 TON

147 TRAILER LOWBOY, PLATFORM 25 TONs 25 TON

148 TRAILER LOWBOY, PLATFORM 40TONs 35 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


Size





166 TRAILER MOBILE OFFICE 8 X 35 FEET 2.5 X 10 M

16

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



181 CRANE TELESCOPIC JIB TRUCK - 15 TONS TRUCK - 14 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 TRUCK - 15 TONS TRUCK - 14 TON




Size







198 CRANE FIXED JIB TRUCK - 120 TONS

TRUCK - 110 TON

201 CRANE FIXED JIB, CRAWLER 15 TONS











212 CRANE TOWER-HORIZ. JIB 10T

MAX 4190LB@164FT

MAX 1900KG @ 50M


MAX 9260LB@213FT

MAX 4200KG @ 65M


MAX 6500LB@247FT

MAX 2950KG @ 75M

216 CRANE ATTACHMENT

CLAMSHELL GRAB 1 CY 0.75 M3






DRAGLINE BUCKET 1 CY 0.75 M3








CONCRETE BUCKET BTM DUMP 1 CY BTM DUMP 0.75 M3


Size




CONCRETE BUCKET BTM DUMP 3 CY BTM DUMP 2.50 M3

226 GIN POLE W/HOIST 50 TONS 45 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





238 PILING DRIVER/EXTRACTOR 70 HP VIBRO VIBRO 50 KW

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


250 CFM 420 M3/H


315 CFM 540 M3/H

246 COMPRESSOR DIESEL(ROTARY SCREW)

250 CFM 420 M3/H


365 CFM 620 M3/H


600 CFM 1000 M3/H


750 CFM 1250 M3/H


900 CFM 1500 M3/H


1200 CFM 2000 M3/H


Size



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





281 WELDING EQUIPMEN

PORTABLE DIESEL 200 AMPERES 200 AMPERES






PORTABLE DIESEL 650 A, TWIN ARC 650 A, TWIN ARC


STATIC RECTIFIER 200 AMPERES 200 AMPERES




Size












PIPE SEMI-AUTO. CO2


PIPE AUTOMATIC SUBMERGED ARC SUBMERGED ARC


AUTO. SUB-ARC TANK BASE PLATE BASE PLATE


AUTO. SUB-ARC TANK WALL HORIZONTAL

WALL HORIZONTAL


AUTO. SUB-ARC TANK WALL VERTICAL WALL VERTICAL


OXY./ACT. WELD & CUT.

COMB. UNIT COMB. UNIT


PROPANE GAS SE T & TRCH

PROPANE GAS SE T & TRCH


ELECTRODE DRYING OVN

311 PIPING EQUIPMENT

SIDEBOOM (CAT 571) (CAT 571)








CRAWLER TACK TRACTOR

QUAD ARCS QUAD ARCS


BENDING MACHINE 6 - 20 INCHES 150 - 500 MM




Size






TAPESTER, HAND WRAP

2 - 12 INCHES 50 - 300 MM


CLEAN PRM TAPE MACH.

8 - 16 INCHES 200 - 400 MM



16 - 26 INCHES 400 - 650 MM



26 - 36 INCHES 650 - 900 MM



36 - 42 INCHES 900 - 1050 MM



42-52 INCHES 1050 - 1300 MM


INTRNL LINE-UP CLAMP

16 - 18 INCHES 400 - 450MM



20 - 22 INCHES 500 - 550MM



24 - 26 INCHES 600 - 650MM



30 - 32 INCHES 750 - 800MM



34 - 36 INCHES 850 - 900MM



40 - 42 INCHES 1000 - 1050MM



44 - 46 INCHES 1100 - 1150MM



OVER 48 INCHES OVER 1200MM


EXTRNL LINE-UP CLAMP

8 - 14 INCHES 400 - 450MM



16 - 26 INCHES 400 - 650MM



28 - 36 INCHES 700 - 900MM



36 - 44 INCHES 900 - 1100 MM



OVER 42 INCHES OVER 1100 MM


CUTTING & BEVELLING

1 - 4 INCHES 25 - 100 MM


CUTTING & BEVELLING

6 - 20 INCHES 150 - 500 MM


CUTTING & BEVELLING

22 - 30 INCHES 550 - 750 MM


Size




CUT & BEVEL, TORCH 10 - 48 INCHES 250 - 1200 MM


PIPE/CONDUIT BENDER

0.5-2IN RATCHET UP TO 6 INCHES


HYDRAUL PIPE BENDER

1.25-4 INCHES 30 - 100 MM


BENDER (MECHANICAL)

2.5-6 IN DIA 65 - 150 MM


CUT & THREAD MACHINE

UP TO 6 INCHES UP TO 150 MM


DOUBLE JOINTING YARD

C/W RACK CONVYRS

C/W RACK CONVYRS


X-RAY EQUIPMENT


INDUCTION HEATER


HOLIDAY DETECTOR


ELECTRIC THREADER UP TO 2 INCHES UP TO 50 MM


BORING MACHINE ROAD BORER ROAD BORER

361 MISCELLANEOUS EQUIP.

POTENTIOMETER12 POINT

12 POINT


STRESS RELIEVER TRIPLE RELIEVER TRIPLE RELIEVER


POWER DIST. CENTER 10 KVA 10 KVA


BENCH SAW 10 - 12 INCHES 250 - 300 MM


PAINT PRESSURE SPRAY

5 GAL. 8CFM 20 LITER, 15 M3/H


GUNITE 8 CY/H 6 M3/H


CABLE PULLER UNIT 5000 LBF. ELEC. E LEC.


AIR RECEIVING TANK 60 CF 2 M3


CHAIN SAW 20 INCHES 500 MM


Size




TELEPHONES & STATION


TENSIOMETER WIRE ROP

200000 LB CAP 90000 KG CAP


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. TOOL

AIR WRENCH 1.25 IN DRIVE 30 MM DRIVE


JACK HAMMER 65 LBS 30 KG


SAND BLAST MACHINE 600 LBS, 7CF 275 KG, 0.2 M3

391 ELECTRIC EQUIP/TOOL

LIGHT PLANT 3000 WATT 3000 WATT


DRILL PRESS 1.5 INCHES 40 MM


DRILL 1.0 INCH 25 MM


GENERATOR SET 6 KW 6 KW










Size








SAW, CIRCULAR 6 INCHES 150 MM


ELECTRIC GRINDER 6 INCHES 150 MM


PEDESTAL GRINDER 12 INCHES 300 MM


LATHE 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


SPREADER TRAILER, GAS

2000 GAL, SPRAY 7.50 M3, SPRAY


BITUMEN TANKER 2000 GALLON 7.50 M3


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

150 MBTU 40 KW


Size




ROLI CRADLE 4 - 12 INCHES 100 - 300MM






ROLI CRADLE 36 - 42 INCHES 900 - 1050 MM


ROLI CRADLE OVER 42 INCHES OVER 1050 MM


HOT TAP MACHINE 2 - 4 INCHES 50 - 100 MM








BUTT FUSION MACHINE

2 - 4 INCHES 50 - 100 MM


BUTT FUSION MACHINE

6 - 8 INCHES 150 - 200 MM


BUTT FUSION MACHINE

10 - 18 INCHES 250 - 450 MM


BUTT FUSION MACHINE

20 - 30 INCHES 500 - 750 MM


BUTT FUSION MACHINE

36 - 48 INCHES 900 - 1200 MM


Size




Base Indices

33 Base Indices (G13)

33 Base Indices (G13) 33-1

Base IndicesThese 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

Base Data for System Costs

System Base Index by Category

General Construction Design Construction

Materials Labor Engineering Management

Labor Labor

US Current:1Q-2009Prior:1Q-20081Q-20071Q-20061Q-20051Q-20041Q-20031Q-20021Q-20011Q-20001Q-19991Q-19981Q-19971Q-19961Q-19951Q-19941Q-19931Q-19921Q-1991

2040

220020601900184016301540151015201520151015251500148514601390137013601350

2010

196018901820175016901630159015501510146014301400136513401320131012901270

1620

162015401490148014601480147014501440145014501450146014801460145014201390

1660

1630154014901480148014601480147014501440145014501450146014801460145014201390

33-2 33 Base Indices (G13)

Country Base





Labor Labor

UK Current:1Q-2009Prior:1Q-20081Q-20071Q-20061Q-20051Q-20041Q-20031Q-20021Q-20011Q-20001Q-19991Q-19981Q-19971Q-19961Q-19951Q-19941Q-19931Q-19921Q-1991

2910

28302630250024202290223021902140208021402100205019901910 185017801670

4290

402038303670351033603220312029802850270025502410 2310 2200 2160 211020501930

4450

442041903970381036703540348033603210295027802620247023802280221021402020

4190

408038903790367035703510341032503110305028802660247023802280221021402020

JP Current:1Q-2009Prior:1Q-20081Q-20071Q-20061Q-20051Q-20041Q-20031Q-20021Q-20011Q-20001Q-19991Q-19981Q-19971Q-19961Q-19951Q-1994

1500

17501760145014101330122012101230126013701350125512501250 1390

1150

11501160117011801200125013001330135013701350 134013501350 1320

1900

193019601460144013801370135013601360136013601350136013901460

1780

182018401470146014001380137013701370135013501350136013901460

33 Base Indices (G13) 33-3

EU Current:1Q-2009Prior:1Q-20081Q-20071Q-20061Q-20051Q-20041Q-20031Q-20021Q-2001

2180

21702030178017001640158015601520

1840

17901720170016701650163016001550

1790

17301660159015601550153015101450

1720

16701600158015601540152014901450

ME Current:1Q-2009Prior:1Q-20081Q-2007

2160

22002060

1930

19701890

1580

16101540

1580

16101540

Country Base





Labor Labor

33-4 33 Base Indices (G13)


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)

3434 Code Accounts (G10) 3434-1

Introduction to Code AccountsAspen 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 user-developed 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 AccountsThe ICARUS standard code of accounts may be transformed into a new code of accounts in one or more of the following ways:

• An ICARUS account name can be changed.

• A new account can be created by defining it. This must be in the range1-999 and must not already be defined as a standard account.

• Costs and manhours can be reassigned from one account to another.

3434-2 3434 Code Accounts (G10)

The account code for the modified code of accounts must not be specified and is determined by the system (e.g., PIPING account code includes all accounts from 300 to 399).

Creating a Different Code of AccountsA 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 User-internal 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 user-internal 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


The following resulting allocations would be reported, if no further reporting COAs are specified:

However, allocations have been specified in a different sequence, the same result will be reported.

Reporting Code of AccountsCreating 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

The following resulting allocations would be reported:

From ICARUS COA

To ICARUS COA Allocate to ICARUS User Matl COA

315 blank 4178325417 blank 5911234591 blank 4178325

COA Cost

315 0

4178325 1000

5911234 110000

COA Cost

3154 1000

3191 10000

3300 100000

From ICARUS COA

To ICARUS COA Allocate to ICARUS User Matl COA

3100 3300 3

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 ReportsThe 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, etc.). 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.


Indirect Codes and DescriptionsField Indirects (P1) Engineering Indirects (PA)01 -09 Titles not assigned 10 LUMP SUM CONST. INDIRECT11 FRINGE BENEFITS12 BURDENS13 CONSUMABLES, SMALL TOOLS14 MISC. (INSURANCE, ETC)15 SCAFFOLDING16 EQUIPMENT RENTAL17 VENDOR REPRESENTATIVES18 FIELD SERVICES19 TEMP. CONST., UTILITIES20 MOBILIZATION, DEMOBILIZE21 CATERING, ACCOMODATION22 TRAVEL23 OVERTIME PREMIUM

80 LUMP SUM CONST. MGMT81 HOME OFFICE CONST. SUPP.82 CONSTRUCTION MANAGEMENT83 -84 Titles not assigned

Special Indirects (P2 Contractor Indirects (PB)

24 SPECIAL INDIRECT ITEM 125 SPECIAL INDIRECT ITEM 226 - 49 Titles not assigned

85 FIELD CONST. SUPERVISION86 STARTUP, COMISSIONING

Freight (P3) G & A Overheads (P6)

50 LUMP SUM FREIGHT51 DOMESTIC FREIGHT52 OCEAN FREIGHT53 AIR FREIGHT54 MODULE FREIGHT55 OTHER FRIEGHT56 - 59 Tittles not assigned

90 G AND A OVERHEADS

Taxes (P4) Contractor Fee (P7)

60 LUMP SUM TAXES, PERMITS61 PERMITS62 MATERIALS TAXES63 CONSTRUCTION TAXES64 ENGINEERING TAXES65 OTHER TAXES66 - 69 Titles not assigned

91 CONTRACT FEE

Engineering (P5) Escalation (P8)

70 LUMP SUM ENGINEERING71 BASIC ENGINEERING72 DETAIL ENGINEERING73 MATERIAL PROCUREMENT74 SUBCONTRACT PROCUREMENT75 ENGINEERING MANAGEMENT76 - 79 Titles not assigned

97 ESCALATION


Royalty, Miscellaneous Charges (P9)

98 ROYALTY, MISC. CHARGES92 - 96 Titles not assigned

Contingencies (P0)99 CONTINGENCY

Field Indirects (P1) Engineering Indirects (PA)


Direct Codes and Descriptions

Equipment and Setting100 EQUIPMENT AND SETTING103 SPECIAL PLANT ITEM104 SPECIAL EQUIPMENT ITEM105 MISC. ITEM ALLOWANCE106 OTHER EQUIPMENT ITEMS107 WAREHOUSE SPARES109 EQUIPMENT DEMOLITION

200 FLUID SEPARATION EQUIP.201 DUST COLLECTORS202 SCRUBBERS203 BAG HOUSES204 PRECIPITATORS205 SEPARATORS

110 PROCESS VESSELS111 TRAY TOWERS & TRAYS112 PACKED TOWERS & PACKING113 VERTICAL VESSELS114 HORIZONTAL VESSELS115 VACUUM VESSELS116 CRYSTALLIZERS117 EVAPORATORS

210 MATERIALS HANDLING EQUIP211 CONVEYORS212 FEEDERS213 CRANES,HOISTS,ETC214 ELEVATORS215 SCALES216 MAGNETS217 CAR DUMPERS & SHAKERS

120 STORAGE VESSELS121 ATMOSPHERIC STORAGE TANK122 PRESSURIZED STORAGE TANK123 SILOS124 BINS AND HOPPERS125 GAS HOLDERS126 STOCK CHESTS

220 ELECTRICAL GENERATORS221 GAS TURBINE GENERATORS222 DIESEL GENERATORS223 STEAM TURBINE GENERATORS224 PORTABLE GENERATORS

130 REACTION,MIXING EQUIP.131 REACTORS & AUTOCLAVES132 AGITATED VESSELS133 BLENDERS134 MIXERS

240 BOILER PLANT EQUIPMENT241 BOILERS242 PACKAGE BOILER243 ECONOMIZERS244 PREHEATERS

150 COMPRESSORS & BLOWERS151 CENTRIFUGAL COMPRESSORS152 RECIPROCATING COMPRESSOR153 TURBO-EXPAND. COMPRESSOR154 FANS AND BLOWERS

250 PROCESS HEATERS251 FURNACES,HEATERS252 WASTE HEAT BOILERS253 INCINERATORS254 KILNS255 STACKS

160 PUMPS161 CENTRIFUGAL PUMPS162 RECIPROCATING PUMPS163 VACUUM PUMPS164 ROTARY,GEAR PUMPS165 VERTICAL PUMPS166 SUMP & WELL PUMPS167 SLURRY PUMPS

260 HEAT EXCHANGERS261 SHELL & TUBE EXCHANGERS262 REBOILERS263 DOUBLE PIPE EXCHANGERS264 AIR COOLERS265 COOLING TOWERS266 MISC. HEAT EXCHANGERS


170 DRIVERS & GEAR REDUCERS171 ELECTRIC MOTORS172 STEAM TURBINES173 GAS TURBINES174 GAS & DIESEL ENGINES175 GEAR REDUCERS

270 LININGS271 REFRACTORY LININGS272 ACID BRICK LININGS273 CAST LININGS274 POND LININGS275 OTHER LININGS

180 SIZE REDUCTION EQUIP181 CRUSHERS,BREAKERS182 MILLS183 PULVERIZERS184 CUTTERS,FLAKERS185 STOCK TREATMENT

280 MISC. PACKAGE UNITS281 REFRIGERATION UNITS282 HVAC EQUIPMENT283 WATER TREATING UNITS284 INSTRUMENT AIR SYSTEMS285 MODULE SETTING

190 SOLIDS SEPARATION EQUIP.191 SCREENS AND GRIZZLIES192 FILTERS193 CENTRIFUGES194 DRYERS195 LIQUID CYCLONES196 FLOATATION CELLS197 THICKENERS,CLARIFIERS

290 MISCELLANEOUS EQUIPMENT291 EJECTORS292 PROPRIETARY EQUIPMENT293 FLARES


Piping300 PIPING302 SUBCONTRACT PIPING303 SPECIAL PLANT PIPING304 SPECIAL EQUIP. PIPING305 OTHER EQUIPMENT PIPE306 PIPING SYSTEM TESTING307 PREFAB PIPE REWORK309 PIPING DEMOLITION

350 NON-METAL PIPE/FITTINGS351 NON-METAL FIELD MAT’L352 NON-METAL FIELD SHOP FAB353 NONMETAL REMOTESHOP MATL354 NONMETAL REMOTESHOP FAB355 NON-METAL VALVES

310 CARBON STL PIPE/FITTINGS311CS FIELD MAT’L312CS FIELD SHOP FAB313CS REMOTE SHOP MAT’L314CS REMOTE SHOP FAB315CS VALVES: FLANGED316CS VALVES: NON-FLANGED317CS PIPE ERECTION

357 NON-METAL PIPE ERECTION

320 STAINLESS PIPE/FITTINGS321SS FIELD MAT’L322SS FIELD SHOP FAB323SS REMOTE SHOP MAT’L324SS REMOTE SHOP FAB325SS VALVES: FLANGED326SS VALVES: NON-FLANGED327SS PIPE ERECTION

360 PIPING SPECIALTIES361 TRAPS & VACUUM BREAKERS362 TRACING TUBING & FITTING363 JACKET INTERCONNECTIONS

330 MISC.METAL PIPE/FITTINGS331 MISC. METAL FIELD MAT’L332 MISC.METAL FIELDSHOP FAB333 MISC.METAL RMT SHOP MATL334 MISC. METAL RMT SHOP FAB335 MISC.METAL VALVE:FLANGED336 MISC.METAL VALVE:NOFLANG337 MISC.METAL PIPE ERECTION

365 HAND CONTROLS366 PIPE HANGERS, SHOES ETC.

340 LINED PIPE/FITTINGS341 LINED PIPE FIELD MAT’L342 LINED FIELD SHOP FAB343 LINED REMOTE SHOP MAT’L344 LINED REMOTE SHOP FAB345 LINED VALVES

368 MECHANICAL CONNECTIONS369 FLOW DIVERSION PANELS

347 LINED PIPE ERECTION 370 FIREWATER, BURIED PIPE371 FIREWATER PIPING372 HYDRANTS,HOSE,NOZZLE,ETC373 DELUGE SYSTEMS374 SHOWER, EYEWASH, ETC.376 BURIED PIPE INSTALLATION377 PIPE TRENCH & BACKFILL378 COAT AND WRAP PIPE


380 DUCTWORK/LAUNDERS381 PROCESS DUCTWORK382 HVAC DUCTWORK383 LAUNDERS

390 PIPELINES391 PIPELINE-MAINLINE PIPE392 PIPELINE-VALVES,FITTINGS393 PIPELINE-FAB. & INSTALL394 PIPELINE-SCRAPER L/R395 PIPELINE-DBL JOINT/COAT396 PIPELINE-SUPPORTS397 PIPELINE-RADIOGRAPH TEST398 PIPELINE-MARINE WORK399 PIPELINE-MISC. PIPING


Civil400 CIVIL402 SUBCONTRACT CIVIL403 SPECIAL PLANT CIVIL404 SPECIAL EQUIP. CIVIL405 SCAFFOLDING409 CIVIL DEMOLITION

450 REBAR, FORMWORK, ETC.451 REBAR452 FOUNDATION ACCESSORIES453 INSTALL REBAR454 FORMWORK MATERIALS455 FIELD FABRICATE FORMWORK456 INSTALL FORMWORK457 STRIP & CLEAN FORMWORK458 BACKFILL

410 EARTHWORK411 CLEAR SITE412 BULK EXCAVATION413 ROCK EXCAVATION414 BLASTING415 HAULING & DUMPING416 SITE FILL & COMPACT417 DEWATERING418 STABILIZATION419 CONTAINMENT,EMBANKMENTS

460 PRECAST CONCRETE461 PRECAST PIPERACK462 PRECAST BEAMS & COLUMNS

420 ROADS,RAILROADS421 GRADE,COMPACT BASE422 ROADS423 PAVING424 RAILROADS425 BOARD ROADS

470 BUILDINGS471 SUBCONTRACT BUILDINGS472 BLDG STRUCTURE/FINISHES473 BUILDING FURNISHINGS474 BUILDING ELECTRICAL475 BUILDING PLUMBING476 BUILDING HVAC

430 OTHER SITEWORK431 TEST BORINGS432 DEMOLITION & RELOCATION433 LANDSCAPING434 FENCING435 RETAINING WALLS436 PILING437 SHORING438 DRILLED WELLS439 DRAINAGE

480 MISCELLANEOUS CIVIL481 LININGS AND COATINGS485 OFFSHORE CIVIL

440 CONCRETE441 AGGREGATE442 CEMENT443 SAND444 POURED CONCRETE445 GROUT446 CONCRETE POUR AND FINISH447 EXCAVATION & BACKFILL448 MISCELLANEOUS CONCRETE449 OTHER EQUIP. CONCRETE

490 PIPELINE CIVIL WORK491 PIPELINE-ROW & SITE WORK492 PIPELINE-ROW CROSSINGS493 PIPELINE-DITCHING494 PIPELINE-ANCHORS/SUPPORT499 PIPELINE-MISC. CIVIL


Steel500 STEEL502 SUBCONTRACT STEEL503 SPECIAL PLANT STEEL504 SPECIAL EQUIP. STEEL509 STEEL DEMOLITION

540 TOWERS AND TRUSSES541 STEEL TOWERS542 STEEL TRUSSES

510 EQUIPMENT STEEL511 EQUIPMENT SUPPORT STEEL512 LADDERS513 PLATFORMS519 OTHER EQUIPMENT STEEL

550 STEEL PLATE ITEMS551 FABRICATED PLATE

520 STRUCTURAL STEEL521 STEEL STRUCTURES522 PIPERACK STEEL523 PIPE SUPPORTS

580 OFFSHORE STEELWORK

530 OTHER STEEL ITEMS531 FLOORING & STAIR TREADS532 HANDRAIL AND TOE PLATE533 OTHER BLDG/STRUCT STEEL534 BUILDING SIDING535 MISCELLANEOUS STEEL ITEM

590 OTHER STEELWORK591 STEEL UNLOAD & HANDLING592 THRUST ANCHORS593 DEFLECTION ANCHORS


Instrumentation600 INSTRUMENTATION602 SUBCONTRCT INSTMENTATION603 SPECIAL PLANT INSTRUMENT604 SPECIAL EQUIP INSTRUMENT609 INSTRUMENT DEMOLITION

640 INSTR. SUPPORT & ENCL.641 TRAYS & SUPPORT642 CONDUIT & FITTINGS644 INSTRUMENT HOUSING645 PNEU. JUNCTION BOXES646 ELEC. JUNCTION BOXES647 T/C JUNCTION BOXES648 MULTIPLEX JUNCTION BOXES649 OTHER SUPPORTS

610 FIELD INSTRUMENTATION611 FLOW INSTRUMENTS612 LEVEL INSTRUMENTS613 PRESSURE INSTRUMENTS614 TEMPERATURE INSTRUMENTS615 ANALYZERS616 MOTION INSTRUMENTS617 BURNER INSTRUMENTS618 ORIFICE PLATES619 OTHER EQUIPMENT INSTR.

650 INSTRUMENT ELECTRICAL651 WIRE/CABLE ETC.653 SOLENOIDS659 OTHER INSTR. ELECTRICAL

620 PANELS, PANEL DEVICES621 CONTROL CENTER PANELS622 CONTROL CTR CONNECTIONS623 BACK OF PANEL INSTRUMENT624 EMERGENCY SHUT-DOWN BOP625 ALARM SWITCH BOP627 EQUIP. CONTROL PANEL628 EQUIP. PANEL DEVICES629 OTHER PANEL DEVICES

660 COMPUTER CONTROL661 CONTROLLER INTERFACES662 INDIC./RECORD INTERFACES663 T/C INTERFACES664 OPERATOR STATIONS665 CABLE/DATA HIGHWAYS666 BARRIERS & TRANSDUCERS667 PROGRAMMABLE CONTROLLERS669 OTHER COMPUTER CONTROL

630 INSTRUMENT RUNS631 AIR SUPPLY PIPING632 INSTRUMENT PIPING633 TERMINATIONS634 PNEUMATIC TUBING635 PNEUMATIC MULTI-TUBE636 INSTRUMENT SIGNAL WIRING637 MULTI-COND. INSTR. WIRE638 T/C EXTENSION WIRING639 T/C MULTI-COND. WIRING

670 MISC. INSTRUMENTATION671 Q.C. EQUIPMENT

680 FINAL CONTROL ELEMENTS681 CONTROL VALVES682 SAFETY VALVES683 RUPTURE DISCS684 MOTOR OPERATED VALVES685 REGULATING VALVES686 DIVERTER VALVES

690 OTHER INSTRUMENT WORK691 INSTRUMENT TESTING


Electrical700 ELECTRICAL702 SUBCONTRACT ELECTRICAL703 SPECIAL PLANT ELECTRICAL704 SPECIAL EQUIP ELECTRICAL709 ELECTRICAL DEMOLITON

747 SUBSTATION STEEL748 SWITCHRACK749 RECTIFIERS750 BLDG/AREA ELECTRICAL751 BLDG/AREA LIGHTING752 LIGHTING FIXTURES753 RECEPTACLES/SWITCHES754 HVAC ELECTRICAL755 MISC. SMALL TRANSFORMERS756 PANELBOARDS757 WIRE/CABLE - LIGHTING

710 WIRE, CABLE, ETC.711 WIRE/CABLE - LOW VOLTAGE712 WIRE/CABLE -HIGH VOLTAGE713 PILOT LIGHT714 PUSH BUTTON STATION715 TERMINATORS/CONNECTORS716 JUNCTION BOXES717 WIRE/CABLE - MV718 WIRE/CABLE - CV 719 OTHER EQUIPMENT WIRING

760 BURIED CABLE761 ELECTRICAL TRENCHING762 UNDERGROUND CABLE DUCT

720 CONDUIT, TRAYS, ETC.721 CONDUIT722 CONDUIT FITTINGS723 CABLE TRAYS

770 GROUNDING, CATH. PROTEC.771 GROUNDING SYSTEMS772 CATHODIC PROTECTION

730 OTHER ELEC. EQUIPMENT731 VARIABLE FREQUENCY DRIVE732 CAPACITORS733 MOTOR CONTROL CENTER - LV734 TRANSFORMERS - MV735 TRANSFORMERS - LV736 SWITCHGEAR - MV737 SWITCHGEAR - LV738 BUS DUCT - LV739 DISCONNECT SWITCH

780 COMMUNICATION,ALARMS,ETC781 TELEPHONE782 INTERCOM783 ANNUNCIATORS

740 MAJOR ELEC. EQUIPMENT741 TRANSFORMERS - HV742 SWITCHGEAR - HV743 MCC EQUIPPED SPACE744 MOTOR CONTROL CENTER - MV745 BUS DUCT - MV/HV746 TRANSMISSION LINES

790 OTHER ELECTRICAL791 ELECTRICAL CIRCUIT TSTNG792 ELECTRICAL TRACING794 SOLAR PANELS795 BATTERY PACKS796 UPS797 EMERGENCY GENERATOR


Insulation

Paint

800 INSULATION, FIREPROOFING802 SUBCONTRACT INSULATION803 SPECIAL PLANT INSULATION804 SPECIAL EQUIP INSULATION809 INSULATION DEMOLITION

810 INSULATION811 PIPE INSULATION812 EQUIP INSULATION813 MODULE INSULATION SHOP814 MODULE INSULATION FIELD815 PERSONNEL PROTECTION819 OTHER EQUIP. INSULATION

820 FIREPROOFING821 STRUCTURAL FIREPROOFING822 SKIRT/LEG FIREPROOFING823 CABLE TRAY FIREPROOFING

830 SPECIAL COATINGS831 ACID TILE PAVING

900 PAINT902 SUBCONTRACT PAINT903 SPECIAL PLANT PAINT904 SPECIAL EQUIP PAINT909 PAINT DEMOLITION

910 PAINTING911 PAINT - EQUIPMENT912 PAINT - PIPING913 PAINT - STRUCTURES914 PAINT MODULE EQUIPMENT915 PAINT MODULE PIPING916 PAINT MODULE STRUCTURES918 OTHER COATINGS919 OTHER EQUIPMENT PAINT

920 SURFACE PREPARATION921 SURFACE PREP - EQUIPMENT922 SURFACE PREP - PIPING923 SURFACE PREP - STEEL



Sequence Numbers of Attributes in Relations

Relationship of Database Relations

DETAILS Relation

DESIGN Relation

REMARKS Relation

PROJDATA Relation

NEWCOA Relation

CERATE Relation

EQRENT Relation

CRWSCH Relation

CSTCTRL Relation

CUSSPC 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

35 Database Relations (G10)

35 Database Relations (G10) 35-1

Z-Table Relation

Attribute Descriptions

35-2 35 Database Relations (G10)

Sequence Numbers of Attributes in Relations

Attribute

Name Type Width

ACCOUNT INT 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 2 - - - - - - - - - - 5 - - - -

ATYPE INT - - - - - - - - - - 1 - - - -

BTSEQ INT - 16 - - - - - - - - - - - - -

CATLNO TEXT 20 - - - - - - - - - 6 - - - - -

CCOA INT - - - - 1 - - - - - - - - - -

COADES TEXT 24 3 - - - - - - - - - - - - 2 -

CEAMT REAL - - - - - 4 - - - - - - - - -

CEDESC TEXT 60 - - - - - 5 - - - - - - - - -

CEFLAG TEXT 2 - - - - - 1 - - - - - - - - -

CENUM INT - - - - - 2 - - - - - - - - -

CESEQ INT 31 - - - - - 1 1 1 1 - - - - 1

CLASS INT 20 - - - - - - - - - - - - - -

CNTRBY INT - - - - - - - - - - - 2 - - -

CNTRNM TEXT 24 - - - - - - - - - - - 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 14 - - - - - - - - - - - - - -

DETA

ILS

(A

)

DES

IGN

(B

)

REM

AR

KS

(C

)

PR

OJD

ATA

(D

)

NEW

CO

A (

E)

CE

RA

TE

(F)

CR

WS

CH

(G

)

EQ

REN

T (

H)

CS

TC

TR

L (

J)

CU

SS

PC

(K

)

REP

GR

P (

L)

CN

TR

CT (

M)

CO

MP

ON

EN

T (

N)

IND

IREC

TS

(P

)

RTA

BLE (

R)


COMCOD TEXT 36 37 - - - - - - - - - - - - - -

COMPWBS TEXT 3 35 - - - - - - - - - - 7 - - -

CONTRACT INT 13 - - - - - - - - - - - - 3 -

DAYPWK INT - - - - - - 7 - - - - - - - -

DESCR TEXT 76 - - 4 - - - - - - - - - - - -

DIAM REAL 24 - - - - - - - - - - - - - -

DUPITEMS INT - - - - - - - - - - - - 4 - -

DUPQTY INT 33 - - - - - - - - - - - - - -

EXTRA1 INT 21 - - - - - - - - - - - - - -

EXTRA2 REAL 22 - - - - - - - - - - - - - -

EXTRA3 TEXT 4 23 - - - - - - - - - - - - - -

HOURRRAT FLOAT - - - - - - - - - - - - - - 4

HRSPDA REAL - - - - - - 9 - - - - - - - -

ICACOA INT 32 - - - - - - - - - - - - 6 -

ICUNIT INT 36 11 - - - - - - - - - - - - -

INDDES TEXT 32 - - - - - - - - - - - - - 9 -

INDAMOUNT INT - - - - - - - - - - - - - 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 24 - - - - - - - - - - - - - - -

LCOST REAL 9 - - - - - - - - - - - - - -

LCOSTRAT FLOAT - - - - - - - - - - - - - - 5

LHOURS REAL 8 - - - - - - - - - - - - -

LINELOOP INT 25 - - - - - - - - - - - - -

LOCID TEXT 8 16 - - - - - - - - - - - - -

Attribute

Name Type Width DET

AIL

S (

A)

DES

IGN

(B

)

REM

AR

KS

(C

)

PR

OJD

ATA

(D

)

NEW

CO

A (

E)

CE

RA

TE

(F)

CR

WS

CH

(G

)

EQ

REN

T (

H)

CS

TC

TR

L (

J)

CU

SS

PC

(K

)

REP

GR

P (

L)

CN

TR

CT (

M)

CO

MP

ON

EN

T (

N)

IND

IREC

TS

(P

)

RTA

BLE (

R)


Sequence Numbers of Attributes in Relations - continued

Attribute

Name Type Width

MATL TEXT 5 10 - - - - - - - - - - - - - -

MCODE INT - - - - - - - - - - - - - - -

MCOST REAL 7 - - - - - - - - - - - - - -

MCOSTRAT FLOAT - - - - - - - - - - - - - - 3

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 8 - - - - - - - - - 2 - - - - -

PIPTYP INT 15 - - - - - - - - - - - - - -

PRCURC TEXT 38 - - - - - - - - - - - - - -

PROPNAM TEXT 36 - 13 - - - - - - - - - - - - -

PROPNUM INT - 10 - - - - - - - - - - - - -

DETA

ILS

(A

)

DES

IGN

(B

)

REM

AR

KS

(C

)

PR

OJD

ATA

(D

)

NEW

CO

A (

E)

CE

RA

TE

(F)

CR

WS

CH

(G

)

EQ

REN

T (

H)

CS

TC

TR

L (

J)

CU

SS

PC

(K

)

REP

GR

P (

L)

CN

TR

CT (

M)

CO

MP

ON

EN

T (

N)

IND

IREC

TS

(P

)

RTA

BLE (

R)


QUANT REAL 5 - - - - - - - - - - - - - -

REFID INT 28 14 5 - - - - - - - - - 1 - -

REPGRP INT - - - - - - - - - - 2 - - - -

RESULT REAL - - - 6 - - - - - - - - - - -

RPGSEQ INT - - - - - - - - - - 3 - - - -

SCHAREA INT - - - - - - 6 - - - - - - - -

SCHED TEXT 4 - - - - - - - - - 3 - - - - -

SHIFTS INT - - - - - - 8 - - - - - - - -

SOURCE TEXT 2 17 - - - - - - - - - - - - - -

SUBAREA INT 30 - - - - - - - - - - - - - -

SUBTYPE INT 29 - - - - - - - - - - - - - -

SUMCODE INT - - - - - - - - - - - - - - -

TITLE TEXT 32 - - - - - - - - - - 4 - - - -

TYPSCT INT - - - - - - - - - 5 - - - - -

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 4 19 - - - - - - - - - - - - - -

Attribute

Name Type Width DET

AIL

S (

A)

DES

IGN

(B

)

REM

AR

KS

(C

)

PR

OJD

ATA

(D

)

NEW

CO

A (

E)

CE

RA

TE

(F)

CR

WS

CH

(G

)

EQ

REN

T (

H)

CS

TC

TR

L (

J)

CU

SS

PC

(K

)

REP

GR

P (

L)

CN

TR

CT (

M)

CO

MP

ON

EN

T (

N)

IND

IREC

TS

(P

)

RTA

BLE (

R)


Relationship of Database Relations


DETAILS RelationNo. 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)


26 USERDES text 25 For instrumentation - the loop number (01-50)For components - Item descriptionFor Mat’l/Man-hour Additions - Item descriptionFor Pipe Bulk - Item Details - Item descriptionFor 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 basisFor Piping - type of valve or fittingFor Civil - type of foundationFor Instrumentation - type of loop main componentFor 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

No. Column Name Type of Data Description of Data Stored under each Column


DESIGN Relation

REMARKS Relation


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


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").



PROJDATA Relation

NEWCOA Relation

CERATE Relation (F-Table)


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.


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)


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 Total Hours for Item for ContractorTotal Hours for Craft for ContractorORTotal Equipment Rental Cost for Equipment Item for Contractor


EQRENT RelationAspen In-Plant Cost Estimator only

CRWSCH RelationAspen In-Plant Cost Estimator only

7 CEAMOUNT integer Total Indirect Cost for Item for ContractorTotal Labor Cost for Craft for ContractorORTotal Equipment Rental Cost for Equipment Item for Contractor

8 CEALLOC integer Allocated Rental Days for Equipment Item for Contractor (DAYS)--Only for Equipment Rental


1 CESEQ integer Key - relates to DETAILS relation

2 NOITEM integer Number of items in list

3 NPCT1 integer List item 1

















2 ACTTYP integer Activity level (area, project, proc.)

3 ACTSEQ integer Activity ID at component level



CSTCTRL RelationAspen In-Plant Cost Estimator only

CUSSPC RelationAspen Capital Cost Estimator only

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





14 NPCT04 integer List item4











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





2 PIPSPC text 8 Custom piping spec



REPGRP Relation

CNTRCT RelationAspen Capital Cost Estimator only

COMPONENT RelationAspen Capital Cost Estimator and Aspen In-Plant Cost Estimator only

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 “ “)


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


1 CNTRNO integer Contractor number

2 CNTRBY integer Contracted by (parent contractor)

3 CNTRNM text 24 Contractor name


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



INDIRECTS RelationAspen Capital Cost Estimator only

4 DUPITEMS integer Number of duplicate items

5 APPTYPE integer Component type


7 COMPWBS text 3 Component Work Breakdown Structure identifier

8 STRUCTAG text 12 User Tag of Structure where component is mounted


1 COA integer Code of Account (COA) (See list on following page).

2 COADES text 24 Title of cost element which is assigned 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”



K (CUSSPC)-TABLE Relation

R-TABLE Relation

QSUM Relations


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


1 CESEQ integer Key- relates (links) to the DETAILS relation (A table or AprojID)

2 COAIND integer Title of cost element which is assigned 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


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 Title of cost element which is assigned 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

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 For instrumentation - the loop number

(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 DescriptionEvaluated 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

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

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 FireproofingEvaluated from A.SUBTYPE

33 SOURCE text 5 Symbol used to characterize direct, sub-contract or remote shop costs. Evaluated from A.SOURCE



34 REFID integer The 4-digit Item reference number for

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 inte-ger value of unity. Evaluated from A.AREA

37 SUBAREA integer Subsidiary area number, within AREA. Evaluated from A.SUBAREA

38 COMPWBS text 5 Component Work Breakdown Structure 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 Sequence number for records in Details Relation. Evaluated from A.CESEQ

43 INTREF integer Internal reference identification. Evaluated from A.INTREF



STORED REPORTS RelationNo. Column Name Type of Data Description of Data Stored under

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 AnalyzerM – 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 Only8: 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_3MacroSet_4

15 Executable text 50 Reserved. Not used

16 Name-Lev1 text 100 Report List Tree Text – Level 1






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 deter-mined by number of contractors/identi-fiers in the project.For example, for report Project Summary by Contractor, the value in this column is QSUM.CONTRACTOR (TableName.Column name)



STORED QUERIES RelationNo. Column Name Type of Data Description of Data Stored under

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 AnalyzerM – 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 Only8: 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 Report List Tree Text – Level 1






CERATE Relation (F-Table)

S-Table Relation


1 CEFLAG text 2 Record type (CR = craft, ER = equip-ment 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 Contrac-tor Total Labor Cost for Craft for Con-tractor

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


1 CESEQ integer Sequence number for records in Details relation


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


5 USERDES text 30 For instrumentation - the loop number (01-50)

For components - Item description

For Mat’l/Man-hour Additions - Item description

For Pipe Bulk - Item Details - Item descriptionFor Instrument Bulk Items - Item Description

6 LINETAG text 36 For Piping Bulk – User TagFor 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



T-Table Relation

U-Table Relation


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


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 Refer-ence 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 Esti-mator 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


13 PROPNAM text 40 System property name


15 INDLVL integer Indicates indent level for reports



V-Table Relation

W-Table Relation

X-Table Relation


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.


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


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 RelationNo. Column Name Type of Data Description of Data Stored under

each Column

1 SeqNo integer Sequence Number2 Field2 text 60 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 Measure of Unit for the Field24 Field4 text 255 Value stored for Field2.5 Field5 text 30 Design, Eng, Procurement Cost for

Project Capital Summary Manhours for Engineering Summary

6 Field6 text 30 Construction Material (Applicable to Project to Project Cost Summary only)

7 Field7 text 30 Construction Manhours (Applicable to Project to Project Cost Summary only)

8 Field8 text 30 Construction Manpower Manhours (Applicable to Project to Project Cost Summary only)

9 Field9 text 30 Construction Indirects Manhours (Applicable to Project to Project Cost Summary only)

10 Field10 text 30 Reserved11 Field11-Field 21 text 10 Reserved


Z-Table Relation

Aspen Capital Cost Estimator Indirect Codes and Descriptions


1 REFID integer The 4-digit Item reference number for 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

Field Indirects Engineering01 -09 Titles not assigned10 LUMP SUM CONST. INDIRECT11 FRINGE BENEFITS12 BURDENS13 CONSUMABLES, SMALL TOOLS14 MISC. (INSURANCE, ETC.)15 SCAFFOLDING16 EQUIPMENT RENTAL17 VENDOR REPRESENTATIVES18 FIELD SERVICES19 TEMP. CONST., UTILITIES20 MOBILIZATION, DEMOBILIZE21 CATERING, ACCOMODATION22 TRAVEL23 OVERTIME PREMIUM

70 LUMP SUM ENGINEERING71 BASIC ENGINEERING72 DETAIL ENGINEERING73 MATERIAL PROCUREMENT74 SUBCONTRACT PROCUREMENT75 ENGINEERING MANAGEMENT76 - 79 Titles not assigned

Special Indirects Engineering Indirects24 SPECIAL INDIRECT ITEM 125 SPECIAL INDIRECT ITEM 226 - 49 Titles not assigned

80 LUMP SUM CONST. MGMT81 HOME OFFICE CONST. SUPP.82 CONSTRUCTION MANAGEMENT83 -84 Titles not assigned

Freight Contractor Indirects

50 LUMP SUM FREIGHT51 DOMESTIC FREIGHT52 OCEAN FREIGHT53 AIR FREIGHT54 MODULE FREIGHT55 OTHER FRIEGHT56 - 59 Tittles not assigned

85 FIELD CONST. SUPERVISION86 STARTUP, COMISSIONING


Taxes G & A Overheads

60 LUMP SUM TAXES, PERMITS61 PERMITS62 MATERIALS TAXES63 CONSTRUCTION TAXES64 ENGINEERING TAXES65 OTHER TAXES66 - 69 Titles not assigned

90 G AND A OVERHEADS

Contractor Fee

91 CONTRACT FEE92 - 96 Titles not assigned

Escalation

97 ESCALATION

Royalty, Miscellaneous Charges

98 ROYALTY, MISC. CHARGES

Contingencies99 CONTINGENCY


Attribute DescriptionsAttribute Description

ACCOUNT Major account for this item, leading digit taken from system code of accounts to characterize the account class:

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.

Component Type Component Type

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

7 C Condensers 65 WFE Wiped film evaporators

8 CTW Cooling towers 66 WTS Water treatment systems

9 CE Cranes 68 MOT Motors

10 CO Conveyors 69 RB Reboilers

11 CP Centrifugal pumps 70 FU Furnaces

12 CR Crushers 71 TUR Turbines

13 CRY Crystallizers 72 AG Agitators

14 CT Centrifuges 73 LIN Linings

15 DDT Double diameter towers 74 PAK Packings

16 D Dryers

Account Description0 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


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 Instrumentation

29 FN Fans 85 ELC Electrical general

32 GC Gas compressors 86 INL Insulation

34 GP Gear pumps 87 PNT Paint

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 Cost Estimator only.

CCOA User-changed code of account.



CCOAACT COA category (EQ, P, C, ST, I, E, IN, PT).

CCOADES User-changed code of account description (text, 24 characters).


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:

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 In-Plant 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).


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).




COAMOD Code of account (COA) modifier

COAMOD COA Range Description

0 1 - 999 Default if not shown below

Equipment

0 100 - 299 Direct Hire

1 100 - 299 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)

Civil - Concrete

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

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.



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 Component level Work Breakdown Structure -- 3 characters.

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


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 In-Plant 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 Aspen In-Plant Cost Estimator only.



ICUNIT Icarus Internal Units of Measure identifier.

Unit No.

I/P Description

Conversion I/P Metric

Metric Description

Notes

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 Piping Diameters

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


16 BAGS 8.5275E-01 BAG-50KG

17 cur/CY cur/M3 Currency Units/Unit Volume

18 cur cur Currency Units

19 cur/LB cur/KG Currency/Unit Weight

20 LB 4.5359E-01 KG

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

26 cur/SF cur/M2 Currency/Unit Area

27 LB/BATCH 4.5359E-01 KG/BATCH

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 Vessel pressure

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 Motor RPM

43 MPH 1.6093E+00 KM/H

44 HERTZ 1.0000E+00 HERTZ Country Based

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


ICUNIT Icarus Internal Units of Measure identifier. (Continued)


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 Motor Power

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

78 BTU/LB/F 4.1868E+00 KJ/KG/K

79 DEGREE 1.0000E+00 DEGREE Slope

80 PERCENT 1.0000E+00 PERCENT

81 GAUGE 1.0000E+00 GAUGE Duct, HEX tubing

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

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




96 FLOORS 1.0000E+00 FLOORS

97 EACH 1.0000E+00 EACH

98 BAYS 1.0000E+00 BAYS Buildings, Air Coolers

99 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


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

0 Other

10 For equipment design data — brief




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:



23 For first 2 lines of remarks

Project Site Development:




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


ITMCOD Item code:


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 CivilTYPE 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 60AREA 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.



PCTOF Description1 Direct materials plus direct field labor costs2 Direct material costs3 Direct field labor cost4 Direct material plus labor, and construction indirect costs5 All project costs6 Unit Cost Library Item(s) Booked to COA 1-487 Unit Cost Library Item(s) Booked to COA 49-988 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 In-Plant Cost Estimator only.

PIPTYP Class of material for piping.PIPTYP Piping Material0 Pipe labor1 Carbon steel2 Stainless steel3 Titanium5 Aluminum6 Monel/Inconel7 Copper8 Hastelloy9 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 flagIn 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 Cost Estimator only.

SHIFTS Number of shifts per day. For Aspen In-Plant Cost Estimator only.



SOURCE Symbol used to characterize direct, subcontract or remote shop costs (text, 2 characters):SOURCE DescriptionRS Remote shopIT User input — total direct costlM User input — direct material costslL User input — direct manpower costIS User input — total subcontract costSS User input — direct costs, system-prepared subcontract costST User input — subcontract total costSM User input — subcontract material costSL 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 Aspen In-Plant Cost Estimator only.


SUBTYPE For Equipment — cost basis0 System calculated1 User specified2 Remote shop paint

For Piping — type of valve or fitting

0 Other2 Remote shop paint80 Steam tracing99 Pipe101 90 DEG elbow102 Flange103 Reducer (to next lower size)104 Tee105 Blind106 Union (also Couplings)107 Spectacle blind108 Strainer109 Threadolet110 Expansion joint111 Transition joint112 WYE for HDPE only113 Steam trap120 Clamp121 45 DEG elbow122 Ferrule






SUBTYPE - continued

For Piping — type of valve or fitting - continued123 Cross124 Eccentric reducer125 Hose adapter126 Pipe adapter127 Swivel joint128 Caps129 Screwable Plugs130 Weldolet131 Sockolet201 Globe valve202 Ball valve203 Butterfly valve204 Gate valve205 Knife gate valve206 Plug valve207 Angle valve208 Check valve311 Rotameter314 Meterrun332 Vortex flow meter333 Mag meter334 Mass flow meter390 Orifice flange-union391 Orifice plate401 Control valve GLO402 On/off ball valve403 Control valve BUO411 Control valve GLP412 Control valve BAP413 Control valve BUP421 Control valve ANO422 Control valve ANP423 Control valve DVS424 Control valve TKS431 Control valve (no reducers)432 Control valve433 3-way valve434 Regulating valve481 Slide gate on/off482 Slide gate positioning483 Diverter valve501 TSV502 Relief valve503 Rupture disk801 Victaulic coupl. - Continued on next page -




SUBTYPE - continued

For Piping — type of valve or fitting - continued

802 Insul. flange

899 Vent/drain

900 Gaskets

950 Bolts


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 910111213141516171819




SUBTYPE - Continued

For Civil — type of foundation

0 Other1 OCT+PROJ2 OCTAGONL3 PAVING4 MASSPOUR5S M BLOCK6 LG BLOCK7 PILECAP8 CONDUIT9 RING10 BASIN11 EL SLAB12 COLM/BM13 WALL14 GRAD BM15 PIER16 FOOTING17 BOX18 SLAB GRD30 Rectangular - Above grade and below grade concrete tanks, and tile chests31 Cylindrical - Above grade and below grade concrete tanks, and tile chests50 User defined excavation in Bulk Adjustment Civil entry71 SHEET PILING72 HPILE80 User defined piles in Bulk Adjustment Civil entry or in Site Design.81 RAYMOND82 WOOD83 PIPE84 PRECAST85 POURED86 STEEL-H87 CAISSON




SUBTYPE - Continued

For Civil — type of foundation

• For Civil — Miscellaneous30 Rectangular - Above grade and below grade concrete tanks, and tile chests31 Cylindrical - Above grade and below grade concrete tanks, and tile chests50 User defined excavation in Bulk Adjustment Civil entry

Subtype Piling88 FRANKI89 AUGUR

• For Steel2 Remote shop paint11 Remote shop CONC Fireproof12 Remote shop MAGN Fireproof13 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 termination100 LV conduit200 MV conduit300 HV conduit400 CV conduit500 LT conduit551 Low Voltage Feeder Cable - Lighting552 Low Voltage Feeder Cable - Electrical Tracing





SUBTYPE - Continued

For Electrical (continued)

• Type of termination611 LV termination612 MV termination613 HV termination614 CV termination615 LT termination• Cathode Protection701 Bonding Station702 Pipeline Cathodic Protection703 Install Anode704 Coke Breeze Backfill705 Anode Bed Watering Pipe706 Galvanic Anodes707 Install Surface Casing708 Anode Support Pipe709 Termin Junction Box710 Transformer/Rectifier711 Solar Panels712 Solar Panel Connection713 Underground Cable714 Potential Measure Test Station• Tracing800 Electrical tracing801 Self-Regulating Heating Cable811 Mineral Insulated Alloy821 Tracing Panelboard825 Heating Cable831 Tracing Controller




SUBTYPE - Continued

For Instrumentation — type of main loop component construction - continued

110 PI Gauge111 PI Gauge112 PI Draft120 PIT121 PT W/ Seal130 PIC Local140 PS Switch160 DPI Gauge170 DPIT171 DPT W/ Seal190 DPS Switch200 Testwell210 TE/TC211 TI Dial230 TT/TC231 TIT/FILL232 TT/RTD233 TT Wet Bulb234 TT Surface250 TIC Local270 TS Switch310 FI Gauge311 FI ROT312 FI DP Cell313 FQI314 FI Meterrun330 FIT DP Cell331 FIT W/O SEN332 FIT Vortex333 FIT Magnet.334 FIT Mass FL335 FIT Ultras

336 FIT Turbine350 FIC Local360 FS Switch361 FQIS390 Orifice Flange391 Orifice Plate410 LI Gauge411 LI Gauge412 LI Bubbler430 LIT DP





SUBTYPE - Continued


431 LIT Tape FL.432 LIT DISP433 LIT Ultras.434 LIT Nuclear435 LIT Radar450 LC DISP460 LS Wet461 LS Dry462 LS Vibrating463 LS Cond.464 LS CAP.510 AT (PH)511 AT (ORP)512 AT (O2)513 AET BTU514 Density Inst.515 Consistency516 AT%LEL517 AT H2S DET.518 AT CO2519 AT VIST.520 AT Color521 AT Flame522 AT Cloud523 AT Smoke524 AT Flash525 AT Gravity526 AT Heating527 AT GC.528 AT H2&HC529 AT H2S PHY.530 AT HC531 AT H2S/SO2532 AT Sulphur600 CT Conduct.620 W LD 4 Cell621 W LD 3 Cell622 W LD 6 Cell640 SIT650 SS660 XE Axial661 XE Radial





SUBTYPE - Continued


670 XS VIB680 PNT Variable681 PNT ON/OFF690 PNS691 EL Position700 HIC Local701 HIC710 HSW720 BS Infrared740 Solenoid999 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 CWOOL6 PURIF (Cold insulation)7 PURIF (Hot insulation)8 CASIL (Cold insulation)11 CONC Fireproof12 MAGN Fireproof13 Pyrocrete FPR

For Piping: PipelineNote: For Cathodic Protection Subtypes, see Electrical601 Haul pipe to R-O-W602 Stringing pipe on R-O-W 603 Launcher 604 Receiver605 Main road/RR crossing 606 Minor/Dirt road crossing607 Clearing and Grading608 Clean up R-O-W609 R-O-W blasting610 Build BERM through marsh611 Build BERM on trench613 Concrete Anchor, Weld Plate614 Haul Concrete Pipe Support615 String, Set Pipe Support616 Ditch Blasting




SUBTYPE - Continued

For Piping: Pipeline

617 Ditch, Sand & Softsoil618 Ditch, Rocky Soil619 Ditch, Weathered Shale620 Ditch, Weathered Rock621 Ditch, Hard Rock622 Rework after Blasting 623 Rock Ditch By Hand624 Ditch Trimming625 Haul, Place Sand626 Haul Piles627 String Piles628 Drive Support Piles629 Drive Thrust Anchor630 Drive Deflection Anchor631 Drilled Piles632 Concrete Fill, Drilled Piles633 Cut Off Piles634 Anode Trench635 Surface Bed Vertical Anode636 Anode Surface Casing637 Drill Cased Anode Well638 Drill Uncased Anode Well639 Cement Plug643 Access Roads to R-O-W644 Concrete Valve Boxes651 Double Joint652 FBE External Coat653 Internal Coating654 Coating Inspection655 Line Up & Connect Pipe656 Tie-in Connection657 Line Up & Weld658 Tie-in Welds659 X-Ray Field Inspection660 Epxoy Shrink Sleeves661 Hydrotest662 Aerial KM Markers663 KM Markers664 Warning Signs665 Pipeline Vents666 Pipeline Drains667 Place Pipe in Support668 Lower In, Backfill, Clean669 Haul Ring Girder670 String Ring Girder




SUBTYPE - Continued

For Piping: Pipeline

671 Dress & Grind Pile Head672 Weld Pipe Pile Cap Plate673 Weld Tee674 Weld Ring Girder675 Place Pipe In Support676 Install Insulation & Bolt Down677 Guide Bars for Tee678 Welding679 Miscellaneous Drains680 Relief Line681 Steel Support Shoes690 Steelwork Thrust Anchor691 Steelwork Deflection Anchor692 Solar Panel Steel699 Pipeline Instruments




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/man-hour 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 ").



Introduction to Areas

Area Specifications

Report Groups

Icarus Systems are Based on Craft Labor

How Questimate Develops Material Costs

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 Icarus Technology (G10) 36-1

Introduction to AreasIn 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 AreasAreas are defined for the following reasons:

• 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.

36-2 36 Icarus Technology (G10)

Area TypesThere 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


“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

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

° Ground grid

• * Truckable Module - TRMD

Equipment Loaded Automatically Loaded when Skirt/Leg is set to 0

Shell & Tube Heat Exchanger

Yes

Horizontal Tank Yes

Thermosiphon reboiler Yes

Other reboilers No

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


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).

• * 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.

• * 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

Default Area BulksThere 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.

Figure A.2: Summary of Area Bulks Automatically Developed for Each Area

Area SpecificationsFor 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

Equipment Automatic Set Skirt/Leg = 0

Shell & Tube Exchanger Yes

Horizontal Tank Yes

Thermosiphon Reboiler Yes

Other Reboilers No

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

Area Bulks On-grade Pad Area Types

Open Ex-open Module Floor

Area Lighting & Grounding X X X X X X

Equipment Grounding X X X X X

Concrete Pad X

Open Steel Structure X X

Module Structure


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 cut-off length of pipe for all system developed piping in an area. The user 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 LaborAll 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:

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 ScheduleA 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.

• 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 ItemsIn 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. Class No.

Equipment Class 1

Receive Quotes (weeks)

2

Receive Vendor Data (weeks)

3

Fabricate and Ship (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

06 Turbines 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


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 FormatFor 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 number of summary bars on each barchart (that is, report length) developed by the system:

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.

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.

25 Pre-Engineered Package 4 4 24

26 Packings, Linings 3 4 12

System Summary Bars With Basic

Engineering

Without

Basic

General Schedule 24 20

Engineering Schedule 16 14

Construction Schedule 19 18

User Additions Bars Equipment

General Schedule N/A 10

Engineering Schedule 5 10

Construction Schedule 5 10

Equip. Class No.

Equipment Class 1

Receive Quotes (weeks)

2

Receive Vendor Data (weeks)

3

Fabricate and Ship (weeks)


Fabricate and Ship WeeksWhen 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 ScheduleTo produce a project schedule when using Aspen Capital Cost EstimatorTM 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:

• Dates and durations for design engineering

• Procurement

• Delivery of materials and equipment


• 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 ControlThe Process Control Data may be used to specify the desired configuration and type of control scheme:

• Analog

• Digital

• Combinations of analog and digital control.

OverviewTwo 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 instrumentation-related items to be reported with project process control items should be included as part of the last Area.

IntroductionThe 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.

• 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 ModelEach 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.

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 ConsiderationsThe 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 CentersThe 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 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 RequirementsThe 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 DesignationShould 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 system-developed 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”.

Operator CentersThe 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.

ExampleIn 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 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





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



Analog for AREA-500: Center No. 11

and for the Area, a reference number of 90.

The Project Control DataThe Project Control Data would be prepared as follows:

Project Control

Center No. Type

90 Operator Center

10 Digital Control Center



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 ExampleIn 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 TitleArea Number Control Center Numberetc.

MAIN-100 01 10


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:

Note: AREA-200 and AREA-300 share Control Center Number 20; SUB-UNIT-100 and AREA-500 share analog Control Center Number 11.

Reporting of Results for this ExamplePROJect 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 CenterThe 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.


MAIN-200 02 20


MAIN-300 03 20


MAIN-400 04 40


MAIN-500 05 11


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.

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. Micro-electronics 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 stand-

alone 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.


Notes for Defining the Standard Control CenterThe following entry field notes are helpful when defining the standard control center.

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:• 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.

Distance to MCC Specifies the distance to the motor control center serving power to this Operator 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.

Entry field Note


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.

Digital Control Center• 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.

Entry field Note


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.

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 substationSpecifies 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 typeDenotes the type of power cable to be used for this Control Center.

Cable placementIndicates 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 MCCSpecifies the distance to the motor control center serving power to this Control Center


Notes for Defining the PLC Control CenterThe 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 Specifies the distance to the motor control center serving power to this Control Center.


Overview of System Input Specifications for Power DistributionThe 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.


Power DistributionThe 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 DistributionThe 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

Secondary voltages

(distribution and equipment voltages)

4160 V480 V

3300 V415 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


Power Distribution ComponentsPower 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).


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 Unit substation for further transformation and distribution at a lower voltage

2 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.


RedundancyWhen 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.

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.

Characteristics Simple Radial Spot Network

Redundancy 0% 100%

Cost Less expensive More expensive

Reliability Less reliable More reliable

Typical usage:Spare partsSkilled maintenance

On-handOn-hand

ScarceScarce

Severity of shutdown Not critical Critical


Figure PD-2B Schematic= Spot Network System


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 InformationThe 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.


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


characteristics of the substations and components are determined from the default values for the Power Distribution Data.

Reporting of ResultsProject 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 DataA 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 DefinitionProject Title Data is used to convey user descriptions and specifications for the following major items:

• 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 BaseTable 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 BaseThe 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 user-defined currency units. The system uses the user-defined currency and


e

rabian

-P variable

ces

(60HZ)

Section vision 1)

ES (750

C, :

rm

hran, Saudi ia

,000 MHR Agreementiftr. week

d ME

s and n

e

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 Bas

Base monetary Unit

US Dollars Pounds Sterling Thousand Yen Euros Saudi ARiyals

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

System Base Indices

US indices UK indices JP indices EU indices ME indi

Electrical Feeder Line Voltage (and entire mode of distribution)

34.5KV (60HZ) 33KV (50HZ) 33KV (50HZ) 33KV (50HZ) 115KV

Pressure Vessel Design Code (materials and temperature/stress relationships)

ASME (Section VIII, Division 1)

BS5500 JIS DIN ASME (VIII, Di

Depth of Concrete Footings

48 INCHES [1200 MM]

36 INCHES [1000 MM]

36 INCHES [1000 MM]

36 INCHES [1000 MM]

30 INCHMM)

Structural Steel Shapes INCH-POUND METRIC

AISCAISC

AISCBSI

AISCBSI

AISCEuronorm

I-P: AISMETRICEurono

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

• DhaArab

• 100• Site• 1 sh• 40 h

Project Schedule: duration

Adjusted US MHRS

Adjusted UK MHRS

Adjusted JP MHRS Adjusted EU MHRS AdjusteMHRS

Equipment Rental/Plant rental rates

US rates and selection

UK rates and selection

JP rates and selection

EU rates and selection

ME rateselectio

Engineering Department: base of disciplines, wage rates, productivity , and expenses

US Base UK Base JP Base EU Base ME Bas


djusted ME r user E indirect

educed to E indirect

models, e costs

modes,

tions, ME sts

e

Cost Reporting: Currency and System Base IndicesCosts developed by the system without assistance of user-entered rates, costs, etc., are evaluated at the reported values of the System Base Indices for the designated country base. See Indexing/Escalation Data.

Cost Reporting: Currency and EscalationCosts 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.

Units of MeasureThe 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

Prime Contractors: construction overheads

From adjusted US MHRS or user entry US indirect rates

From adjusted UK MHRS or user entry Uk indirect rates

From adjusted JP MHRS or user entry JP indirect rates

From adjusted EU MHRS or user entry EU indirect rates

From aMHRS oentry Mrates

Contract Fee Structure: based on costs reduced to base time

Costs reduced to $, US indirect rates

Costs reduced to £, UK indirect rates

Costs reduced to Thous ¥, JP indirect rates

Costs reduced to €, EU indirect rates

Costs rSAR, Mrates

Power Distribution MAIN distribution voltage UNIT voltage Wire types

60 HZ13.8 KV4160Vwire (trayed or in conduit) or armored US wire gauge

50 HZ11KV3300 Vmulti-core cable (trayed or in conduit) or armored gauge in MM2)



60 HZ13.8 KV

Process equipment

US cost models, US base costs

UK cost models, UK base costs

JP cost models, JP base costs

EU cost models, EU base costs

ME costME bas

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 type descriptions, JP base costs

EU cost modes, EU type descriptions, EU base costs

ME costME typedescripbase co

User-specified supplemental cost

none none none none none

Primary Effect of Selected Country Base

Item Description US Base UK Base JP Base EU Base ME Bas


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.

WorkforceTwo 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/ProductivityThere 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:

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.% = 80Example 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.

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 man-hour 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 ModificationsThe 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 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 NamesThe 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.

ReportsWage 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 ConceptsThis section is devoted to a discussion of:

• 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 man-hours.

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.


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.


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, etc. 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 ElementLow

Productivity (%) Average High

50 85 100 115 140

1 General EconomyLocal business trendConstruction volumeUnemployment

ProsperousStimulatedHighLow

NormalNormalNormalNormal

Hard timesDepressedLowHigh

2 Amount of workSite complexityManual OperationsMechanized operations

ExtensiveDenseExtensiveLImited

AverageAverageAverageAverage

LimitedSparseLimitedExtensive

3 Field Manpower PoolTrainingWagesSupply

PoorPoorLowScarce

AverageAverageAverageNormal

GoodGoodHighSurplus


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 - PV3The 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

4 Field Manpower SupervisionTrainingWagesSupply

PoorPoorLowScarce

AverageAverageAverageNormal

GoodGoodHighSurplus

5 Job ConditionsManagementMaterials and siteRequired workmanshipLength of operation

PoorPoorUnfavorableFirst RateShort

AverageAverageAverageRegularAverage

GoodGoodFavorablePassableLong

6 WeatherPrecipitationColdHeat

BadMuchBitterOppressive

FairSomeModerateModerate

GoodOccasionalOccasionalOccasional

7 Construction EquipmentApplicabilityConditionMaintenance and repairs

PoorPoorPoorSlow

NormalNormalFairAverage

GoodGoodGoodQuick

8 DelaysJob FlexibilityEquipment deliveryExpediting

NumerousPoorSlowPoor

SomeAverageNormalAverage

MinimumGoodPromptGood

Productivity ElementLow

Productivity (%) Average High


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:

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).

Item Productivity

Element Category

Deviation,%

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


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 ConceptThe 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


Adjustment for Craft Productivity

The system contains several hundred Work Item Models with base manpower requirements established for the particular country base location. A user-entered 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.


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 man-hours for each craft by the relationship illustrated in Figure W-6.

Figure W-6: Job Duration Versus Work Week


EngineeringThe 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 man-hours and cost or by specifying a proportional adjustment to system-calculated 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 EngineeringThe 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 EngineeringBy 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:

• Engineering Management

• Construction 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 AdjustmentsThe 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 AdjustmentsAdjustments 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.


Engineering ReportsIf 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 Balances• Equipment Process Data Sheets and Requisitions• Long-Lead Equipment Purchase/Commitment

• Equipment Lists• Piping and Instrumentation Diagrams• Control System Vendor Selection• Interconnecting Piping Diagrams• Utility Process Flow Diagrams

• Utility Balance• Utility Piping and Instrumentation Diagrams

• Electrical One-Line Diagram• Electrical System Distribution• Equipment Specifications• Job Specifications• Overall Facilities Plot Plans

• Site Location Plot Plans• Area Equipment Arrangements• Fire Protection and Safety Systems• Environmental Data• Building and Enclosure Requirements

• Comparative Economic Evaluations• Documentation• Early Scheduling

DETAIL ENGINEERING - Includes engineering and drafting for the following items

Equipment• Review Vendor Design

Piping• Piping Arrangements• Piping Isometrics• Pipe Support• Steam Tracing Drawings• Piping Text Schedules - Continued on next page -


Table EN-1: Engineering Accounts - Tasks and Work Products - continued

Instrumentation• Instrumentation Location Drawings• Cable Schedules• Instrumentation Schematics & Connection Diagrams• Instrument Loop Diagrams• Control Room/Console Design

Electrical• One-Line Diagrams• Electrical Schematics• Substation Layout Drawings• Power Distribution• Lighting• Tracing

Civil• Equipment Foundation Drawings• Steelwork Foundation Drawings• Area Paving Drawings• Misc. Concrete, Supports, Etc.• Underground Piping Drawings• Structural Steel Plans and Elevations• Ladder and Platform Details• Grating Drawings

Buildings and Enclosures• Building Arrangement Plans and Elevations• Architectural Details

General Facility Requirements• Facility Plot Plans• Area Equipment Layouts• Site Preparation Plans, Details

Other Job Requirements• Cost Estimation• Planning and Scheduling• Material Takeoffs• Equipment, Line Lists• Project Operations and Start-up Manual

PROCUREMENT - Includes all in-country purchasing, inspection, and expediting. International purchasing and shipping administration costs are not included. Requisitioning and technical review are included in Basic or Detail Engineering.



Table EN-1: Engineering Accounts - Tasks and Work Products - continued

ENGINEERING MANAGEMENT - Client liaison and design coordination for projects with multiple design contractors.

HOME OFFICE CONSTRUCTION SERVICES - Includes costs for construction department, cost control, construction planning and scheduling, industrial relations and administration, subcontract administration, construction cost engineering, and drafting.

FIELD OFFICE CONSTRUCTION SUPERVISION - Includes costs for project superintendent, site engineers, subcontract coordination, planning and scheduling, safety and medical, field engineering, field drafting, and construction accounting.

CONSTRUCTION MANAGEMENT - An independent, client- appointed, organization responsible for overall construction budget and schedule monitoring, inspection for contract and specifications compliance, subcontract coordination.

SUPPORT PERSONNEL - Includes costs for secretarial, clerical, administrative, and accounting support in each engineering category.

INDIRECTS - Includes rent, heat, electricity, and other operating expenses not specifically covered in other accounts in each engineering category.

PAYROLL BURDENS - Includes the following:

For US country base - mandatory contributions to vacations, holidays, workmen’s compensation, social security, and unemployment insurance in each engineering category.

For UK country base - mandatory contributions for National Insurance, pensions in each engineering category.

ENGINEERING AND MISCELLANEOUS EXPENSES - Includes cost of reproduction, communication (telephone, telex, and postage), travel, and computer services in each engineering category.

PROJECT START-UP - Includes the construction contractor's support of plant start-up, instrument calibration, and plant commissioning. Does not include the Owner's costs.

MECHANICAL COMPLETION: The point in time when instrument testing, electrical testing and piping system testing are all complete for all construction areas. Landscaping, insulation and painting may still be unfinished.


Prime Contractor EngineeringIf the Engineering report option is not selected, only an Engineering Summary report is provided, illustrating total hours and costs for Basic, Detail, Procurement, and Home Office Construction Services. Field Office Supervision and Start-up are summarized on the Construction Overhead Cost report.

Contracts EngineeringDetailed reports are included with the reports for each contract, where applicable, when the Engineering report option is selected.

The Engineering Summary for each contract is part of the Contract Data Sheet.

Construction Management will not be developed by the system unless assigned to a specific contractor (see Contract Scope - Engineering Data). The system-calculated man-hours would then be based on the scope of work for all construction contracts to be managed.

Engineering Management will not be developed by the system unless assigned to a specific contractor (see Contract Scope - Engineering Data) and all man-hours are specified in the Engineering Data. The system will not develop man-hours for Engineering Management.

Table EN-2: Plant Complexity - Guidelines for Adjusting Basic and Detail Engineering Man-hours

Suggested Percent Adjustment to Engineering Man-hours

Basic Detail Typical Facility Type

48 60 Storage FacilitiesGas/Oil Separation Facilities

60 70 Mining FacilitiesOre Processing Facilities

84 90 Basic Chemical ManufacturingAmbient Temperature and Pressure Processes

100 100 Typical Petrochemical/Refinery FacilitiesMunicipal Sewage Treatment FacilitiesIndustrial Wastewater Treatment Facilities

120 125 Organic Chemical ManufacturingVacuum ProcessesCryogenic ProcessesHigh Pressure/High Temperature Processes

140 150 Coal Gasification/Liquification FacilitiesSpecialized Polymer Production Facilities

160 175 Pharmaceutical FacilitiesSpeciality Food Processing Facilities

200 200 Coal Gasification/Liquification Pilot FacilitiesHigh Temperature/High Pressure Pilot Facilities


The Engineering OrganizationEngineering costs may be affected not only by the scope of the project and its complexity, but also by the size and nature of the engineering organization assigned to execute the design and procurement phases of the project.

As engineering man-hours, costs, and calendar time comprise a large proportion of the total project effort, it is important to consider the nature of the organization(s) assigned to perform the various phases of engineering. The system evaluates engineering man-hours and costs based upon the user’s project scope definitions, as if performed in-country by a large national or international engineering organization for a large-scale project. An expanded discussion of project types and guidelines for adjusting from a large-scale project/large contractor basis to the user’s project requirements follows.

Adjustments to Engineering CostsEngineering costs may be affected not only by project size and complexity (see Table EN-2), but also by the size of the engineering organization executing the design and procurement phases of the project. In order to illustrate the effect of organization size, three guideline categories are defined:

Small - 100 to 400 employees, performing smaller, local projects to less than US $50 [PS25] million total installed cost (TIC).

Medium - 300 to 750 employees, performing fairly large national projects of $50-500 [PS25-250] million TIC.

Large - over 600 employees, performing large and very large national or international projects of greater than $50 [PS 25] million TIC. (The system basis is in-country design and procurement by a large engineering contractor.)

For the purpose of estimating, the three categories generally are defined with the following characteristics:

Small organizations, under normal marketing conditions, pay slightly less in salaries, offer slightly less in fringe benefits, and yet have higher productivity for a number of reasons. Work volume is typically steadier, staff turn-over lower, and time management more effective than in larger design groups because problems are less likely to be obscured by the volume of work and the number of people involved. Staff are productive since their work is highly visible, projects are rarely very complex and the effects of changes are minimized because of ease of communication within the group. However, working conditions and limited equipment/systems may be a drawback. Such organizations tend to use less specialists in scheduling and estimating; instead the project manager may develop his own barcharts, while project engineers may handle all estimating except for take-off. Overhead costs are reduced by lower real estate and office equipment expenses. While ideally structured for a certain project size and complexity, small organizations will usually be unable to quickly staff larger, fast-tracked projects or meet the technical needs of complex projects. It should be noted, however, that many larger organizations currently maintain a specialized small projects group, with the benefits of economy and flexibility.


Medium-sized, national engineering companies are generally very close to the large organizations in terms of adjustments to engineering cost estimation, except in the areas of overhead costs for maintaining under-utilized office space and key staff, and productivity advantages derived from low staff turn-over and centralized engineering offices. Productivities may further improve if the company tends to specialize in certain kinds of work. Salaries will be the same or slightly less than paid by the largest companies.

Large organizations are accustomed to maintaining excess capacity in terms of offices and staff in order to be responsive to the client’s needs on large projects, and this naturally carries a price reflected in overhead costs. Productivity will generally be dependent upon project size, time constraints and project definition. The largest projects also often cause unusually high project management and procurement costs due to complex contracting procedures and exacting approval cycles. Note that the system does not currently allow for worldwide procurement of equipment or materials, nor for overseas expediting and ocean freight.

Evaluation of these effects for each project is a matter of estimating judgement. Different engineering organizations can be characterized, phase-by-phase, as illustrated in the following table. The use of engineering adjustments is strongly recommended, since few other elements of a project comprise as large a proportion of the total project costs as does engineering.

The following table demonstrates how the appropriate adjustments for different sizes of engineering organizations may be represented to the system.

Adjustment to:

Size of Organization Phase Discipline Adjustment Item Adjustment Range

** Operation Costs **

Small (on local projects)

All nanana

% rates% indirects% expenses

85-9555-650 (incl.)

Medium (on national projects)

All

BasicDetail

nananana

% rates% indirects% expenses% expenses

90-10065-756-86-8

Large (for worldwide procurement)

Procurement na % expenses 50-100



General Instructions: SPAN* Users Only

Since only four activity groups have been reserved for each account in the SPAN* network, no more than four user-specified drawing types should be added to any one major account (piping, civil, etc.). User drawings in excess of four per account will not be passed from the estimate into the network.

*SPAN is a Proprietary Mark of Icarus Corporation.

Adjustment to:

Size of Organization Phase Discipline Adjustment Item Adjustment Range

**Man Hours**

Small (on local projects)

Basic

Detail

ProcurementHome Office

Field Office

All011415All01141501All030407All131516

% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours% manhours

85-9095-10005080-8595-10505090-9550-7000060-80000

Medium (on national projects)

BasicDetailProcurementHome OfficeField Office

AllAll01AllAll

% manhours% manhours% manhours% manhours% manhours

90-10085-9595-1008509585-100

Large (for worldwide procurement)

Procurement All % manhours 150-200


Construction Overhead - Prime Contractor BasisThe information in this section applies only to estimates prepared on a prime contractor reporting basis. If the project estimate require contracts based on reporting, the procedures of this section are bypassed.

Construction overhead includes field manpower fringe benefits, associated burdens, small tools, temporary facilities, field services, construction equipment rental and miscellaneous overhead expenses. The construction overhead data can be used to adjust any of the values within the construction overhead accounts. The user may adjust each account by specifying the cost in the user-defined currency units or as a percentage of the direct field manpower cost. Note that the user-defined costs are presumed to be referenced to a time frame denoted by the User Base Construction Index. Costs are subject to escalation.

The following table includes a description of the overhead accounts.

Description of OVerhead Accounts

Project Costs

Engineering General and Administrative overhead costs for engineering (basic, detail, procurement, engineering management, home office construction services and construction management) performed under this contract, as a percent or lump sum of engineering discipline costs, payroll burdens and other indirects and expenses. The fee for engineering performed under this contract, as a percentage of engineering and G&A costs.

Construction General and Administrative overhead costs for construction performed under this contact, as a Overhead & Feespercentage or lump sum of construction costs (direct field manpower, construction equipment rental, field supervision and other indirects). The fee for construction performed under this contract, as a percentage or lump sum of construction and G&A costs.

Contingency The contingency for materials purchased under this contract, as a percentage of cost of materials, G&A and fee.

Indirects:

Fringe Benefits Prime contractor’s contribution to vacations, holidays, sick leave, retirement, health insurance, etc.

Burdens

US Country Base

UK Country Base

Prime contractor’s mandatory contributions for Federal Social Security (FICA), Federal Unemployment Insurance (FUI), Workmen’s Compensation and State Unemployment Insurance (SUI).

Prime contractor’s mandatory contributions for National Insurance.

Consumables/Small Tools

Includes small tools and consumable materials.

Miscellaneous (Insurance, Safety, etc.)

Includes job cleanup costs, watchmen, construction equipment servicing and handling, public liability, public damage, automobile and all-risk insurance, warehousing and nonproductive field manpower.


Contracts: Description/ScopeThe contracts feature provides the user with the means of:

• Describing the desired owner-contractor relationships and scopes of effort to prevail during the course of the proposed project.

• Obtaining detailed estimates of the cost-to-construct for the project, the owner and each contractor in turn, with each estimate reflecting the tiered nature of contracts, scope of effort, and individual contractors’ costs of “doing business”.

In this section, the term “owner” is used to identify the “one” or “Number 01” contract at the top of the tier of contracts. The “owner”, whether operating company or contractor, is the focal point for payment of all contract costs relative to the project. An operating company preparing an estimate of the cost-to-construct might designate itself as the owner for purposes of evaluating bid package proposals and the total cost of the project. Or, a contractor might designate itself the owner when preparing a client bid.

Organizations providing services directly to another organization are termed contractors, or, if indirectly through another contractor, are termed subcontractors.

Prime Contractor Basis: Default Condition (Contracts Not Defined)In the absence of contract descriptions the system will revert to its standard reporting method. That is, all costs and cost structures will be on a Prime Contractor basis. Engineering, materials, and construction will be charged to the Prime Contractor and reported in a single summary report.

Scaffolding Includes all scaffolding, except as required for assembly and/or field erection by vendor.

Vendor

Representatives

Includes travel and subsistence as well as average rates for vendor field representatives.

Field Services Includes medical, first aid, transportation, weld tests and welding supplies.

Construction Rental Equipment

Construction rental equipment costs.

Temporary Construction and Utilities

Cost of temporary sanitary and shelter facilities, roadways, rigging, utilities and fencing.

Mobilization/Demobilization

Cost of construction equipment handling and transport to and from jobsite.

Catering/Accommodations

Includes all catering and accommodations for all field personnel at site.

Travel Includes all travel and subsistence when required.

Description of OVerhead Accounts


Within the Prime Contractor basis of reporting, subcontracting is limited to individual bulk accounts for designated Unit Areas and site development, all under nonadjustable cost structures. The contracts feature of this section relieves these constraints.

Contract Definition - Description and ScopeTwo sets of contract information must be assembled. The Contract Description Data and the Contract Scope Data provide the means of assembling this information.

Contract DescriptionThe contract description must be provided for each contract and is assembled in the Contract Description Data. The contract description includes:

• Characteristic name or title, for reporting purposes

• Reference number of contract, to identify the contract and chain of responsibility

• To whom responsible, via contract reference number

• Contract overheads to be applied (G&A, fee, contingency) for -

- engineering

- materials

- construction

• Charge for handling subcontracts

• Field indirects, in lieu of the Indirect Data, see Construction Overhead - Prime Contractor Basis Data Equipment rental

• Definition of the engineering workforce (EWF) to be used for each engineering contract. Adjustments to wages, man-hours and overheads for the desired EWF are made using Engineering Data.

• Definition of the construction workforce (CWF) to be used for each contract. Adjustments to wages, productivity and crafts for the desired CWF are made in the Workforce Data.

The second set of contract information is entered in the Contract Scope Data. Contract Scope Data describes the scope of each contract for:

• has of engineering, which may be allocated to areas (Unit Areas):

- basic engineering

- detail engineering and procurement

- engineering management (optional)

- construction management (optional)

- start up.

• Materials and/or construction (installation) within defined areas (Unit Areas) and covering or excluding items or tasks in the following categories as defined by the code of accounts:

- equipment


- piping

- civil

- steel

- instrumentation

- electrical

- insulation

- paint.

Contracts - ConceptsBy the very nature of contracts and this contracts feature, costs of engineering, materials, and construction are assigned to that contact bearing the scope responsibility. Contract Scope Data forms a contract set (CONSET) and is used to assign scope responsibilities. The function of the CONSET is to define a framework of contract responsibilities for engineering, materials, and construction. This framework may be detailed down to the phase level for engineering, and to the code of account (COA) level for materials and construction. The CONSET number which identifies this framework may then be indicated in the following project areas to designate responsibility:

• Unit areas

• Power Distribution items

• Process Control Centers or Operator Centers

• Site Development items (project-level only).

Multiple CONSETS would be required only where different frameworks of responsibility exist; for instance, varying by area or groups of areas.

The responsibilities of a contract for materials purchasing and construction are defined first for each major account, that is, equipment, piping, etc., then by COA exception. Materials contract responsibilities are for payment for materials, but not procurement. The responsible purchasing contractor is defined for each major account. Construction contract responsibilities include field manpower, equipment rental, field supervision, and home office construction services. The responsible construction contractor is identified for each major account.

Contract exceptions are defined for materials and construction by identifying the contract (contract number) responsibility by the code of account (COA).

Owner-contract-subcontract responsibilities are identified by the system based upon the user’s assignment of contract numbers. The owner is always assigned contract reference number “01”. Contractors directly responsible to the owner would be assigned contract numbers such as “02”, “03”, etc. To identify the chain of responsibility, a “contracted-by” reference number is required. Thus “02” is responsible to “01”. Should a subcontractor to “02” be desired and identified as contractor number “13”, the chain would be: “13” is responsible to “02”. These reference numbers are assigned as part of the contract description.


Contracts - Cost ElementsTable CDS-1 illustrates the principal cost elements of a contract; each will be discussed in turn relative to the manner of evaluation and adjustment.

na = not applicable

(1) = Subcontract costs are allocated to each contractor based on the contract hierarchy established.

Overheads, fee, and contingency are added to the direct costs to develop the contract total for each category.

Contract costs are then charged to the responsible contract higher in the chain as a subcontract with attendant handling charge.

Contract Engineering and Procurement

Each phase of contract engineering:

• Basic

• Detail (with procurement)

• Engineering management

• Construction Management

• Start-up

is considered assignable to an individual contract. Work efforts within a phase may be split among several contracts. A contract may cover one or more phases for the entire project. Contracts must be assigned for basic, detail, and

Table CDS-1: Cost Components of Contract Elements

Class Expenditures

Construction

Data Type Design Eng’g @ Procurement

Materials Manpower Indirects All Subcontracts

Engineering Basic, Detail, Procurement Mgt, Construction Mgt.

G@A, Fee, Contingency

na na Start-up


na

Purchasing na


Equipment and bulks

na Freight, Taxes


na

(1)

Installation Home Office Construction Services


na


Manpower to Install

Field Indirects, Field Supervision


na

(1)


start-up. If construction management is not assigned, construction management will not be included in the estimate. If engineering management is not assigned and the required man-hours and cost have not been specified by the user, engineering management will not be included in the estimate.

Note that the procurement effort for materials and equipment is not assigned by the user, but follows the detail engineering assignment automatically. The procurement effort for subcontracts is automatically assigned to the responsible contract.

Similarly, home office construction services and field office supervision are not assigned by the user, but follow the construction assignment. However, these costs are adjustable by the user via Engineering Data.

Discipline man-hours are evaluated by the system using engineering models for equipment, unit bulk items, area and project bulks, and site development for the above categories in the same manner as for Prime Contractor reporting (construction management excluded). For contract engineering, the system uses the Engineering Data to define the engineering workforce (EWF). An engineering contract is cross-referenced to an EWF, and discipline and phase adjustments are made in the Engineering Data.

Engineering discipline costs (product of man-hours x wage rate for each discipline) are combined with user-specified or system default values for payroll burdens, office indirects, and miscellaneous expenses. The contract total is evaluated upon considering G&A, fee, and contingency as described later in this section as Contract Overheads.

Materials

A materials contract consists of payment for materials, subcontracts, freight, and taxes. General and administrative costs (G&A), fee and contingency specific to each contract are combined with these material costs to form the contract total.

The system generates material types, quantities, and costs based upon Equipment Models and Volumetric Models. Material costs are established by the system through the appropriate country base of costs, adjusted for escalation and indexing and any other material adjustments, and converted to the user’s country base.

Each contract assigned the responsibility for materials is charged with payment for those materials.

The total material cost is reported in the contract summary as the cost of materials, including freight and taxes, for construction. Detail reports identify the contract responsibility for materials.

Construction ContractsA construction contract consists of the following classes of expenditure:

• Construction:

- direct field manpower

- field supervision

- G&A, fee, contingency.


• Construction Supervision:

- home office construction services

- field supervision

- G&A, fee, contingency.

Each of these classes is described in detail below. G&A, fee and contingency are covered below under Contract Overheads.

Construction - Direct Field Manpower

The system develops crew mix, man-hours and construction equipment requirements from Work Item Models for equipment, unit and area bulks, and site development. These values and user-entered man-hours are combined with the appropriate craft wage rates to obtain manpower costs.

Construction - Field-erected VesselsA special contracts feature may be used to change the way the system reports manpower for field-erected storage vessels.

The system will normally include the cost of field-erection (materials and manpower) as part of the purchased equipment cost of a field-erected storage tank. The user may then only adjust the overall equipment cost, but will not have the opportunity to adjust manpower (such as wages, productivity, burdens). In fact, the manpower would be considered to be the equipment vendor’s manpower and not subject to adjustments pertinent to the materials contractor.

However, if the user includes an installation assignment to designate a specific contract for code of account 121 (or the equivalent new COA, the system will then consider all field-erected storage vessels (within the area specified), as being installed by direct manpower and consequently the particular designated contract adjustments for manpower will be observed. Note that this must be done specifically for the indicated COA only, not as part of a range.

In the absence of an installation assignment designating a contract for this specific code of account, the costs for field-erection vessels would be charged as a material cost to the contract responsible for equipment purchase.


Construction - Field IndirectsAn equipment rental estimate is developed for each construction contract based upon rental items developed from Work Item Models. In determining equipment rental rates and rental durations, the system uses a contract duration based upon the user’s defined schedule or a system-developed schedule. The value for contract equipment rental is adjustable in terms of rental rates. Should the user wish to enter a lump sum cost or take equipment rental as a fraction of manpower costs, the user-specified value will prevail over the system-calculated figures.

Other field indirect costs such as fringe benefits, burdens, travel, consumable, scaffolding, field services, temporary construction and utilities, and miscellaneous items may be specified relative to direct field manpower.


Costs of vendor representatives, mobilization/demobilization, catering and accommodation, and any special items may be specified as lump sum costs. Should a single value for field indirect costs be entered, this value will prevail for field indirects over any other user-specified or system-developed field indirect category value.

Construction - Field SupervisionField supervision is estimated for each construction contract based upon the direct field manpower requirements and contract duration in the same manner as for Prime Contractor reporting. Payroll burdens, indirects, and miscellaneous expenses are evaluated and added to the supervision cost, thus arriving at the total cost for field supervision - classed as a construction field indirect cost.

Construction - Home Office Construction ServicesHome office construction services cost is estimated in the same manner as field supervision. Man-hour requirements (tied to contract duration and field requirements) are combined with appropriate discipline rates to develop direct discipline costs. The payroll burdens, indirects, and miscellaneous expenses are added to develop the total cost. Associated costs for G&A, fee, and contingency are applied as described below.

Contract OverheadsThe overheads:

• General and administrative costs (G&A)

• Fee

• Contingency

are part of the user’s contract description or are evaluated through system default procedures. These overheads are applied and reported against costs in the following categories:

• Design (engineering and procurement, including home office construction services)

• Materials

• Construction.

General and administrative costs are evaluated as a percentage of direct and indirect costs.

Contract fee percentages are calculated by the system as a function of the total cost of the scope of effort: directs, indirects, and G&A. Figure CDS-1 and the example below illustrate the method used by the system to develop a fee. The fee is determined by the phase (engineering, materials, construction) and extent (total cost) of each phase. The total cost of directs, indirects, and G&A is reduced by the Escalation Index to a graph base. The fee percentage obtained from Figure CDS-1 using this reduced cost is applied to the phase total cost.


For example, suppose (1) a US country base is chosen and all costs are in US Dollars, (2) the System Base Index for all costs is set and tabulated (see Indexing/Escalation Data) at “1200,” (3) the user has indicated a requirement for 21% escalation from the base by entering 1.21 x 1200 = 1452, and (4) the system has arrived at an escalated total cost for construction directs, indirects, and G&A of $290,400. The system would develop a reduced total cost of $290,400/(1452) = 200. Applying this value to Figure CDS-1, the curve for construction would be used to obtain the fee percentage (11.1% for construction) applied to the $290,400 figure. The user of another country base location and currency would use the appropriate country base scale and currency conversion to use Figure CDS-1; the system would perform these conversions automatically.

Contingency may be adjusted by the user on a contract basis or on a project basis.

A fee for handling other contracts is determined by the percentage of the value of contracts handled.

The above individual fee categories are disregarded should the user enter a single lump sum fee for the contract.


Contracts - Impact Upon Other User InputThe use of the contracts feature has a significant impact on other user input. The interrelationships between contract definitions and other system data are described in each section of this document so affected.

Figure CDS-1: System Calculated Fee Percentage to be Applied to Total Cost of Directs, Indirects, and Overheads for Engineering (Curve E), Materials (Curve M), and Construction (Curve C).

Note: Use the appropriate country base location scale and Escalation Index and should apply the appropriate currency conversion to enter this chart. The system will perform this calculation in normal fashion.


Reserved for future use

37 Reserved (G7)

37 Reserved (G7) 37-1

37-2 37 Reserved (G7)

A

AACE American Association of Cost Engineers.

ABC Tracking costs on an activity-by-activity basis. Tracking costs this way provides the ability to identify tasks which are on track and are beginning to run over budget.

Accelerated depreciation Depreciation methods that allow the company to depreciate and write-off the cost of assets at a rate faster than the write-off under the straight line method.

Account A major account series, e.g., piping 300-399.

Acid-test ratio See Quick ratio.

Action button An action that may be performed represented by a button on a menu.

Activity An individual task needed for the completion of a project. It is the smallest discrete block of time and the resources are typically handled by project management software. It is a single task which needs to be done in a project. Multiple activities are related to each other by identifying their immediate predecessors. Solitary activities, which have no predecessors or successors, are allowed.

38 Glossary (G5)

38 Glossary (G5) 38-1

Activity duration Specifies the length of time (hours, days, weeks, months) that it takes to complete an activity. This information is optional in the data entry of an activity. Work flow (predecessor relationships) can be defined before durations are assigned. Activities with zero durations are considered milestones or hammocks.

Actual dates Actual dates are entered as the project progresses. These are the dates that activities really started and finished as opposed to planned or estimated dates.

Addendum A change or graphic instrument issued before the date bids are opened. An addendum may interpret and/or modify the bidding documents by making additions, deletions, clarifications or corrections.

AFC Approved for construction.

AFD Approved for design.

AFE Authorized for expenditures.

Allocate To book the costs under one COA to another COA.

Allowances Additional resources included in estimates to cover the cost of known but undefined requirements for any individual activity, work item or account.

Alternate A request from the owner for the cost of adding or deleting an item or work element from the basic bid. The cost of adding an item is usually known as additive alternate, while the cost of deleting an item is known as deductive alternate.

Amortization See Loan amortization and Full loan amortization.

38-2 38 Glossary (G5)

ANSI American National Standards Institute.

API American Petroleum Institute.

Apply For Aspen Capital Cost Estimator, includes the entered information in the project specifications.

Apply & Close For Aspen Capital Cost Estimator, includes the entered information in the project specifications and closes the entry window.

ASME American Society of Mechanical Engineers.

Aspen Capital Cost Estimator ICARUS’ state-of-the-art, integrated, ready-to-use, computer aided design, estimating, and scheduling system for evaluating major process plants and mills worldwide. Aspen Capital Cost Estimator is available on both a UNIX workstation and a PC running Microsoft Windows NT.

Asset structure The particular mix of possessions a corporation holds. These are divided into those to be held for a short time (current assets) and those to be held for a long time (fixed assets). In a dynamic corporation this mix is continuously changing. It is the job of the financial manager to keep this mix at the most desirable combination.

Average collection period An efficiency ratio. A measure of how long it takes the company on the average to collect on a credit sale = receivables X 360/net sales. It should be approximately the same length as the credit terms of the company.

Average rate of return (ARR) A non-discounted capital budgeting technique. This is the ratio of average net income to average investment.


B

Balance sheet A record of the company’s assets, liabilities and equity as of a certain date.

Balloon Symbol for field instrument in a P&ID.

Balloon payment A very large payment due at the maturity of a loan arrangement, which has not fully amortized the loan.

Baseline schedule A fixed project schedule. It is the standard by which project performance is measured. The current schedule is copied into the baseline schedule which remains frozen until it is reset. Resetting the baseline is done when the scope of the project has been changed significantly. At that point, the original or current baseline becomes invalid and should not be compared with the current schedule.

Basic engineering Engineering required to bring the Phase I design to the AFD level. Basic engineering is the initial stage of projects where process flow diagrams (Puffs) are created to arrange process operations, functionality and the necessary equipment list. This is accomplished by taking the results of the process analysis (from a simulator) of a general design to define process conditions, requirements, functionality and equipment for the specified process. The basic process design is then created. At this stage, design conditions are defined based on process conditions and operations and models of actual equipment are mapped out.

Benefit-cost ratio (BCR) A discounted cash flow capital budgeting technique; also called the profitability index. This is the ratio of the present value of the future cash inflows of a project to the initial investment.

Bid documents The advertisement for bids, instructions to bidders, information available to bidders, bid form with all attachments and proposed contract documents (including all addenda issued before the receipt of bids).

Bond A corporate promissory note issued to an investor.


Bond covenants The terms and provisions of a debt issue contained in the indenture. These include the interest rate, maturity date, call price, protections and other specifics.

Bond indenture The contract in a debt issue that outlines all the covenants.

Bond refunding The procedure of recalling an existing bond issue and replacing it with another. This is usually done to take advantage of changes in market interest rates.

Book value For a company, the book value is total net worth.

Book value per share The total net worth divided by the number of shares outstanding.

Break-even analysis A planning procedure that analyzes the relationships between costs, revenues and volume and uses these relationships to project profits at various levels of sales.

Break-even budget The amount of the budget at which the company has exhausted all internally generated equity and must begin to use externally generated equity.

Break-even point That point in the level of production or sales at which total revenues equal total costs.

BS5500 British Standards.

Clear Erases entries currently selected or displayed in active window.

Click To press and release the left mouse button.


Close For Aspen Capital Cost Estimator, makes no changes to the project specifications — simply closes the entry window.

Closed-end mortgage bond A mortgage bond issue that prevents the company from issuing additional senior debt by pledging the same assets.

CM Construction manager/management.

COD A credit term that means “Cash on Delivery” and specifies that goods must be paid for in full upon delivery.

Code of account (COA) A specific cost code (e.g., 315 CS VALVES: FLANGED.)

Coincident indicator An economic indicator that changes concurrently with changes in the general economy.

Collateral An asset used as security to guarantee payment of the principal and interest on a loan.

Collection costs Clerical and administrative costs involved with granting credit and managing accounts receivable.

Commercial paper Short-term promissory notes issued only by very financially secure corporations. It is generally safe and very liquid. It has very short maturities and very high denominations. It has yields higher than treasury bills. It usually can be either placed directly or through commercial paper dealers.

Common equity That portion of the balance sheet accounts composed of common stock, capital in excess of par and retained earnings. Also called net worth and stockholders’ equity.


Comparative analysis An analysis of the overall performance of a company that compares the ratios of a given company with ratios of other companies in the same industry.

Compensating balance A credit arrangement restriction that requires a borrower to keep a specified percentage of the outstanding balance of a certain loan in a checking account with the bank.

Components The pieces of the process plant (or mill) that when linked together complete a process. ICARUS components are categorized into process equipment, plant bulks, site development, buildings, quoted equipment, unit cost libraries and equipment model libraries.

Composition A voluntary financial agreement whereby creditors accept partial payment on debts owed them as full payment.

Conglomerate merger A merger between two companies whose businesses are not directly related.

Construction overhead and fees See Overhead

Consumable The cost of small tools, fixings, consumable material other than welding supplies.

Consumer survey method for forecasting A survey method of sales forecasting in which consumers are asked to reveal their purchasing intentions.

Contingency An amount added to the estimate to allow for changes that will likely be required. This may be derived either through statistical analysis of past-project costs or by applying experience gained on similar projects. Contingency usually does not include changes in scope or unforeseeable major events such as strikes or natural disasters.

Contract documents The contract forms, general and special conditions, drawings, specifications and addenda describing the project scope and contract terms.


Control The process of comparing actual performance with planned performance, analyzing the differences and taking the appropriate corrective action.

Control process A procedure to determine whether or not actual performance is in keeping with planned or budgeted performance.

Conversion premium The difference between a convertible bond’s issue price and its conversion value at issue time.

Convertible security A convertible bond or preferred stock that allows the holder to convert the security into a specified number of shares of common during a specified time period.

Copy & change For Aspen Capital Cost Estimator, copies an existing component (with any associated bulks) and displays the copy for modifications.

Cost The amount a contract item is known or estimated to cost the contractor.

Cost index A number that relates the cost of an item at a specific time to the corresponding cost at some arbitrarily specified time in the past. A cost index is useful in taking known past costs for an item and relating them to the present.

Cost modeling Taking basic process data (such as capacity of tanks, flow rates of pumps and areas of heat exchange) and applying them to industry standard design procedures and codes (ASME, API, TEMA, NEMA, BS5500, JIS and DIN). Cost modeling also includes developing a mechanical design and simulating the fabrication and manufacturing of equipment to determine a total equipment cost and man-hours for installation.

Cost of capital Cost incurred by utilizing various forms of financing for capital projects. It is the minimum return required from a project in order for that project to be acceptable into the capital budget.


Coupon rate The published rate of a bond. It is equal to the annual interest amount divided by the face value = I/F.

Covenants See Bond covenants.

Create For Aspen Capital Cost Estimator, creates a new project for entering specifications.

Credit discount A credit term that specifies the percentage discount which may be taken if the invoice is paid within a specified number of days.

Credit period A credit term that specifies the number of days a client can take to pay an invoice without being considered delinquent.

Credit period only A credit term that specifies that no discount will be given, but the bill is due within a specified time period.

Credit policy Policy for management decisions on credit standards, limits and specific terms.

Critical activity A critical activity has zero or negative float. This activity has no allowance for work slippage. It must be finished on time or the entire project will fall behind schedule. (Non-critical activities have float or slack time and are not in the critical path. Super-critical activities have negative float.)

Critical path There may be several paths within one project. The critical path is the path (sequence) of activities which represent the longest total time required to complete the project. A delay in any activity in the critical path causes a delay in the completion of the project. There may be more than one critical path depending on durations and work flow logic.

CS Carbon steel, specifically A285C plate, A106, pipe

< 2”, A 53 pipe > = 2”, A299 castings.


Current ratio A liquidity ratio. The ratio of total current assets to total current liability equals CA/CL. It indicates the amount of money in CA for each unit of CL and is a measure of liquidity.

Current yield The return a bond is presently producing, which is equal to the annual interest rate divided by its current market value.

D

Database A collection of data that can be used to produce additional information.

Debenture A bond that is backed only by the earning power of the company and no specific assets. Debenture holders are general creditors of the company.

Decision engineering An engineering of decisions. Decision engineering allows you to develop a series of process strategies based on information developed from ICARUS’ systems. The best strategy is then identified from the series of strategies. Considering the best strategy, a decision can then be made which then becomes your tactic on which to act.

Decision point A point on a decision tree over which management has control.

Decision tree A graphic method of risk analysis that shows the magnitude of expected net cash flows, their associated probabilities, and the interrelationships between the various outcomes.

Deferred call provision A restricted call provision that does not permit a bond to be called before a specified amount of time passes after the initial issue.

Definitive: -5 to +15 percent estimate (as defined by AACE)

This type of estimate is developed from very defined engineering data including plot plans and elevations, piping and instrumentation diagrams, one-line electrical diagrams, equipment data sheets and quotations, structural


sketches, soil data and sketches of major foundations, building sketches and a complete set of specifications.

Degree of financial leverage Quantification of financial leverage that measures the fractional change in net income due to a fractional change in operating income.

Degree of operating leverage The fractional change in earnings before interest and taxes for each fractional change in sales.

Delete For Aspen Capital Cost Estimator, removes the specified item from the project.

Delphi method for forecasting A qualitative sales forecast method in which several experts give their own opinions, listen to the opinions of the others, give individual opinions again and continue through this process until they reach a consensus. This consensus then constitutes the sales forecast.

Demand-diversity factor The ratio of the actual power demand of an electrical system to the sum of the nameplate ratings of each piece of equipment within that electrical system. This ratio will always be less than unity for three reasons. First, motors are manufactured in standard sizes so the actual power used will always be less than the nameplate rating of the motor. Second, electrical equipment is normally brought with some excess capacity; and third, not all equipment operates at the same time.

Demobilization See Mobilization/Demobilization.

Design basis A set of specifications defining the country base, units of measure and currency used in a project.

Detailed engineering Defining specific equipment needs, areas, capacities, plot plans, utility systems and tracks based on process engineering specifications and designs defined during the Basic engineering phase. Pads and Oasis are created during the detailed engineering phase. In addition, equipment is defined in relation to the process flow during this phase.


DH (Direct hire) Practice by some general contractors of hiring craftsmen directly from the local labor pools rather than subcontracting the work.

Dialog box A window that either requests or provides information.

DIN Dutch-Industrie-Normen.

Direct costs Costs that can be directly attributed to a particular item of work or activity.

Direct field cost (DFC) Permanent equipment and materials and the construction contractor’s labor to install them.

Discount period A credit term that specifies the number of days during which the credit discount can be taken.

Discount rate The interest rate used to discount a future amount of money back to the present. It is equal to the opportunity cost rate.

Display For Aspen Capital Cost Estimator, shows the selected P&ID.

Distributable A cost item that is spread over other cost items rather than managed as a separate account.

Distribution of assets Both the payment of dividends by the corporation to its stockholders and the distribution of the liquidation proceeds to the creditors and the stockholders.

Dividend declaration date The date upon which the board of directors met and declared the dividend.

Dividend payment date The date upon which the dividend checks are mailed to the stockholders.


Dividend payout ratio A measure of the percentage of earnings that are paid out in dividends. It can be calculated by dividing dividends per share by earnings per share or by dividing total dividends by net income.

Dividend policy The established course of action management maintains in terms of that portion of retained earnings paid out in dividends.

Dividend yield A measure of the dividend return to investors for their investment in the company. It is calculated by dividing dividends per share by the price of a share of common stock.

Dividends That portion of retained earnings which is paid to the stockholders.

Duration Length of time needed to complete an activity. The time length can be determined by user input or resource usage. Activities with no duration are called milestones which act as markers. Estimating durations for future activities is difficult. It is recommended that the largest duration possible be used to account for possible delays.

E

E-P-C (Engineering, procurement and construction) Consolidation of the responsibility for those activities under a single contract(or).

• Engineering-Designing the plant or facility, calculating all the sizes, dimensions, quantities and how and when the plant is to be assembled.

• Procurement-Purchasing material quantities and setting contracts with engineering firms.

• Construction-Actually building the plant or facility based on engineering specifications.

Early finish The earliest calculated date on which an activity can end. It is based on the activity’s Early start which depends on the finish of predecessor activities and the activity’s duration.


Early start The earliest calculated date on which an activity can begin. It is dependent on when all predecessor activities finish.

Earned surplus Also called retained earnings — the accumulated annual earnings of a corporation.

Earnings per share The amount of earnings available for each share of common stock. It is calculated by dividing the net income by the number of common shares outstanding.

Economic forecast Projection of those factors that indicate the general condition of the national economy.

Economic indicator The factor within the national economy that can be used to identify a particular trend in the general economy.

Economic order quantity The appropriate number of units that should be ordered to efficiently balance holding and reorder costs.

Efficiency The ability of a corporation to most effectively use its assets to produce sales in a particular sales period.

Efficiency ratios Ratios drawn with items concerning the company’s asset base and sales. They are useful in evaluating the ability of management to generate sales using the assets.

Elapsed time Total number of calendar days needed to complete an activity. This provides a realistic view of an activity’s length.

Engineering Expense rate Used to calculate the Basic Engineering Report's "Overhead Items," which collectively comprise engineering expenses. See Chapter 31 for more information.


EOM A credit term that means “End of Month” and indicates that the credit period begins on the first of the following month.

Equity See Common equity.

Equity ratios Ratios generated using items of interest to stockholders that give the stockholder an indication of how desirable the company is for investment.

Equivalent dividend return This is a theoretical evaluation of the return the investor would be receiving if the returns on the convertible bonds were thought of as dividends for each share that could be realized by conversion. It allows for comparison of the return on the bond and the current return on the common stock of the company.

Escalation Provision for an increase in the cost of equipment, material, labor, etc., over the costs specified in the contract, due to continuing price-level change over time.

EWF Engineering workforce.

Exercise price The price for which one share of common stock can be purchased through the exercise of warrants.

Exit Leaves the program.

Expected return The mathematically anticipated return of a project, obtained by multiplying each possible outcome by the associated probability of that outcome and summing all the resulting values.

Exponential smoothing A quantitative sales forecasting method in which past sales data and past sales forecasts are used to forecast sales.


Export Copies data from the current project into a format that can be read by another application, such as a spreadsheet program.

Extension A voluntary financial agreement whereby the repayment period for debt is extended.

F

Factored estimating Making estimates based on multiple factors. Equipment items are on-site as are completed costs, equipment schedules and plotting schedules from earlier projects. These numbers are then adjusted with multipliers from current equipment and man-hour costs. Factored estimating is a method of generating the cost of related items without designs. ICARUS’ systems are not based on factored estimating.

Fast tracking Overlapping of project activities normally executed in a consecutive manner.

Field costs Indirect costs of engineering and construction associated with the project’s field site rather than with the home office.

Field services An indirect cost including medical, first aid, transport, welder tests and welding supplies.

Field warehouse receipt Short-term financing instrument used with pledged inventories whereby the goods are transferred to a specified warehouse on the borrower’s property. The goods cannot be released without the lender’s authorization. This is done in cases when it is impractical to move the inventory.

Financial forecasting Projection of future revenues and costs.

Financial lease A lease that cannot be canceled until the lessee has paid an entire fixed amount of money over a specified period in order that the lessor gets back all


costs plus a reasonable return. It generally does not include repair and maintenance service.

Financial leverage The operationalization of financial risk that can be measured to show the influence of differing forms of financing on net income as operating income changes.

Financial ratios Ratios drawn between items from the balance sheet and income statements that provide indications of a company’s strengths and weaknesses.

Financial risk The risk inherent in using a particular form of funding for the asset base of a corporation.

Financial statements The financial records of a corporation some of which are used as internal controls and some of which are published for various external parties.

Financial structure The particular combination of common equity, preferred stock and short- and long-term liabilities maintained by a company.

Finish float The amount of excess time an activity has at its finish before a successor activity must start. This is the difference between the start date of the predecessor and the finish date of the current activity, using the early or late schedule. (Early and late dates are not mixed.) This may be referred to as slack time. All floats are calculated when a project has its schedule computed.

Finish-to-finish lag The minimum amount of time that must pass between the finish of one activity and the finish of its successor(s). If the predecessor’s finish is delayed, the successor activity may have to be slowed or halted to allow the specified time period to pass. All lags are calculated when a project has its schedule computed. Finish-to-finish lags are often used with start-to-start lags.

Finish-to-start lag The minimum amount of time that must pass between the finish of one activity and the start of its successor(s). The default finish-to-start lag is zero. If the predecessor’s finish is delayed, the successor activity’s start will have to be delayed. All lags are calculated when a project has its schedule computed. In most cases, finish-to-start lags are not used with other lag types.


Finishing activity The last activity that must be completed before a project can be considered finished. This activity is not a predecessor to any other activity — it has no successors.

Fixed costs Costs that do not vary over the production or sales range.

Flg. Flanged.

Float The amount of time that an activity can slip past its duration without delaying the rest of the project. The calculation depends on the float type (start float, finish float, positive float and negative float.) All float is calculated when a project has its schedule computed.

Floating lien A loan arrangement used when accounts receivable and inventories are used as collateral. With this there is a general loan against the accounts on the goods without any records being kept on specific ones.

Free float The excess time available before the start of the following activity, assuming that both activities start on their early start date. Free float can be thought of as the amount of time an activity can expand without affecting the following activity. If the current activity takes longer to complete than its projected duration and free float combined, the following activity will be unable to begin by its earliest start date.

Fringe benefits (FB) Contractual adders to the base labor rate: medical and pension plans, vacation, travel pay, holidays, etc.

Full loan amortization A type of loan amortization procedure under which periodic payments are made until all of the principal of the loan and all interest due are paid in full.

Funded debt Debt with a maturity of more than 1 year. It includes bonds, debentures, term loans and mortgages.


Funded debt to net working capital The leverage ratio, which gives an indication of the company’s ability to retire its debt by using its liquid assets = funded debt/NWC.

Funds forecast The projection of any additional financing that may be necessary to achieve and support projected sales.

G

G & A General and administrative costs. Includes head office (corporate) expenses, such as rental, heating and air conditioning (HVAC), maintenance, and allocated costs (e.g., accounting).

Gantt (bar) chart A graphic display of activity durations. It is also referred to as a bar chart. Activities are listed with other tabular information on the side with time intervals over the bars. Activity durations are shown in the form of horizontal bars.

GC General contractor.

General conditions A specific portion of the contract documents. They state the responsibilities and relationships of all parties to the contract, as well as any conditions applicable to the contract.

GMP Guaranteed maximum price.

Go Back For Aspen Capital Cost Estimator, retraces your steps one level.

Grassroots Constructing an entirely new facility from pre-basic, through basic, through detailed engineering through construction on an undeveloped site.


H

Hammocks A hammock groups activities, milestones, or other hammocks for reporting. Most project management software calculates the duration of a hammock from the early and late dates of the activities to which they are linked.

Hedging approach In the hedging approach to working capital financing, the portion of current assets that fluctuates is financed with current liabilities, and the portion that is in effect fixed is financed through permanent financing.

Help In Aspen Capital Cost Estimator, accesses the online help system.

Histogram A graphic display of resource usage over a period of time. It allows the detection of overused or under-used resources. The resource usage is displayed in bars.

Historical average cost of capital The cost associated with the company’s existing financing.

Historical cost estimating Using old specifications and estimates from similar, earlier and already built projects, and then adding some form of index to these past numbers to determine costs for a current project.

Host For Aspen Capital Cost Estimator (on a UNIX workstation), the computer that is in charge of the operation of a group of computers linked in a network.

HP Horsepower.

HVAC Heating, ventilating and air conditioning.


I

Aspen Process Economic Analyzer (IPE) ICARUS’ powerful PC-based software package designed for the automatic preparation of detailed process facility designs, estimates and engineering and construction schedules from your process simulation results.

Aspen In-Plant Cost Estimator (IPM) ICARUS’ easy-to-use, fully-integrated, PC-based design, estimating, scheduling, cost tracking and reporting system for in-plant and mill projects.

Icon A graphical representation of an application or document.

Import For Aspen Capital Cost Estimator, copies specified information from an existing project into the current project.

Income bonds A debt instrument that requires interest payments only when the corporation has positive earnings. It is often used for reorganizations.

Income statement A record of a company’s recorded earnings and expenses for a given time period.

Incremental average cost of capital The cost associated with using or generating new funds.

Indenture See Bond indenture.

Indirect costs All costs that do not become a final part of the installation. Indirect costs are temporary construction costs and contractor overheads, burdens, fees, project freight, design engineering, project management, taxes, insurance, cleanup and contingency.

Industry forecast Projection of revenue and cost trends for a particular industry.


Industry ratios Ratios generated for an entire industry by calculating the ratios for each corporation in that industry.

Inflation An economic situation in which the costs of goods and services increase and the relative worth of a given amount of money decreases.

Info For Aspen Capital Cost Estimator, lists information about the current backup or retrieval.

Input-output model A causal sales forecasting method in which interindustry transactions are used to set up a purchaser-seller matrix, which in turn is used to establish sales trends.

Installation bulks Items that are directly associated with the component being defined and that are used to complete the installation of the item. Refer to the user’s guide for details on the twelve types of installation bulks summarized below:

1 Material/man-hour% adjustment - specifies percentage adjustments to system developed material costs and man-hours.

2 Material/man-hour additions - adds lump sum material costs and/or man-hours to a specified code of account.

3 Piping - General Specs - defines the rules for developing all of the component’s installation piping, which carry liquids, gasses and/or solids between successive equipment items in the process stream.

4 Piping - Detail Items - specifies individual runs of piping and associated fittings, tracing, paint and insulation.

5 Duct - for applicable components, specifies individual runs of ducting and associated fittings and insulation. Up to five duct lines may be specified for each component.

6 Civil - specifies additional bulk excavation and up to three different foundation types/sizes. Includes the excavation, erection of formwork, installation of reinforcing steel and pouring of concrete for foundations to support equipment.

7 Steel - specifies ladders, stairs, platforms, and up to three different steel items (e.g., structural elements such as the pipe rack and open steel structures).

8 Instrumentation - specifies individual instrumentation loops (or parts of loops) with associated sensors, transmitters and signal cabling. Up to 50 loops may be defined for each component.

9 Electrical - specifies local equipment wiring and up to three different types of loads. Electrical equipment and cable carries power from a main plant


substation to a unit area substation and, in turn, to each equipment item requiring electricity.

10 Insulation - specifies insulation and fireproofing for component and installation bulk steel. For components, the insulation type, jacket type, thickness, and area can be specified. For component and steel fireproofing, type, rating and area can be specified.

11 Paint - specifies paint preparation and painting of component and installation bulk steel.

12 Nozzel - for applicable components, replaces the system-standard nozzle schedule for vessels and towers. Up to 12 sets of nozzles may be specified, including diameter, quantity, and location (e.g., shell or jacket).

Intermediate term loan A loan that is repaid within 1 to 10 years. These loans are usually acquired through banks, insurance companies and pension funds.

Internal rate of return (IRR) A discounted cash flow capital budgeting technique. The internal rate of return is that discount rate which equates the present value of future cash inflows with the initial investment. It is calculated using a trial and error procedure.

Intrinsic value The underlying “true” value of a company as determined by its management of assets and liabilities and by the risks taken on, and the returns given its shareholders. It is also in part determined by the individual investor’s attitudes toward risk and return. For an actively traded stock, given sufficient information availability, the intrinsic value is equal to the market value.

Inventory holding costs The inventory costs that arise from the fact of actually having the inventory. Included in the holding costs are costs of storing, handling, insuring and auditing the inventory, and also the costs of taxes, obsolescence, theft, physical damage and capital investment.

Inventory reorder costs The inventory costs incurred when inventory stocks must be replaced. These include the costs of processing, telephoning, typing and receiving orders and mailing and stationery and invoice costs.

Inventory shortage costs The inventory costs incurred when a company runs out of inventory. Included in this are the costs of lost sales, ill will and special orders.


Inventory turnover An efficiency ratio. A measure of how many times the inventory is “sold” or “turned over” in a sales period = net sales/inventory. It indicates how well the size of the inventory has been managed.

ISO (Isometric drawing) A very detailed piping and engineering drawing which includes very specific equipment items like valves, fittings, elbows, nuts and bolts, etc. Can also refer to three-dimensional computer drawings which display this piping and engineering detail as it will appear when fully constructed.

Issued stock The common stock of a corporation that has actually been sold to an investor.

Item In Aspen Capital Cost Estimator, a capsule-shaped element of a tree diagram representing project specifications.

Item run The process of having Aspen Capital Cost Estimator prepare a design and estimate at the component level for all or selected components in a project.

J

JIS Japanese Industrial Standard.

Jury of executive opinion method for forecasting A qualitative method of sales of forecasting in which a group of executives estimate sales and then have these estimates averaged to give the forecast.

K

KV Kilovolts


KVA Kilovolts-amperes

KW Kilowatts

L

Labor burden Taxes and insurance costs based on labor payroll that the employer is legally required to pay on behalf of or for the benefits of laborers. (In the U.S., these include federal old age benefits, federal unemployment insurance tax, state unemployment tax and workers’ compensation.)

Labor cost The base salary, plus all fringe benefit costs and labor burdens associated with labor, that can be definitely assigned to one item of work, product, area or account.

Lag The time delay between the start or finish of an activity and the start or finish of its successor(s).

Lagging indicator An economic indicator the changes in which follow the changes in the general economy during a known period of time.

Late finish The latest dates by which an activity can finish to avoid causing delays in

a project.

Late start The latest dates by which an activity can start to avoid causing delays in a project.

Leading indicator An economic indicator the changes in which precede concomitant changes in the general economy in a known amount of time.


Lease A legal contract whereby a lessee is able to obtain the use of certain assets without having to actually purchase these assets. The assets remain the property of a lessor who receives a series of payments for the use of the assets.

Lease capitalization The evaluation of a lease arrangement that uses the present value of future lease payments as the value for lease obligations to be shown as liabilities and an equal value to be shown as net leased assets on the balance sheet of the lessee. This is done by capitalizing the lease payments at an appropriate lease capitalization rate. If this rate is applied to the lease payments after the first payment is made, it results in a net capitalized value. If it is done before the first payment is made, a gross capitalized value results.

Lease capitalization rate See Capitalization rate for leases.

Leverage The amount of debt financing used by a corporation. A general measure is the ratio of total debts to total assets.

Leverage ratios The ratios generated using items dealing with the company’s indebtedness, which monitor the company’s ability to meet its financial obligations.

Library A set of user-defined specifications that may be added into a project when requested.

Lien A legally recognized pledge against specific physical property.

Line of credit An arrangement between a bank and a client company that allows the client to borrow up to a maximum amount of cash at its own discretion within a set amount of time. Designed to get the company through periods of short-term seasonal needs, a line of credit also allows the company the flexibility of determining the timing and size of amounts outstanding at any one time. The account generally must be paid up each year.

Link For Aspen Capital Cost Estimator, a connection between an item in one tree diagram with an item in another tree diagram.


Liquidation value The residual proceeds from selling off the company’s assets and paying off the company’s liabilities.

Liquidity The nearness of a certain asset to cash, the ease with which it can be converted into cash and the amount of cash realized at conversion.

Liquidity ratios The ratios using current assets and current liabilities that measure a company’s ability to pay its short-term liabilities.

LJ Lap joint.

Loaded labor rate Base labor plus PAC's, fringe benefits and other subcontractors costs, including overhead and project.

Loan amortization The procedure of paying off a loan by making a series of equal payments at regular intervals. These payments include both interest and principal repayment.

Lock-box system A method of improving funds collections, based upon having funds mailed to post office boxes. These funds are then collected several times a day by representatives of the company’s local banks and deposited into the banks. The company’s market is divided into regions and the post offices and banks are chosen for each region.

Log For Aspen Capital Cost Estimator, lists prior backups for selecting files to retrieve.

M

Main substation A substation which feeds power at the distribution voltage to either a unit substation or directly to a motor driven at the distribution voltage.


Maintenance lease A type of financial lease under which the lessor pays maintenance and insurance costs.

Making a market The act of maintaining an inventory of unlisted stocks and selling them as orders for them are received.

Marginal average cost of capital The weighted average cost associated with raising the last dollar of a hypothetical new budget.

Marginal cost of capital The minimum rate of return expected by the company’s suppliers of capital.

Mark text For Aspen Capital Cost Estimator, to select text by dragging the mouse pointer over the selected text while holding down the left mouse button.

Mark-up As variously used in construction estimating, such percentage applications as general overhead, profit, and other indirect costs. When mark-up is applied to the bottom of a bid sheet for a particular item, system or other construction price, any or all of the above items (or more) may be included, depending on local practice.

Market extension merger A horizontal merger by which the geographical market of the merging companies is extended.

Market value The value established in the market place by supply and demand and market transactions.

Maturity value of a bond The value of a bond if held until the maturity date and then redeemed. It is usually the same as the face value and remains constant over the life of the bond.

MCC Motor control center.


MCC equipped space Motor control center equipment, i.e., cabinetry and back-plane wiring, exclusive of starter gear; unfilled MCC space available for rearrangement or expansions.

Mechanical engineering Primarily concerned with the function, use, design and fabrication of equipment. The designing, testing, building and operating of machinery are also of importance. Mechanical engineering focuses on two areas: machinery and thermodynamics (heat and energy management based on laws of conversion of matter and energy).

Micro-scheduling The scheduling of activities with durations less than one day (in hours or fractional days.)

Milestones An activity with zero duration (usually marking the end of a period.)

Minimum market value For a convertible bond at any given point in time, this is the higher of the pure bond value or the conversion value.

Miscellaneous indirect costs Job cleanup costs, watchmen, equipment servicing (insurance and safety), public liability, damage, automobile and all-risk insurance, warehousing and nonproductive field labor.

Mobilization/Demobilization An indirect cost including transportation cost of equipment, offices, etc. to and from the construction site.

Mortgage bond A bond that is backed by the pledge of specific assets of the company. If the company is liquidated, proceeds from the liquidation of these assets are used to satisfy these bondholders’ claims. They are considered the most secure type of bond although they do not guarantee perfect safety. They can be either senior or junior mortgage bonds, the senior having priority over all other creditors of the company, the junior coming next.

Mouse A device connected to the computer, that when moved, moves the cursor on the monitor screen. In addition, the buttons on the mouse enable the user to select text and objects.


Moving averages A quantitative sales forecasting method in which an arithmetic average over some predetermined number of sales periods is used to determine trends.

MPS Master project schedule.

Multi-project analysis Used to analyze the impact and interaction of activities and resources whose progress affects the progress of a group of projects or for projects with shared resources or both. Multi-project analysis can also be used for composite reporting on projects having no dependencies or resources in common.

N

Negative float Indicates activities must start before their predecessors finish in order to meet a target finish date. All float is calculated when a project has its schedule computed. Negative float occurs when the difference between the late dates and the early dates (start or finish) or any activity are negative. In this situation, the late dates are earlier then the early dates. This can happen when constraints (activity target dates or a project target finish date) are added to a project.

Negatively correlated projects Projects whose net cash flow patterns are inversely related.

NEMA National Electrical Manufacturing Association.

Net cash flows The difference between cash inflows and outflows.

Net present value (NPV) A discounted cash flow capital budgeting technique: NPV is the difference between the present value of the future net cash flows of a project and the initial investment.


Net working capital (NWC) The difference between current assets and current liabilities: CA - CL = NWC. It can be thought of as the company’s “conscious commitment in CA to generate sales.”

Net working capital turnover An efficiency ratio. A measure of how well management generates sales utilizing current assets = net sales/net working capital.

Net worth Total stockholders’ equity or total assets minus total liabilities.

Net worth turnover An efficiency ratio. A measure of how well management utilizes stockholders’ equity to generate sales = net sales/net worth.

Network A group of computers connected together.

Network analysis The process of identifying early and late start and finish dates for project activities.

Network diagram A graphic representation of activity sequence and relationships. Activity boxes are connected together with one-way arrow to indicate precedence. The first activity is placed on the left side of the diagram with the last activity on the right side. Activity boxes are usually placed at different levels (not in a single row) to accommodate activities that are done simultaneously.

O

Offsets Items located external to the facility battery limits, including cooling towers and boilers.

OH Overhead.


OK For Aspen Capital Cost Estimator, specifies that you wish to continue with the current activity.

Open-end mortgage bond A mortgage bond issue that does not limit the ability of the company to sell additional senior mortgage bonds by pledging the same assets.

Operating lease Also called service lease — a lease that allows the lessee to terminate the lease at his convenience. The payments under an operating lease usually include service and maintenance charges.

Operating leverage A measure of the effect of changes in sales level on changes in earnings before interest and taxes. The magnitude of the effect is determined by the portion of sales revenue that has to be used to cover fixed costs.

Operational unit area Any physical or geographical area of the facility, either inside or external to the battery limits.

Opportunity cost The cost incurred by foregoing the opportunity to take advantage of the next best alternative.

Option menu Within a dialog box or entry form, a listing of all allowable entries/options.

Order of magnitude: -30 to +50 percent estimate (as defined by AACE) This type of estimate is made without any detailed engineering data. The estimate is often developed using cost-capacity curves, scale-up or -down factors or ratio estimating techniques.

Organizational goal The aim or end product that the corporation as a whole works to achieve. All of the decisions made within the corporation should be made in terms of this aim.

Organized exchange An organized capital market complete with physical facilities, governing boards and membership regulations and requirements.


Orifice union Special set of flanges designed to hold an orifice plate.

Origin The identity of a direct cost component (such as a pump), consisting of a 3-character symbol and a number from 100 to 999 (e.g., CP 100 for Centrifugal Pump numbered 100). This identity is also used to label all installation bulks attached to the pump.

OSHA U.S. Occupational Safety and Heath Administration.

OT Overtime.

Overhead A cost or expense inherent in performing an operation, i.e., engineering, construction, operating, or manufacturing, that cannot be charged to or identified with a part of the work, product, or asset and which, therefore, must either be allocated on some arbitrary basis believed to be equitable, or handled as a business expense independent of the volume of production.

P

P&ID Piping and instrumentation diagram. Basics of detailed engineering. P&IDs are detailed drawings of a specific process to be built. P&IDs do not list specific items, such as inessential valves, fittings and elbows.

PAC's Payroll added costs: Social Security, workers' compensation, insurance, federal and state taxes.

Paid-in capital See Paid-in surplus.

Paid-in surplus Also called paid-in capital, excess over par, and capital in excess of par — the difference between the par value of a share of stock and the amount the company realized on the initial issue of that share.


Par value An arbitrary value assigned to each share of common stock. It is used for accounting purposes only and has no influence on either the issue price or the market price of a share of stock.

Parallel activities Two or more activities that can be done at the same time. This allows a project to be completed faster than if the activities were arranged serially in a straight line.

Path A series of connected activities. Refer to Critical path for information on critical and non-critical paths.

Payback method (PM) A non-discounted capital budgeting technique. This method calculates the length of time necessary to recover initial investment. Most calculations of payback assume that the cash inflows occur uniformly.

PC Any personal computer (such as an IBM PC or compatible) using MS-DOS, OS/2, Windows, Windows for Workgroups, Windows 95, Windows NT Workstation, or Windows NT Server operating systems.

Percent-of-sales method for forecasting A funds forecasting method in which it is assumed that a change in sales will require a determined change in the assets of the company, which in turn need to be funded in some way.

Perpetual bond A bond with no maturity date.

Perpetual warrants Warrants with no expiration date.

PFD Process flow diagram. Process configuration with heat and material balances.

Phase 0 Preliminary process design.


Phase I Firm process design.

Phase II Detailed engineering design, procurement and project control.

Plant bulk An item (piping, civil, steel, instrumentation, electrical, insulation and/or paint) which is needed to properly install a project component or operate a facility

Plant start-up Includes man-hours spent by the contractor’s discipline representatives (specialists, foremen, superintendents, etc.), after mechanical completion of the project, to perform the following tasks:

1 Support the testing and calibration of field instruments, electrical measuring devices, etc.

2 Assist the owner with starting the plant and address any technical issues.

3 Consult with the owner on adjustments during the commissioning process.

Items not included in this contractor cost are such things as conferring with the DCS vendor, developing control software, temporary utilities (e.g., more steam required for start-up than thereafter), initial catalyst charges, changes to the project scope or exchanging items, and any of the owner’s calibration or commissioning staff.

PLC Programmed logic controller.

Plot plan A geographic (sky-view) plan for a future site. This is sometimes called “dimensioning.”

PM/PE Project manager/engineer.

PO Purchase order.

Portfolio effect The reduction in portfolio risk realized by diversification into negatively correlated projects.


Portfolio risk The total risk incurred by holding a portfolio of assets.

Positive float The amount of time that an activity’s start can be delayed without affecting the project completion date. An activity with positive float is not on the critical path and is called a non-critical activity.

Power factor The ratio of KW/KVA for an electrical system.

Precautionary motive A motive for holding cash reserves that stems from management’s desire to be able to handle any extraordinary and unexpected cash outflows.

Precedence notation A means of describing project work flow. It is sometimes called activity-on-node notation. Each activity is assigned a unique identifier. Work flow direction is indicated by showing each of the activity’s predecessors and their lag relationships. Graphically, precedence networks are represented by using descriptive boxes and connecting arrows to denote the flow of work.

Predecessor An activity that must be completed (or partially completed) before a specified activity can begin. The combination of all predecessors and successors relationships among the project activities forms a network. This network can be analyzed to determine the critical path and other project scheduling implications.

Preferred stock A type of equity that has certain priorities over common stock. It is generally characterized by fixed dividend payments, which are payable before common stock

dividends and claims on the liquidation value of the company that are subordinate to all creditor claims but prior to common stockholder claims.

Preprocessor A set of one or more ICUE commands stored in a file which can be opened, edited, saved and run. Preprocessors are helpful when you access the estimate results database and run the same ICUE commands.

Present value The mechanism whereby future costs and benefits can be made comparable to present costs and benefits.


Price The amount of money asked or given for a product. The chief function of price is to ration the existing supply among prospective buyers. Price incorporates direct and indirect costs, general overhead, profit and contingency.

Primary KV Voltage in KV of the incoming power to a substation.

Primary market That segment of the capital market which deals with new issues of securities and the movement of funds from investors to issuing companies.

Prime rate The lowest interest rate applicable to business loans.

Privilege level For Windows NT, one of three settings (User, Administrator, or Guest) assigned to each user account. The privilege level a user account has determines the actions that the user can perform on the network.

Pro forma financial statements Projections of possible future statements developed by taking existing statements and changing them according to the effects of assumed financial transactions. This is most often done with income statements, balance sheets and funds statements.

Process engineering Performing and determining process needs prior to Basic engineering and Detailed engineering. Process engineering, usually performed by chemical engineers, includes defining process streams using the data from process simulators.

Process equipment Equipment for handling liquids, gasses and solids.

Process fluid A gas or liquid raw material, intermediate project or chemical (e.g., a solvent) used in the manufacture of the product.

Product extension A horizontal merger by which the product line of the merger companies is extended.


Productivity A relative measure of labor efficiency, either good or bad, when compared to an established base or norm as determined from an area of great experience. Alternatively, productivity is defined as the reciprocal of the labor factor.

Profit margin A profitability ratio. A measure of how well management has controlled costs while successfully marketing the company’s products = net profits/net sales. It shows how many cents of profit are realized out of each sales dollar.

Profitability The ability of a corporation to show a surplus of income over expenses in a particular sales period. This is usually measured in dollars of total profit to sales for the period.

Profitability ratios Ratios that measure how effective management has been in generating a return utilizing the assets of the company.

Program evaluation and review technique (PERT) A project management technique for determining how much time a project needs before it completed. Each activity is assigned a best, worst and most probable completion time estimate. These estimates are used to determine the average completion time. The average times are used to figure the critical path and the standard deviation of completion times for the entire project.

Project A collection of general specifications and component design specifications which describe a facility for an ICARUS system to designate/estimate.

Project database The design and cost information stored in multiple SQL files for a specific project.

Project estimate The process of designing and costing the direct cost components and the indirect costs in the project scope and creating database files.

Project manager In owner/operator plants, someone who is responsible for design decisions and reviewing processes, their viability and sometimes their completion. In contractor companies, someone who is responsible for detailed design decisions (integrating PFD, P&ID and ISO specifications) to complete a project’s construction.


Project run The process of having an ICARUS system prepare a design and estimate at the project level for the entire project.

Promissory note An IOU that establishes tangible proof of debt.

Proxy An arrangement that allows common stockholders of a corporation to assign their voting rights over to someone else for one particular stockholders’ meeting.

Q

QA/QC Quality assurance and control.

Queue For Aspen Capital Cost Estimator, lists active print jobs.

Quick ratio The liquidity ratio. Ratio of total current assets less inventories to total current liabilities = (CA - Inv)/CL. Also called the acid-test ratio.

Quit For Aspen Capital Cost Estimator, terminates an activity.

R

Rapid growth stocks Stocks for which the dividends are expected to grow at a rapid rate for a few years and then level to a normal, constant growth rate.

Recession A situation in which the economy of a given area worsens.


Red herring A preliminary prospectus on a new securities issue sent out by the underwriters. It includes a history of the company, the intended use of the funds, up-to-date certified financial statements and a statement on risks. It is used to provide information, generate interest and help set the final selling price of the new securities.

Refit Changing an existing facility by adding something left out, overhauling worn out components or adding or subtracting from the current capacities of existing components.

Registered bond A bond that belongs to a specific investor whose name is recorded with the company. This bondholder receives interest payments automatically.

Regression analysis A causal sales forecasting method in which sales are defined as a function of a number of independent variables. Changes in these independent variables are then used to determine a model that will forecast future sales levels. Regression analysis can also be used to forecast the need for funding.

Remote Shop Fab Contains vendor costs for labor, overhead and profit, which is typically reported from the vendor in weight.

Remote Shop Mat Contains material cost (excluding freight, taxes, and duties, which should be specified as project indirects).

Reorganization Under bankruptcy proceedings, this is the formal restructuring of the debtor company’s financial structure. It involves discharging the debt, making managerial and operational changes and acquiring new working capital.

Rescheduling Recalculating the start and finish dates of all uncompleted activities based on progress as of a specified date.

Residual assets Any assets that remain after assets have been liquidated to pay off creditors.


Residual theory of dividends A dividend policy which maintains that retained earnings should first be applied to any financing needs of the corporation. Any retained earnings not needed internally can be paid out as dividends.

Resource Anything that is assigned to an activity or needed to complete an activity. This may include equipment, people, buildings, etc.

Resource based duration Provides the option to determine activity duration, remaining duration and percent complete through resource usage. The resource requiring the greatest time to complete the specified amount of work on the activity determines its duration.

Resource leveling Provides the capability to adjust project schedules to minimize the peaks in daily resource usages. This is usually done when resources are over-allocated. Activities are moved within their available float to produce a new schedule. Resources and projects may have leveling priorities. Some activities may not have any rescheduling flexibility due to lack of float. Either resource-constrained or schedule-constrained leveling may be selected.

Retrofit See Refit.

Return on net worth A profitability ratio. A measure of the amount of profit realized through the use of the company’s equity, which represents a return to stockholders = net profits/net worth.

Return on net working capital A profitability ratio. A measure of the amount of profit realized through the use of the company’s current assets = net profit/NWC.

Return on total assets A profitability ratio. A measure of the amount of profit realized through the utilization of the company’s assets = net profit/total assets.

Revamp See Refit.


Revolving credit A credit arrangement between a bank and a client in which the bank makes a formal, legally binding commitment to extend credit to the client up to a specified limit. It incurs a commitment fee in addition to the interest. Quite often it extends for more than 1 year.

Rights offering The method whereby stockholders who have the preemptive right are offered the opportunity to maintain their proportionate share when new stock is being issued.

Risk averter A person who possesses very little utility for high risk undertakings.

Risk neutral The state of having utility only for the expected return of a project.

Risk-adjusted discount rate A discount rate that includes a premium to allow for the risk associated with the net cash flows to be analyzed.

Risk-free interest rate The return offered by investments that have no risk in them. This rate is usually established by the rate of return offered by U.S. Treasury debt instruments.

Risk-seeker A person who has very high utility for high risk projects.

ROG A credit term that means “receipt of goods” and indicates that the credit period does not begin until the day the goods are received.

Run For Aspen Capital Cost Estimator, produces the selected estimate type.


S

Safety stock A quantity of inventory above the amount determined by using an EOQ model, which will handle unanticipated demand. These levels are dependent upon lead time to delivery, the probability distribution of demand and customer service policies.

Sale and leaseback A type of financial lease whereby a company sells an asset to a second company, which in turn leases the asset back to the first company. These assets can be either old or new. They must be sold near their appraised market value and the lease must be fully amortized. The only real difference between a sale and leaseback arrangement and a financial lease is that the former usually involves assets the company is already using and the latter usually involves assets new to the company.

Sale of assets A business combination whereby one company purchases the assets of another. The buying company may also assume some or all of the liabilities of the other company.

Sales force composite method for forecasting A Sales forecast The projection of estimated sales for a specific period for a particular company, which serves as the basis for other forecasts made by the company and for many of its decisions.

Salvage value The expected value of an asset at the end of its usable life for the company. The difference between an asset’s cost and its salvage value is the amount to be depreciated over the asset’s usable life.

SC Subcontract/subcontractor.

Scan The process of checking the project scope for feasibility of design.

Scheduling The process of determining when project activities will take place depending on defined durations and precedent activities. Schedule constraints specify when an activity should start or end based on duration, predecessors, external predecessor relationships, resource availability or target dates.


Scope The equipment and materials to be provided, and the work to be performed. Scope is documented by the contract parameters for a project to which the company is committed.

Seasonal dating A credit arrangement that extends the credit period for certain seasonal goods into their selling season.

Secondary markets That segment of the capital markets that deals with existing securities and the transactions that occur between investors.

Security A means of ensuring that shared files can be accessed only by authorized users.

Select For Aspen Capital Cost Estimator, to highlight an item by clicking it with the mouse or using key combinations. Selecting does not initiate an action.

Selling group A group of brokerage houses and dealers who sell the new securities to investors.

Semi variable costs Costs that have both fixed and variable components.

Sensitivity analysis in cash budgeting The systematic change of certain assumptions underlying the cash budget in order to study the effects of these changes and to anticipate and control any real life situations involving these assumptions.

Sequence The order in which activities occur with respect to one another. This establishes the priority and dependencies between activities. Successor and predecessor relationships are developed in a network format. This allows those involved in the project to visualize the work flow.


Sinking fund A bond indenture provision that requires the company to make periodic payments to the trustee. This fund is to be used to retire portions of the bond issue, either by buying the bonds off the market or calling and retiring portions of it by lottery.

Site development Includes those actions that must be taken to convert a prospective facility site into a reasonably flat plant area, free of major obstructions, and with provisions for water drainage, fencing, paving and rail spurs.

Slippage The amount of slack or float time used by the current activity due to a delayed start. If an activity without float is delayed, the entire project will slip.

Source of funds The inflows of funds from operations, decreases in assets and increases in liabilities and net worth accounts.

Sources and use of funds statement A financial statement that traces the flow of funds through the income, assets and liabilities of a company.

Special reports Customized reports created by the ICUE Reporter.

Speculative motive for holding cash A motive for holding cash reserves that stems from management’s desire to take advantage of any unexpected opportunities.

SQL Structured query language, a database sub language for querying, updating, and managing relational databases. The basic structure of the relational model is a table, consisting of rows and columns. Data definition includes declaring the name of each table to be included in a database, the name and data types of all columns of each table, constraints on the values in and among columns, and the granting of table manipulation privileges to prospective users. Tables can be accessed by inserting new rows, deleting or updating existing rows, or selecting rows that satisfy a given search condition for output.

SS Stainless steel.


Stable dollar dividend policy A dividend policy adopted by a company to pay out a fixed dollar amount of dividend per share annually.

Stable payout ratio policy A dividend policy used by a company that would result in the dollar amount of the dividend per share changing from year to year to conform to an established ratio of earnings per share and dividends per share. This policy is used by companies with fluctuating earnings.

Standard basis A previously defined project which is copied to provide the starting point for a new project.

Start float The amount of excess time an activity has between its early start and late start dates.

Start-to-start lag The minimum amount of time that must pass between the start of one activity and the start of its successor(s).

Starting activity A starting activity has no predecessors. It does not have to wait for any other activity to start.

Statutory consolidation A merger in which both merging companies cease to exist as separate companies and a brand new company is formed. Shares of the old companies are exchanged for shares of the new. The new company assumes all the assets or liabilities of the old companies.

Statutory merger A merger in which one of the partners is completely taken over and ceases to exist as a separate business. There is a tax-free exchange of shares. All of the assets and liabilities of the acquired company are assumed by the surviving company.

Stock dividend The payment of dividends in stock. This increases the number of shares outstanding, leaves unchanged the par value of the stock and capitalizes part of the retained earnings.


Stock markets Stock markets such as the New York Stock Exchange, the American Stock Exchange and the Midwest Stock Exchange are examples of organized exchanges where corporate securities are traded.

Stock right A subscription option that exists with each share of existing stock during a rights offering. It has a value during the rights offering but is worthless thereafter. The existing stockholder can choose to exercise the right, sell it or allow it to expire.

Stock split A stock dividend that results in an increase of 25 percent or more in the number of shares of stock outstanding. The par value of the stock is adjusted to account for this increase in number. Retained earnings do not change.

Stockholders’ equity See Total stockholders’ equity.

Straight run equivalent pipe A shortcut method to approximate the material plus labor cost of insulating pipe valves and fittings. The SREL is the length of like type, diameter and thickness straight run pipe insulation which has an "equivalent" cost.

Straight run pipe Pipe with no fittings/valves; just the straight pipe (no bends or turns).

Structured query language (SQL) A database sub language for querying, updating, and managing relational databases. The basic structure of the relational model is a table, consisting of rows and columns. Data definition includes declaring the name of each table to be included in a database, the name and data types of all columns of each table, constraints on the values in and among columns, and the granting of table manipulation privileges to prospective users. Tables can be accessed by inserting new rows, deleting or updating existing rows, or selecting rows that satisfy a given search condition for output.

Sub-critical activity A sub-critical activity has a float threshold value assigned to it by the project manager. When the activity reaches its float threshold, it is identified as being critical. Since this type of criticality is artificial, it normally does not impact the project’s end date.


Subordinated debenture A bond whose holders’ claims are subordinate or lower than the claims of all other creditors. They tend to have rather high interest rates.

Subproject A distinct group of activities that comprise their own project which in turn is a part of a larger project. Subprojects can be summarized into a single activity to hide the detail.

Subscription price The price at which a new share of common stock can be purchased at issue.

Successor An activity whose start or finish depends on the start or finish of a predecessor activity.

Summary funds statement A sources-and-use-of-funds statement that combines certain accounts into broad categories.

Super-critical activity An activity that is behind schedule is considered to be super-critical. It has been delayed to a point where its float is calculated to be a negative value. The negative float is representative of the number of units an activity is behind schedule.

SW Socket weld.

T

T-T Tangent to tangent. Straight-side dimension of vessels, columns and reactors.

Take-off Detailed quantity count of work components: cubic yards, tons, feet, etc.

Target finish — activity The user’s imposed finish date for an activity. A target finish date is used if there are pre-defined commitment dates.


Target finish — project A user’s target finish date can be imposed on a project as a whole. A target finish date is used if there is a pre-defined completion date.

Target start — activity An imposed starting date on an activity.

Technical insolvency A financial state in which a company cannot pay its due and payable financial obligations.

TEFC Totally enclosed fan cooled. Term applied to electrical motors.

TEMA Tubular Exchanger Manufacturing Association.

TEWAC Totally Enclosed Water Cooled.

Temporary construction An indirect cost including temporary shelter and sanitary facilities, utilities, temporary power, roadways, rigging and fencing.

Tender offer An offer made by one company directly to the stockholders of another to purchase the shares of the second company. This is a method used in a takeover of a company. It is usually done without the consent of the management of the second company.

Terminal warehouse receipt Short-term financing instrument used with pledged inventories by which the goods are transferred to a public warehouse and released only by authorization of the lender. It is used when there is concern that the borrower might liquidate the inventory without paying.

TEWAC Totally enclosed water cooled.

Text string A set of one or more characters, including letters, numbers, symbols and blank spaces.


Time value of money The concept that the value of an amount of money changes over time. It assumes that money now is preferable to the same amount later and implies that $1 received today is worth more than $1 received later.

Times interest earned A leverage ratio. The ratio of operating income to interest expense = OI/interest. This measures the ability of the company to meet interest payments with funds generated from operations.

Total assets turnover An efficiency ratio. A measure of how well management uses the assets of the company to generate sales = net sales/TA.

Total debt to total assets ratio A leverage ratio. This gives an indication of the amount of debt used to finance each dollar of total assets = TD/TA.

Total float The excess time available for an activity to be expanded or delayed without affecting the rest of the project — assuming it begins at its earliest time.

Total stockholders’ equity Also called total net worth — the sum of common stock, paid-in surplus and retained earnings less treasury stock.

Trade acceptance A formal acknowledgment of debt that is initiated by the seller of the goods and accepted by the buyer in order to permit shipment of the desired goods.

Trade credit Also called accounts payable. A short-term financing source realized by assuming a liability by buying goods on credit. Three types of trade credit arrangements are open accounts, notes payable and trade acceptances.

Transaction loans A short-term, 30 - 90 days, credit arrangement that allows a bank client to borrow money for some special purpose.

Transactional motive for holding cash A motive for holding cash that stems from management’s desire to meet operating requirements.


Treasury stock The authorized and issued stock of a corporation that the corporation itself has repurchased off the market. This stock is no longer outstanding.

Tree diagram Branched graphical representation of specifications for contractors, contractor scopes, power distribution, process control and areas.

Trend projection A quantitative sales forecasting method in which sales trends are estimated through the analysis of data that have been systematically gathered for some period of time.

Trust receipt A short-term financing instrument used in inventory pledging in which the borrower acknowledges it holds merchandise in trust for the lender. It is used when the goods are more easily held by the borrower and when they can be identified by serial number.

Trustee The overseer of a bond issue who protects the interests of the bondholders. It is usually a bank or some other responsible financial institution.

U

Underwriting syndicate A temporary alliance of investment brokers who jointly underwrite a particular new issue.

Unit cost database An electronic, computer-based version of the once encyclopedic versions of lists of process equipment items and their associated unit costs. Mean’s and Richardson’s and other book versions have been transferred to computer databases. Unit cost databases are used for definitive (detailed) engineering and estimating.

Unit substation A substation which feed power at a voltage less than the distribution voltage (a) electrical equipment such as motors and lights within the process facility or (b) another unit substation for further transformation to a lower utilization voltage. Thus for (b), the subordinate unit substation would draw power from the serving principle unit substation.


Unsecured loan A loan for which the bank requires no collateral.

Uses of funds The outflow of funds used for increases in assets and decreases in liabilities and net worth accounts.

V

Value The perceived utility or satisfaction inherent in a product or service.

Value engineering A practice function that is targeted at the design itself. The objective of value engineering is to develop or design a facility or item that will yield the least life cycle costs or provide the greatest value while satisfying all performance and other criteria established for it.

Variable cash budget A series of budgets developed at various levels of production or sales that allows for immediate reaction to any shifts.

Variable costs The costs that change directly with changes in production or sales levels.

Variable payment sinking fund A sinking fund arrangement that requires payments only when the company’s earnings are high enough. This arrangement minimizes the possibility of default due to a missed payment.

Vendor representatives An indirect cost including travel, sustenances and average rates for vendor field representatives, e.g., a compressor specialist.

Vertical merger A merger that involves two companies in the same business at different manufacturing and distribution levels.


W

Wage rate The wage paid to a specific discipline.

Weighted cost of capital Also called average cost of capital. Calculation of the cost of capital that takes into account the proportionate weights of each component utilized.

Windows NT workstation The portable, secure 32-bit preemptive multitasking member of Microsoft Windows operating system family.

Work breakdown structure (WBS) A tool for defining the hierarchical breakdown of responsibilities and work in a project. It is developed by identifying the highest level of work in the project. These major categories are broken down into smaller components. The subdivision continues until the lowest required level of detail is established. These end units of the WBS become activities in a project. Once implemented, the WBS facilitates summary reporting at a variety of levels.

Work flow The relationship of the activities in a project from start to finish. Work flow takes into consideration all types of activity relationships.

Work load The amount of work units assigned to a resource over a period of time.

Work unit Standard unit established to value all work components in a rational and consistent manner. (The measurement of resources.) For example, people as a resource can be measured by the number of hours they work.

Working capital Current assets such as cash, marketable securities, accounts receivable and inventories. Working capital has a life of less than 1 year.

Working capital management Managerial decisions on the amount of capital to be invested in various current assets and how this investment is to be financed.


Y

Yield to maturity That discount rate which makes the present value of future inflows from a bond equal to its present market value.

Z

Zero float Zero float is a condition where there is no excess time between activities. An activity with zero float is considered a critical activity. If the duration of any critical activity is increased (the activity slips), the project finish date will slip.

Zero growth stocks Stocks for which expected dividends are considered to remain constant.

Zero-base budgeting A planning procedure that assumes that the relevant base for all planning is zero dollars.


Index (G6)

Numerics1 1, 2, 5, 2, 50, 9, 10, 14, 17, 18, 19, 20, 6, 7,

24, 25, 29, 2, 6, 8, 12, 15, 16, 29, 43, 46, 47, 10, 29, 32, 39, 43, 52, 53, 57, 61, 62, 65, 69, 1, 7, 9, 10, 12, 15, 16, 21, 24, 25, 32, 38, 44, 46, 49, 50

1 SPEEDHoists (HO) 18

2 STAGEEjectors (EJ) 4

4 STAGEEjectors (EJ) 5

4-STAGE BEjectors (EJ) 5

5 SPEEDHoists (HO) 18, 22

5-STAGE BEjectors (EJ) 6

AAACE 1ABC 1Above-grade piping

piping plant bulks 3, 6Absorber towers 3Absorption towers 3ABVGR-TANK

civil plant bulks 2AC/DC Transformer

electrical plant bulks 16Accelerated depreciation 1Accelleration

seismic data 15Accomodations

construction overhead 62Account 1ACID BRICK

Packing, Linings (PAK, LIN) 8Acid-test ratio 1Action button 1Activated aluminas

packing 4Activated carbon

Index (G6)

pacing materials 66packing 4

Activity duration 2Actual dates 2Addendum 2Adsorption towers 3AERATOR

Water Treatment Systems (WTS) 8AFC 2AFD 2Agitated falling film

Evaporators (E) 4Agitated pan batch dryer

Dryers (D) 9Agitated Tanks (AT) 7

COND-CELL 20FLOAT-CELL 20general nomenclature 21MACH-PULP 17MIXER 8, 9OFF-MACH 17, 18OPEN TOP 11

Agitated thin film evaporatorWiped Film Evaporators (WFE) 7

Agitators (AG) 7ANCHOR 3DIRECT 2FIXED PROP 3GEAR DRIVE 2HIGH SHEAR 5MECH-SEAL 3PORT-PROP 3PULP STOCK 4SAN-FIXED 6SAN-PORT 7side entry 4top entry 4

Air Compressors (AC) 8CENTRIF-M 2packaged unit 2, 3RECIP-GAS 3RECIP-MOTR 4SINGLE 1-S 4

1

SINGLE 2-S 4AIR COOLER

Heat Exchangers (HE) 3AIR DRYER

Dryers (AD) 8Air Dryers (AD) 15

AIR DRYER 8Air fan

AIR COOLER (HE) 3Allocate 2Allowances 2ALMNA 66Alternate 2Alumina

packing materials 66Aluminum

non-ferrous plate materialsASME 8DIN 44JIS 32

Amortization 2Analog, process control 13ANCHOR

Agitators (AG) 3Anion exchangers

DEMINERAL 8SOFTENING 8

Anodeselectrical plant bulks 11

ANSI 3Centrifugal Pumps (CP) 2

ANSI PLASTCentrifugal Pumps (CP) 4

API 3API 610

Centrifugal Pumps (CP) 5API 610-IL

Centrifugal Pumps (CP) 7Apply 3Apply & Close 3APRON

Conveyors (CO) 7Area

insulation/fireproofing 2Area lighting

electrical plant bulks 8AREA-LIGHT

electrical plant bulks 8, 9Areas

pipe envelope 7process control 19types 3unreferenced requiring power 35

ASME 3ASPHALT

site development 12Asphalt equipment

construction equipment 14Asphaltic resin lining 63

2

ATM SUSPENCentrifuges (CT) 2

Atmosphericsolid/liquid storage

Vertical Tanks (VT) 33Atmospheric tray batch dryer

Dryers (D) 9ATM-SYSTEM

Tray Drying Systems (TDS) 14ATTRITION

Mills (M) 7Attrition mill

Mills (M) 7AUTOGENOUS

Mills (M) 8Autogenous mill

Mills (M) 8Automotive

construction equipment 2Average collection period 3Average rate of return (ARR) 3Axial

Gas Compressors (GC) 5AXIAL FLOW

Centrifugal Pumps (CP) 11

BBACKFILL

earthwork - site development 7Baghouse

cloth bay 6Balance sheet 4Ball

Fisher control valve information 23BALL MILL

Mills (M) 8Ball mill

Mills (M) 8Balloon 4Balloon payment 4BAR

Screens (VS) 29Barcharts

project schedule 9BAROMETRIC

Condensers (C) 2Base indices

country baseUS 2

BASE-PREPsite development 12

Basic engineering 4disciplines and wage rates

JP 6, 8UK 4US 2, 10

BASINSdrainage - site development 4

Basins, catch

Index (G6)

drainage - site development 4Batch

Centrifuges (CT) 2Batch dryer

Dryers (D) 9Tray Dring Systems (TDS) 14

Batch tray dryerTray Drying Systems (TDS) 14

BATCH VACCrystallizers (CRY) 2

Batch vacuumCrystallizers (CRY) 2

BATCH-AUTOCentrifuges (CT) 2

BATCH-BOTMCentrifuges (CT) 3

BATCH-TOPCentrifuges (CT) 3

BEAM SCALEScales (S) 19

Beamssteel plant bulks 16

BELGR-TANKcivil plant bulks 3

BELTFeeders (FE) 14Scales (S) 19

Belt feederFeeders (FE) 14

BENCHScales (S) 19

Benefit-cost ratio (BCR) 4Berl saddle

packing 4Berl saddles 66Bid documents 4Bin activator

Feeders (FE) 14BIN-ACTVTR

Feeders (FE) 14BLASTING

earthwork - site development 7BLENDER

Blenders (BL) 25Blenders (BL) 8

BLENDER 25KETTLE 25RIBBON 32, 33, 34ROTARY 25ROTARYBOWL 26

BOILERSteam Boilers (STB) 4

Bond covenants 5Bond indenture 5Bond refunding 5Book value 5Book value per share 5BORINGS

earthwork - site development 6

Index (G6)

BOT-UNLOADCentrifuges (CT) 3

BOXFurnaces, Process Heaters (FU) 39, 40

Boxessteel plant bulks 16

Boxes, junctioninstrumentation plant bulks 4

Bracingsteel plant bulks 16

Bracketssteel plant bulks 16

BRADFORDCrushers (CR) 6

Brassnon-ferrous plate materials

JIS 32non-ferrous tube materials

DIN 50JIS 38

BREAKERelectrical plant bulks 15

Break-even analysis 5Break-even budget 5Break-even point 5Bridge crane

Cranes (CE) 13BRIDGE-CRN

Cranes (CE) 13BRUSH

earthwork - site development 6BS design code

ferrous tube materialshigh alloy steel 25low alloy steel 24

BS5500 5Bubble cap trays 3Bucket elevator

Conveyors (CO) 10Buildings

demolish 3mill, steel plant bulks 12

BUMPERrailroads - site development 17

Bundle runs - pneumaticinstrumentation plant bulks 3

Burdensconstruction overhead 61

Buried pipepiping plant bulks 3, 20

BUS DUCT 14Butterfly

Fisher control valve information 23Butyl rubber

lined steel pipe 58Butyl rubber lining 63

CCABLE DUCT 12

3

Cable trayelectrical plant bulks 4instrumentation plant bulks 3

Cable, data-highwayinstrumentation plant bulks 9

Caged ladders 15steel plant bulks 6

CAISSONpiling - site development 15

Calcium chloridepacking materials 66

Calcium silicateinsulation materials 4

CANNEDCentrifugal Pumps (CP) 11

CANNED RTRGear Pumps (GP) 19

Carbonpacking materials 66

Carbon steellining materials 63packing materials 67

Carpenter 20ASME non-ferrous

tube materials 14BS non-ferrous

plate materials 21DIN non-ferrous

plate materials 45tube materials 50

JIS non-ferrousplate materials 33tube materials 38

CARTRIDGEFilters (F) 11

Cartridge filterFilters (F) 11

Cascade rings 67Cast steel

casting materials 65Castable refractories, linings 5Catalyst

bed reactor, packed 8, 16Catch basin

drainage - site development 4Catering

construction overhead 62Cation exchangers

DEMINERAL 8Cement

lined steel pipe 58CENT-BKT-L

Conveyors (CO) 9, 10, 11, 12CENT-COMPR

Refrigeration Units (RU) 6CENTRF-PRE

Dust Collectors (C) 6CENTRIF

Centrifugal Pumps (CP) 12

4

Fans, Blowers (FN) 11Gas Compressors (GC) 5

CENTRIF-IGGas Compressors (GC) 6

CENTRIF-MAir Compressors (AC) 2

CentrifugalFans, Blowers (FN) 11filters

Centrifuges (CT) 2Centrifugal precipitator

Dust Collectors (DC) 6Centrifugal Pumps (CP) 11

ANSI 2ANSI PLAST 4, 17API 610 5API 610-IL 7AXIAL FLOW 11CANNED 11CENTRIF 12FLUME PUMP 17GEN-SERV 13IN LINE 13MAG DRIVE 15PULP STOCK 14SAN-PUMP 15TURBINE 14

Centrifuges (CT) 17ATM SYSPEN 2BATCH-AUTO 2BATCH-BOTM 3BATCH-TOP 3BOT-UNLOAD 3DISK 4INVERTING 5RECIP-CONV 4SCREEN-BWL 5SCROLL-CON 4SOLID BOWL 4TOP UNLOAD 3TUBULAR 5VIBRATORY 5

CENT-TURBOFans, Blowers (FN) 10

Ceramicpacking materials 66

CERATE Relation 1, 11Chain drivers

variable speed motor reducer 5CHAIN-LINK

fencing - site development 10Chemical lead lining 63CHEST-CYL

Vertical Tanks (VT) 37CHEST-MTL

Vertical Tanks (VT) 39CHEST-REC

Vertical Tanks (VT) 35Chests, tile

Index (G6)

Vertical Tanks (VT) 35Chutes

steel plant bulks 16Circuit breakers

electrical plant bulks 15Civil

code of accounts 12concrete foundations 3concrete tanks 2structures 3

Cladding materialASME design code 10BS design code 22DIN design code 46JIS design code 34

Classified-suspension crystallizerCrystallizers (CRY) 3

Clear brushearthwork - site development 6

CLEAR-GRUBearthwork - site development 6

Clearingearthwork - site development 6

Click 5Close 6CLOSED-BLT

Conveyors (CO) 4Closed-end mortgage bond 6CLOTH BAY

Dust Collectors (DC) 6Cloth bay baghouse

Dust Collectors (DC) 6CM 6CNTRCT Relation 1, 14COAT WRAP

piping plant bulks 34Coatings

Packing, Linings (PAK, LIN) 9COD 6Code of account 6Code of accounts

contingencies 7, 30creating 3, 4equipment and setting 9modifying 2output reports 5summary reports 5

Coincident indicator 6Coke

paking materials 66Collateral 6Collection costs 6Columns

packed 8, 16steel plant bulks 2, 16tray towers 12, 20washers 10

Commercial paper 6Commissioning

Index (G6)

disciplines and wage ratesJP 7, 9UK 5US 3, 11

expenses and indirects 12, 13, 14, 15Common equity 6COMPACT

earthwork - site development 7Compaction

construction equipment 5Comparative analysis 7Compensating balance 7COMPONENT Relation 1, 14Components 7Composition 7COMPRESGAS

Filters (F) 16Compressed gas filter

Filters (F) 16Compressor

construction equipment 8Concentrators

THICKENERThickeners (T) 26

CONC-PAVNGsite development 12

CONCRETEcivil plant bulks 3

Concreteconstruction equipment 9pipe, piping plant bulks 20tanks, civil plant bulks 3

Concrete drainagecivil 5

COND-CELLAgitated Tanks (AT) 20

Condensers (C) 12BAROMETRIC 2

CONDENSINGTurbines (TUR) 9

Conditioning cellAgitated Tanks (AT) 20

CONDUITelectrical plant bulks 2, 3

CONECrushers (CR) 2

Cone bottomVertical Tanks (VT) 31

CONE BTMVertical Tanks (VT) 31

Cone roof tank (storage)Vertical Tanks (VT) 26

Conglomerate merger 7Conical rotary vacuum dryer

Rotary Dryers (RD) 13Coning 4CONSET (contract set number) 21, 22, 26Construction

contracts 66

5

direct field manpower 67field office 56field supervision 69home office 56home office construction services 69management 52, 56

Construction eqiupmentintroduction 2

Construction equipmentasphalt equipment 14automotive 2compaction 5compressor 8concrete 9crane 6crane attachment 7drilling 4earthmoving 3electric equipm/tool 13hoist 14miscellaneous equipment 12piping equipment 10pneumatic port. tool 13pump 13site/office equipment 14trailer 5truck 2welding equipment 9, 10

Construction managementdisciplines and wage rates

JP 8US 2, 10

Construction overheadaccomodations 62burdens 61catering 62construction overhead & fees 61construction rental equipment 62consumables 61field services 62fringe benefits 61miscellaneous 61scaffolding 62small tools 61vendor representatives 62

Construction overhead & feesconstruction overhead 61

Construction overhead and fees 7Construction rental equipment

construction overhead 62Consumables 7

construction overhead 61Consumer survey method for forecasting 7CONTAINMNT

civil plant bulks 5CONT-BKT-L

Conveyors (CO) 10, 11, 12Contingencies

code of accounts 7, 30

6

Contingency 7Continuous spray drying system

Dryers (D) 10Contract documents 7Contracts

concepts 64construciton - home office construction

services 69construction 66construction - direct field manpower 67construction - field erected vessels 67construction - field indirects 68cost benefits 65description 63engineering 57, 65materials 66overheads 69prime contractor defaults 62procurement 65

Control 8Control centers 13, 14, 16

analog 16default 17defining 22, 24digital 16electrical plant bulks 15PLC 26redundant control 24requirements 17spares 24types 22

Control process 8Control valve size

piping 6Controllers, multifunction

instrumentation plant bulks 6CONTYP 14Conversion premium 8Convertible security 8Conveyor belt scale

Scales (S) 19Conveyor transfer tower

steel plant bulks 15Conveyors (CO) 16

APRON 7CENT-BKT-L 9, 10, 11, 12CLOSED-BLT 4CONT-BKT-L 10, 11, 12OPEN BELT 2PNEUMATIC 7ROLLER 8S BELTCONV 10S VERTICAL 11S VIBRATORY 11sanitary

horizontal 10vertical 11vibratory 11

SCREW 8

Index (G6)

VIBRATING 8COOLING

Cooling Towers (CTW) 2Cooling Towers (CTW) 19

COOLING 2COOLING-WP 3factory assembled 3PACKAGED 3

COOLING-WPCooling Towers (CTW) 3

CopperASME non-ferrous

tube materials 14BS non-ferrous

tube materials 26DIN non-ferrous

tube materials 50JIS non-ferrous

tube materials 38Copy & change 8Cost 8Cost index 8Cost modeling 8Cost of capital 8Cost reporting

currency and escalation 39COST…f1COST® ICARUS’ mainframe-based es-

timating and scheduling system for evaluating major process plants and mills. COST® was first marketed by ICARUS in 1969. 12

Counter flow trays 3COUNT-ROT

Agitators (AG) 5Country base

base indicesEU 2JP 2UK 2US 2

project definition 37Covenants 9Crafts

names 43productivity 50wage rates 42

Craneconstruction equipment 6

Crane attachmentconstruction equipment 7

Cranes (CE) 16BRIDGE-CRN 13HOIST 13hoist trolley 13travelling bridge crane 13

Create 9Credit discount 9Credit period 9Credit period only 9Credit policy 9

Index (G6)

Crew mixesworkforce 42

Critical activity 9Critical path 9CROSS BORE

Heat Exchangers (HE) 24Cross gutter

site development 12Crossflow trays 3

bubble cap 3sieve 3valve 3

CROSS-GUTTsite development 12

CROSSINGrailroads - site development 17

Crossing signalrailroads - site development 17

Crushed limestonepacking materials 66

Crushed stonepacking materials 66

Crushers (CR) 14BRADFORD 6CONE 2ECCENTRIC 3GYRATORY 3HAMMER-MED 6JAW 4PULVERIZER 6reversible hammermill 6REV-HAMR 5ring granulator 7ROLL RING 7ROTARY 4rotary breaker 6SAWTOOTH 5S-IMPACT 6single roll 4size reduction 5S-ROLL-HVY 5S-ROLL-LT 4, 5S-ROLL-MED 5swing jaw 4SWING-HAMR 6

CRWSCH Relation 1, 12CRYOGENIC

Vertical Tanks (VT) 28Cryogenic storage tank

Vertical Tanks (VT) 28Crystallizers (CRY) 15

BATCH VAC 2batch vacuum 2classified-suspension 3growth 3MECHANICAL 2mechanical scraped-surface crystallizer 2OSLO 3scraped surface 2

7

CS 9CSTCRL Relation 12, 13CSTCTRL Relation 1CURB

site development 12Curb and gutter

site development 13Currency base

conversion 37project definition 37

Current ratio 10Current yield 10CUSSPC Relation 1, 13CUT-FILL

earthwork - site development 7CYCLONE

Dust Collectors (DC) 9CYLINDER

Heating Units (HU) 5Vertical Tanks (VT) 11

Cylindrical chestsVertical Tanks (VT) 37

DDatabase 10Data-highway cable

instrumentation plant bulks 9DC HE TW

Single Diameter Towers (TW) 23Debenture 10Decision engineering 10Decision tree 10DEEP-ANODE

electrical plant bulks 11Deferred call provision 10Definitive

-5 to +15 percent estimate 10DEFLAKE-CN

Stock Treatment (ST) 10DEFLAKE-DK

Stock Treatment (ST) 9Deflakers

Stock Treatment (ST)concentric conical type 9plate type 9

Degree of financial leverage 11Degree of operating leverage 11Delete 11Delivery times

process equiment procurement 10Delphi method for forecasting 11Demand-diversity factor 11DEMINERAL

Water Treatment Systems (WTS) 8Demineralizers

packed towers 8, 16Demineralizing system

Water Treatment Systems (WTS) 8Demobilization 11

8

DEMOLdemolition - site development 3

DEMOLITIONdemolition - site development 3

DERRICKFlares (FLR) 3, 4

Design basis 11DESIGN Relation 1, 10Desorption towers 3Desulferization reactors

packed 8, 16Detail engineering 54

disciplines and wage ratesUK 4US 2, 10

Detailed engineering 11DETAILS Relation 1, 8DEWATERING

drainage - site development 4Dewatering wells

drainage - site development 5DH (Direct hire) 12Dialog box 12DIAPHRAGM

Piston, Other Positive Displacement Pumps (P) 22

Digital, process control 13DIKE

earthwork - site development 6DIKE-MEMBR

civil plant bulks 5, 7DIRECT

Rotary Dryers (RD) 13Direct contact heat exchanger tower 23Direct costs 12Direct feld fanpower

construction 67Direct field cost (DFC) 12Direct steam heat module

sanitary 29Discharge elevator

Conveyors (CO) 9DISCNCT SW 14Discount period 12Discount rate 12DISK

Centrifuges (CT) 4Disk filter

Filters (F) 12Display 12DISPOSAL

demolition - site development 3Distillation towers 2Distributable 12Distribution of assets 12Ditching

earthwork - site development 9Dividend declaration date 12Dividend payment date 12

Index (G6)

Dividend payout ratio 13Dividend policy 13Dividend yield 13Dividends 13Dollars

currency base 37DOUBLE ATM

Drum Dryers (DD) 11Double Diameter Towers (DDT) 12

PACKED 8TRAYED 12

Double-armKneaders (K) 28Mixers (MX) 30

Dowtherm unitHeating Units (HU) 5

Drain fielddrainage - site development 4

DRAINAGEdrainage - site development 5

Drainagecivil 5

DRAINSdrainage - site development 4

Drillingconstruction equipment 4

DRUMFlakers (FL) 7

Drum Dryers (DD) 15DOUBLE ATM 11S-COOKCOOL 11SINGLE ATM 11single atmospheric 11SINGLE VAC 11vacuum rotary 11

Drum filterFilters (F) 13

Dryers (D) 15agitated pan batch 9atmospheric tray-type batch 9continuous spray system 10PAN 9SPRAY 10VAC-TRAY 9vacuum tray-type batch 9

DUCT RDpiping plant bulks 21

DUCT SQpiping plant bulks 22, 23

Ductworkpiping 21

DUPLEXPiston, Other Positive Displacement Pumps

(P) 21Duration 13Dust Collectors (DC) 18

CENTRF-PRE 6CLOTH BAY 6CYCLONE 9

Index (G6)

ELC-H-VOLT 10ELC-L-VOLT 10MULT-CYCLO 10PULSE SHKR 8WASHERS 10

EEarly finish 13Early start 14Earned surplus 14Earnings per share 14Earth (dirt)

packing materials 66Earthmoving

construction equipment 3EARTHWORK

earthwork - site development 6Ebonite

lined steel pipe 58ECCENTRIC

Crushers (CR) 3Economic forecast 14Economic indicator 14Economic order quantity 14Efficiency 14Efficiency ratios 14Ejectors (E) 12Ejectors (EJ)

2 STAGE 44 STAGE 54-STAGE B 55-STAGE B 6SINGLE STG 3TWO STAGE 3

EL6 4Elapsed time 14ELC-H-VOLT

Dust Collectors (DC) 10ELC-L-VOLT

Dust Collectors (DC) 10ELEC-TRAY

electrical plant bulks 4Electrical

cable tray 4circuit breakers 15code of accounts 15construction equipment 13galvanic anode 11ground grid 7group of anodes in shallow surface bed 11motor control center 15potential measurement test station 11rigid conduit 2, 3solar panel 12tracing (existing equipment) 4tracing (existing piping run) 5transformer/rectifier 11uninterupted power supply 16

Electrical Generators (EG) 20

9

PORTABLE 7TURBO-GEN 7

Electrical Motors (MOT) 9ENCLOSED 3explosion proof 4EXP-PROOF 4OPEN 2SYNCHRON 3Synchronous motors 3TEFC 3TEWAC 4VARY-SPEED 5

Electronic signal wireinstrumentation plant bulks 3

Elevated access platformssteel plant bulks 13

Elevators, Lifts (EL) 16FREIGHT 13PASSENGER 13

Ellipsoidal towers 5Elliptical towers 5EMER LIGHT 12Emergency diesel generator

electrical plant bulks 16Emergency eyewash and shower units 40Emergency light

electrical plant bulks 12EM-PWR-SET

electrical plant bulks 16ENCLOSED

Electrical Motors (MOT) 3Engineering

adjustments to costs 58construction management 56contracts 57contracts assignment 52detail 54discipline adjustments 53field office construction supervision 56home office construction services 56indirects 56miscellanious expenses 56organization 58payroll burdens 57phase adjustments 53prime contractor 52procurement 55reports 54, 57SPAN* 60start-up 56support personnel 56workforce 53

Engineering management 52disciplines and wage rates

JP 9UK 5US 3, 11

EOM 15E-P-C (Engineering, procurement and

10

construction) 15Epoxy resin lining 63EQPT-TRACE

electrical plant bulks 4EQRENT Relation 1, 13Equipment and setting

code of accounts 8, 9Equipment fabricate/ship times 10Equipment model library 2Equipment SUBTYPE 43Equity 15Equivalent dividend return 15EROSION

landscaping - site development 11Erosion control

landscaping - site development 11Escalation 15Escalation, cost reporting 39EU country base

base indices 2Euros 37Evaporators (E) 15

agitated falling film 4FALL-FILM 4FORCED CIR 4forced circulation 4LONG TUBE 4long tube rising film 4long tube vertical 5LONG-VERT 5standard horizontal tube 6STAND-HOR 6STAND-VERT 5

EWF 15EWF (engineering work force) 53Excavation

earthwork - site development 7machine 9manual 7

Exchange resindemineralizer 8packed towers 8, 16Packing (PAK) 7

Exercise price 15Exit 15Expected return 15EXPL-DEMOL

demolition - site development 3Explosion-proof motors

Electrical Motors (MOT) 4Exponential smoothing 15Export 16EXP-PROOF

Electrical Motors (MOT) 4Extension 16Extraction towers 3EXTRUDER

Mixers (MX) 29Eyewash

Index (G6)

WSHWR 40

FFabric filters

Dust Collectors (DC) 6Fabricated plate items

steel plant bulks 16FABR-PLATE

steel plant bulks 16Factored estimating 16FALL-FILM

Evaporators (E) 4Fans, Blowers (FN) 9

CENTRIF 11CENT-TURBO 10general purpose blower 12heavy duty, low noise blower 10PROPELLER 11ROT-BLOWER 12VANEAXIAL 12

Fast tracking 16Feeders (FE) 17

BELT 14BIN-ACTVTR 14ROTARY 14SACK-DUMP 16SAN-BELT 17SAN-FLOOR 21SAN-SCREW 16VIBRATING 15WT-LOSS 15

FENCE-WOODfencing - site development 10

FENCINGfencing - site development 10

Fiber optic cablesinstrumentation plant bulks 9

Field costs 16Field erected vessels

agitated open tanksAgitated Tanks (AT) 12

construction 67floating roof tanks 25gas holders 30lifter roof tanks 26open top tanks 26storage tanks 25tray towers 12, 20

Field Manpower Summary reportworkforce 43

Field officedisciplines and wage rates

JP 6, 8UK 4US 2, 10

Field office construction supervision 56Field services 16

construction overhead 62Filter

Index (G6)

pressesPLATE+FRAM 12

Screens (VS) 29Filters (F) 18

CARTRIDGE 11COMPRSGAS 16LEAF-DRY 11LEAF-WET 11PLATE+FRAM 12RECL-REEL 17ROTY-DISK 12ROTY-DRUM 13SAN-PIPE 18SAN-PRESS 19SAN-STRAIN 22SCROLL 14SEWAGE 14SPARKLER 15TUBULAR 15WHITEWATER 15

Fin fan coolersAIR COOLER (HE) 3

FIN TUBEHeat Exchangers (HE) 23

Financial forecasting 16Financial lease 16Financial leverage 17Financial ratios 17Financial risk 17Financial statements 17Financial structure 17Finish float 17Finishing activity 18Finish-to-finish lag 17Finish-to-start lag 17Finned double-pipe heat exchanger 23Fireclay

lining materials 61Fireproofing

insulation plant bulks 2FIREP-SSTL

insulation plant bulks 2, 3FITSPC.DAT file 13Fitting Connection 14Fitting specs file 13Fixed costs 18FIXED PROP

Agitators (AG) 3Mixers (MX) 29

Fixed tubeHeat Exchangers (HE) 4

FIXED-T-SHeat Exchangers (HE) 4, 5, 6, 7

Flakers (FL) 14DRUM 7

Flares (FLR) 20DERRICK 4diameter of flare tip 2emmisivity of flame 3

11

GUYED 5height of flare stack 2HORIZONTAL 8introduction 2SELF-SUPP 7STORAGE 10THRM-OX LC 9vapor control 10

Flat roof tank (storage)Vertical Tank (VT) 25

Flg. 18FLO PANEL

piping plant bulks 41FLOAT-CELL

Agitated Tanks (AT) 20FLOAT-HEAD

Heat Exchangers (HE) 8, 9, 10Floating lien 18Floating roof tank (storage)

Vertical Tanks (VT) 25Flue gas scrubbing systems

packed towers 8, 16Fluid heat tracing

existing equipment 24existing pipe runs 25

Fluidized bed reactorsdemineralizers (WTS) 8SPHERE 21SPHEROID 23WASHERS (DC) 10

FLUME PUMPCentrifigal Pumps (CP) 17

Foam glassinsulation materials 4

Foam spray systemsFOAM 38

FORCED CIREvaporators (E) 4

Forced circulationEvaporators (E) 4

Foundation subdraindrainage - site development 4

Foundationscivil plant bulks 3

Frame filters (F) 12Free float 18Free standing wall

fencing - site development 10FREIGHT

Elevators, Lifts (EL) 13Freight

code of accounts 6, 29Freight elevator

Elevators, Lifts (EL) 13Fringe benefits

construction overhead 61Fringe benefits (FB) 18Froude number

Agitated Tanks (AT) 21

12

Full loan amortization 18FULL-FRAME

Scales (S) 19Funded debt 18Funded debt to net working capital 19Funds forecast 19Furnaces, Process Heaters (FU) 10

BOX 39BOX - continued. 40HEATER 40PYROLYSIS 40PYROLYSIS - continued. 41REFORMER 41VERTICAL 41

GG & A 19GALLERY

steel plant bulks 14Galvanic anode

electrical plant bulks 11Gantt (bar) chart 19GAS

Turbines (TUR) 10Gas

standard equations for piping diameters 44

Gas absorbersdemineralizer 8packed columns 8, 16

Gas Compressors (GC) 9axial 5CENTIFG-IG 6CENTRIF 5inline 5RECIP-GAS 9RECIP-MOTR 8

GAS HOLDERVertical Tanks (VT) 30

Gas turbine 9GATES

fencing - site development 10GC 19GEAR

Gear Pumps (GP) 19GEAR DRIVE

Agitators (AG) 2Gear Pumps (GP) 11

CANNED RTR 19GEAR 19MECH-SEAL 20

General conditions 19General electrical

electrical plant bulks 5General service pumps 2GEN-SERV

Centrifugal Pumps (CP) 13Globe

Fisher control valve information 23

Index (G6)

GMP 19Go Back 19Grading, site development

landscaping 11roads - slabs - paving 12

Grassroots 19GRATE

steel plant bulks 15Grating

GRATE, steel plant bulks 15Gravel

packing materials 66GRND-GRID

electrical plant bulks 7Ground grid

electrical plant bulks 7Grout

CONCRETE - civil plant bulks 3Growth crystallizer

Crystallizers (CRY) 3Grubbing

earthwork - site development 6GUNITE

earthwork - site development 6Gunite

lining materials 62Gunite slope protection

earthwork - site development 6Gunning mixes, linings 1, 5Gutter (and curb)

site development 13GUYED

Flares (FLR) 3, 5GYRATORY

Crushers (CR) 3

HHAMMER-MED

Crushers (CR) 6Hammocks 20Hand excavation

earthwork - site development 7HAND GT

Hoists (HO) 18Hand hoists

Hoists (HO) 18HAND NT

Hoists (HO) 19HAND PT

Hoists (HO) 18HAND-EXCV

earthwork - site development 7Hangers

piping plant bulks 3Hastelloy

non-ferrous plate materialsASME 9DIN 44JIS 33

Index (G6)

non-ferrous tube materialsASME 14DIN 50

HAULINGearthwork - site development 7

HD STOCKPiston, Other Positive Displacement Pumps

(P) 24HDPE PIPE 41Head design, towers/columns 1, 6Heat Exchanger (HE)

MULTI-P+F 27Heat Exchangers (HE) 9

AIR COOLER 3, 27CORRUGATED 26, 27CROSS BORE 24FIN TUBE 23FIXED-T-S 4FIXED-T-S - continued 5, 6, 7FLOAT-HEAD 8FLOAT-HEAD - continued 9, 10HEATER-ELC 22HEATER-STM 22HOT WATER 27JACKETED 22, 23MULTI-P+F 27ONE SCREW 24PLAT+FRAM 26PRE-ENGR 20PRE-ENGR - continued. 21SHELL+TUBE 24SPIRAL PLT 25SUC-HEATER 25TEMA-EXCH 14TWO SCREW 24U-TUBE 11, 37, 38U-TUBE - continued 12, 13WASTE HEAT 25

Heat tracingpiping plant bulks 24

HEATERFurnaces, Process Heaters (FU) 40

HEATER-ELCHeat Exchangers (HE) 22

HEATER-STMHeat Exchangers (HE) 22

Heating Units (HU) 20CYLINDER 5dowtherm unit 5

Hedging approach 20Help 20Helper, crew mix 43Hemispherical towers 5Hemispheriod

speheroid vertical tanks 23High alloy steel

ferrous tube materialsBS 25

High density polyethylene pipe 41

13

High density stock pumpPiston, Other Positive Displacement Pumps

(P) 24High energy level process interface units

instrumentation plant bulks 9High pressure gas/liquid storage

Vertical Tanks (VT) 21HIGH SHEAR

Agitators (AG) 5HIGH SPEED

Mixers (MX) 32Histogram 20Historical average cost of capital 20Historical cost estimating 20History module 6HL-PIU

instrumentation plant bulks 9HOIST

Cranes (CE) 13Hoists (HO) 18

Hoistconstruction equipment 14

Hoist trolleyCranes (CE) 13

Hoists (HO) 171 SPEED 185 SPEED 18, 22HAND GT 18HAND NT 19HAND PT 18HOIST 18

Home officedisciplines and wage rates

JP 6, 8UK 4

Home office construction services 56Honeywell TDC 2000/3000 process control

system 6HORIZ-DRUM

Horizontal Tanks (HT) 2HORIZONTAL

Flares (FLR) 8Horizontal plate filters 12Horizontal Tanks (HT) 13

HORIZ-DRUM 2JACKETED 7MULTI WALL 5SAN-TANK 9

Hortonspheriodspheroid vertical tanks 23

Host 20HOT TAP

piping plant bulks 34HOT WATER

Heat Exchangers (HE) 27HP 20HUMMER

Screens (VS) 28HVAC 20

14

Hydrogenation reactorspacked columns 8, 16

HydrotreatersCYLINDER 11

IICARUS Process Evaluator (IPE) 21ICARUS Project Manager (IPM) 21Icon 21Immersion heaters

HEATER-ELC (HE) 22Import 21IN LINE

Centrifugal Pumps (CP) 13Incoloy

tube materialsASME 14BS 26DIN 50

Income statement 21Inconel

clad plate materialsASME 10JIS 34

tube materialsASME 14BS 26DIN 50JIS 38

Incremental average cost of capital 21Indenture 21INDIRECT

Rotary Dryers (RD) 13Indirect costs 21INDIRECT Relation 15INDIRECTS 1Indirects 56

construction 68INDIRECTS Relation 1Industrial gate

fencing - site development 10Industry forecast 21Industry ratios 22Inflation 22Info 22Inline

Gas Compressors (GC) 5Input-output model 22Installation bulks 22INST-PANEL

instrumentation plant bulks 2Instrumentation

cable tray 3fiber optic cables 9Honeywell TDC 2000/3000 process control

system 6Honeywell TDC3000 5junction boxes 4multifunction controllers 6

Index (G6)

operator center 6panel 2pneumatic multi-tube bundle runs 3signal wire 3SUBTYPE 43, 46, 47thermocouple wire 4

INST-TRAYinstrumentation plant bulks 3

INST-WIREinstrumentation plant bulks 3

INSUL-AREAinsulation plant bulks 2

Insulationcode of accounts 16existing piping 3existing surface area 2fireproofing 2piping (existing) 3structural steel (existing) 2SUBTYPE 51

Intalox saddlespacking materials 66

Intermediate term loan 23Internal rate of return (IRR) 23Intrinsic value 23Inventory holding costs 23Inventory reorder costs 23Inventory shortage costs 23INVERTING

Centrifuges (CT) 5Ion exchangers

demineralizer 8I-P (inch-pound)

units of measure 39Iron

casting materials 64ISO 24Issued stock 24Item 24Item run 24Item symbols

process equipment 6

JJACKETED

Heat Exchangers (HE) 22, 23Horizontal Tanks (HT) 7Vertical Tanks (VT) 18

Jacketed rotary vacuum dryerRotary Dryers (RD) 14

Jackhammerearthwork - site development 8

JAC-VACUUMRotary Dryers (RD) 13

JAWCrushers (CR) 4

J-HAMMERearthwork - site development 8

JIS 24

Index (G6)

JIS design codeferrous plate materials

low alloy steel 29JP country base

units of measure 39JUNC-BOX

instrumentation plant bulks 5Junction boxes

instrumentation plant bulks 4Jury of executive opinion method for

forecasting 24

KKETTLE

Blenders (BL) 25Reboilers (RB) 30, 31, 32, 34

Kettle reboilerReboilers (RB) 30

Kneaders (K) 8STATIONARY 28TILTING 28VAC-TILTING 28

KV 24KVA 25KW 25Kynar

lined steel pipe 58Kynar sheet lining 63

LLabor burden 25Labor cost 25LADDER

steel plant bulks 15Ladders 15

caged 6, 15Lag 25Lagging indicator 25LANDSCAPE

landscaping - site development 11Late start 25LAUNDER RD

piping plant bulks 34LAUNDER SQ

piping plant bulks 34Launders

piping 34LD STOCK

Screens (VS) 29Lead

linings 6Leading indicator 25LEAF-DRY

Fitlers (F) 11LEAF-WET

Filters (F) 11Lease 26Lease capitalization 26Lease capitalization rate 26

15

Levelsensor loop descriptions 14

Leverage 26Leverage ratios 26Libraries

equipment model 2unit cost 2

Library 26Lien 26LIFT

Vertical Tanks (VT) 25Lifter roof tank (storage)

Vertical Tanks (VT) 26Lighting

(area) electrical plant bulks 8Limestone

packing materials 66Line of credit 26Line siding crossing

railroads - site development 17Lining materials

fireclay 61gunite 62

Liningsacid brick 5, 8brick 1, 6, 9castable refractories 5, 9firebrick 9fluorocarbon 1, 5glass 9, 63gunning mixes 1, 5, 8introduction 7Lead 1, 6lead 6organic 9refractory brick 6resin 6rubber 6zinc 6

Link 26Liquid

standard equations for pipe diameters 44Liquidation value 27Liquidity 27Liquidity ratios 27Live bottom

Vertical Tanks (VT) 33LIVE BTM

Vertical Tanks (VT) 33, 34LL-PIU

instrumentation plant bulks 9Loaded labor rate 27Loan amortization 27Local control network (LCN) 17Lock-box system 27Log 27LONG TUBE

Evaporators (E) 4Long tube rising film

16

Evaporators (E) 4Long tube vertical

Evaporators (E) 5LONG-VERT

Evaporators (E) 5Low alloy steel

plate materialsJIS 29

tube materialsBS 24

Low consistency stock pumpCentrifugal Pumps (CP) 14

Low energy level process interface unitsinstrumentation plant bulks 9

Lump sum quotationsite development

demolition 3drainage 5earthwork 6landscaping 11railroads 17

MMachine excavation

earthwork - site development 9MACH-PULP

Agitated Tanks (AT) 17MAG DRIVE

Centrifugal Pumps (CP) 15Main substation 27

power distribution 31Maintenance lease 28Making a market 28Manholes

drainage - site development 4towers 5

Marginal average cost of capital 28Marginal cost of capital 28Mark text 28Market extension merger 28Market value 28Mark-up 28Materials of construction

towers 6Maturity value of a bond 28MCC 28

electrical plant bulks 15ME Country Base 10MECHANICAL

Crystallizers (CRY) 2Refigeration Units (RU) 6Vacuum Pumps (VP) 7

Mechanicalseal agitators, MECH-SEAL (AG) 3

Mechanical booster 7Mechanical engineering 29Mechanical oil-sealed vacuum pump 7mechanical scraped-surface crystallizer

Crystallizers (CRY) 2

Index (G6)

MECH-BOOSTVacuum Pumps (VP) 7

MECH-SEALAgitators (AG) 3Gear Pumps (GP) 20

Mercalli Numberseismic data 15

METAL TRAPFilters (F) 17

Metalic chestsVertical Tanks (VT) 39, 40

METRICunits of measure 39

Micro-scheduling 29MIKRO-PULV

Mills (M) 8Milestones 29Mill building

steel plant bulks 12MILL-BLDG

steel plant bulks 12Mills (M) 14

ATTRITION 7attrition mill 7AUTOGENOUS 8autogenous mill 8BALL MILL 8ball mill 8MIKRO-PULV 8rod charger 8ROD MILL 8rod mill 8ROD-CHARGR 8ROLLER 8roller mill 8

Mineral woolinsulation materials 4

Minimum market value 29Miscellaneous

construction overhead 61Miscellaneous equipment

construciton equipment 12Miscellaneous expenses 56Miscellaneous indirect costs 29MISC-STEEL

steel plant bulks 16MIXER

Agitated Tanks (AT) 8, 9Mixers (MX) 8

EXTRUDER 29FIXED PROP 29HIGH SPEED 32MULLER EXT 29PAN 29PISTON HOM 34PORT-PROP 29SHEAR HOM 35SIGMA 30SPIRAL RIB 30

Index (G6)

STATIC 30TWO-ROLL 32

Mobilization/Demobilization 29Molecular sieve

packing materials 67Monel

tube materialsASME 14DIN 50JIS 38

Monolithic 8Mortgage bond 29Motion

axial, radial, vibrationsensor loop descriptions 17, 18, 19, 20

Motor control centerelectrical plant bulks 15

Mouse 29Moving averages 30MPS 30MULCH

landscaping - site development 11MULLER EXT

Mixers (MX) 29MULT-CYCLO

Dust Collectors (DC) 10MULTI WALL

Horizontal Tanks (HT) 5Vertical Tanks (VT) 15

Multifunction controllersinstrumentation plant bulks 6

MULTI-P+FHeat Exchanger (HE) 27

Multiple workforces 40Multi-project analysis 30

NNear-atmospheric liquid storage

Vertical Tanks (VT) 25Negative float 30Negatively correlated projects 30NEMA 30Neoprene rubber

lined steel pipe 58Neoprene sheet lining 63Net cash flows 30Net present value (NPV) 30Net working capital (NWC) 31Net working capital turnover 31Net worth 31Net worth turnover 31Network 31Network analysis 31Network diagram 31NEWCOA Relation 1, 11Nickel

casting materials 65plate materials

BS 21

17

JIS 33tube materials

ASME 14BS 26DIN 50JIS 38

NON-CONDTurbines (TUR) 9

Non-condensing turbine 9Non-reversible hammermill

Crushers (CR) 6Norman-type mixer

Mixers (MX) 32Nozzles

towers 5Number of walkways

AIR COOLER 3

OOFF-MACH

Agitated Tanks (AT) 17, 18Offsites 31OH 31OIL C BRKR 14OIL-WATER

Separation Equipment (SE) 25ONE DECK

Screens (VS) 28ONE SCREW

Heat Exchangers (HE) 24OPEN

Electrical Motors (MOT) 2OPEN BELT

Conveyors (CO) 2Open excavations

drainage - site development 4Open structure

steel plant bulks 2OPEN TOP

Agitated Tanks (AT) 11Open top tank (storage)

Vertical Tanks (VT) 26Open-end mortgage bond 32Operating lease 32Operating leverage 32Operational unit area 32Operator center

instrumentation plant bulks 6Operator centers 13, 14, 17

defining 20, 21major cost items 17

OPN-STL-STsteel plant bulks 2

Opportunity cost 32Option menu 32Order of magnitude

-30 to +50 percent estimate 32Organizational goal 32Organized exchange 32

18

Origin 33OSHA 33OSLO

Crystallizers (CRY) 3OT 33OTHER

Packing, Linings (PAK, LIN) 9Overhead 33

PP&ID 33PAC's 33PACKAGED

Cooling Towers (CTW) 3PACKED

Double Diameter Towers (DDT) 8Single Diameter Towers (TW) 16

PACKINGPacking, Linings (PAK, LIN) 7

Packingactivated aluminas 4activated carbon 4berl saddle 4

Packing, Linings (PAK, LIN) 11ACID BRICK 8activated aluminas 4activated carbon 4Berl saddle 4Intalox saddle 3OTHER 9PACKING 7Pall ring 3Raschig rings 3ring type packing 2Saddle type 2

Packingstower internals 4

Paid-in capital 33Paid-in surplus 33Paint

code of accounts 16grades 2

Pall rings 66introduction 3packing materials 4

PANDryers (D) 9Mixers (MX) 29

Panelinstrumentation plant bulks 2solar, electrical plant bulks 12

PANEL BRD 12Par value 34Parallel activities 34PASSENGER

Elevators, Lifts (EL) 13Path 34PAVING

site development 14

Index (G6)

Payback method (PM) 34Payroll burdens 57PC 34Percent-of-sales method for forecasting 34Permits

code of accounts 6, 30Perpetual bond 34Perpetual warrants 34PF-CORRECT

Power factor connection capacitor 16PFD 34Phase 0 34Phase I 35Phase II 35Piles, site development

piling 15PILING

piling - site development 16PIPE

piling - site development 15Pipe

supports, steel plant bulks 10, 11Pipe envelope

area specifications 7Pipe rack

steel plant bulks 6pipe routing type 13Pipe runs

piping plant bulks 3Pipe strainer, sanitary

Filters (F) 22PIPE TRACE

piping plant bulks 25Pipe Type 14PIPEDATA.SET file 13Pipeline reactors

jackedted pipe heat exchanger (HE) 22, 23PIPE-RACK

steel plant bulks 6PIPE-SUPPT

steel plant bulks 10, 11PIPE-TRACE

electrical plant bulks 5Piping

above-grade 3, 6buried 3buried concrete 20coat and wrap 34construction equipment 10control valve size 6drainage - site development 4DUCT RD 21DUCT SQ 22, 23ductwork 21fluid heat tracing 25hot tap 34launders 34paint 2PIPE TRACE 25

Index (G6)

Pipeline 51, 52, 53process ductwork 21tracing existing piping run 5transfer lines 3UTIL PIPE 19, 20utility headers 19well head 36YARD PIPE 3yard pipe runs 3

PIPTYP 14Piston, Other Positive Displacement Pumps

(P) 11DIAPHRAGM 22DUPLEX 21HD STOCK 24ROTARY 23SIMPLEX 21SLURRY 22TRIPLEX 21

PKG-TRANSFelectrical plant bulks 16

Plant bulk 35PLANTING

landscaping - site development 11PLAST TANK

Vertical Tanks (VT) 29Plastic storage tank

Vertical Tanks (VT) 29PLAT+FRAM

Heat Exchangers (HE) 26Plate

and frame filters (F) 12and frame heat exchanger 26and frame heat exchanger, sanitary 27spiral heat exchanger 25steel plant bulks 16towers, tray towers 20

PLATE+FRAMFilters (F) 12

PLATFORMsteel plant bulks 13

PLC 26, 35PLC control centers 26Plot plan 35Plunger pump, reciprocating

Piston, Other Positive Displacment Pumps (P) 23

PM/PE 35PNEUMATIC

Conveyors (CO) 7Pneumatic portable tool

construction equipment 13PNU-TUBING

instrumentation plant bulks 3PO 35POLE LINE 14POLE-LINE

electrical plant bulks 5, 16Polypropylene

19

lined steel pipe 58packing materials 66

PONDearthwork - site development 6

Porcelainpacking materials 66, 67

PORTABLEElectrical Generators (EG) 7

Portfolio effect 35Portfolio risk 36PORT-PROP

Agitators (AG) 3Mixers (MX) 29

Positive float 36Potential measurement test station

electrical plant bulks 11POT-TEST

electrcial plant bulks 11Pounds Sterling

currency base 37POURED

piling - site development 15Power distribution

country base location differences 29default 35main substation 31primary feeders 31reporting 36transmission lines 31unit substations 31unreferenced area requiring power 35usage instructions 34

Power factor 36Power factor connection capacitor 16Power function

Agitated Tanks (AT) 21Power number

Agitated Tanks (AT) 21PRECAST

piling - site development 15Precast concrete piles

piling - site development 15Precautionary motive 36Precedence notation 36Predecessor 36PRE-ENGR

Heat Exchangers (HE) 20, 21Preface iiiPreferred stock 36Preprocessor 36Present value 36PRESSURE

Screens (VS) 29Pressure

drumHorizontal Tanks (HT) 2

vesselVertical Tanks (VT) 11

Price 37

20

Primary KV 37Primary market 37Prime contractor

engineering 52, 57Prime rate 37Privilege level 37Pro forma financial statements 37Process control

area types 3considerations 15control centers 13, 16, 17, 22, 24default 13example 18, 19, 20introduction 14operator centers 13, 17, 20, 21overview 13project control data 19reporting 20volumetric models 15

Process ductworkpiping 21piping plant bulks 21, 22

Process engineering 37Process equipment 37

code of accounts 8item symbols 6symbols 6

Process fluid 37Process interface units

high enery level 9low enery level 9

Procurement 55disciplines and wage rates

JP 8UK 4US 3, 11

Product extension 37Productivity 38

other variables 47reporting 43workforce 40, 42

Profit margin 38Profitability ratios 38Program evaluation and review technique

(PERT) 38PROJDATA Relation 1PROJDATA Relations 11Project 38Project database 38Project definition

country base 37currency base 37reporting 39units of measure 39

Project estimate 38Project manager 38Project run 39Project schedule

barcharts 9, 11

Index (G6)

impacting 12introduction 9

Promissory note 39PROPELLER

Fans, Blowers (FN) 11Proxy 39PULP STOCK

Agitators (AG) 4Centrifugal Pumps (CP) 14Separation Equipment (SE) 23, 24

PULSE SHKRDust Collectors (DC) 8

Pulse type unitsDust Collectors (DC) 6

PULVERIZERCrushers (CR) 6

Pumpscasting materials 65construction equipment 13oil-sealed 7water-sealed 7

PVCpacking materials 67

PYROLYSISFurnaces, Process Heaters (FU) 40, 41

QQA/QC 39Queue 39Quick ratio 39Quit 39

RRadial network

power distribution 32RAILROADS

railroads - site development 17Rapid growth stocks 39Raschig rings 66

introduction 3RAYMOND

piling - site development 15RCON PIPE

piping plant bulks 20Reactors

CYLINDER, Vertical Tanks (VT) 11HORIZ-DRUM, Horizontal Tanks (HT) 2jacketed horizontal vessel, JACKETED

(HT) 7jacketed vertical vessel, JACKETED

(VT) 18OPEN TOP

AgitatedTanks (AT) 11packed towers 8, 16tray towers 12, 20

Reboilers (RB) 10KETTLE 30KETTLE - continued 31, 32, 34THERMOSIPH 34

Index (G6)

U-TUBE 35, 36Receivers

CYLINDER, Vertical Tanks (VT) 11HORIZ-DRUM, Horizontal Tanks (HT) 2

Recession 39RECIP-CONV

Centrifuges (CT) 4RECIP-GAS

Air Compressors (AC) 3Gas Compressors (GC) 9

RECIP-MOTRAir Compressors (AC) 4Gas Compressors (GC) 8Piston, Other Positive Displacement Pumps

(P) 24Reciprocating

Air Compressors (AC) 3Gas Compressors (GC) 8, 9

RECL-REELFilters (F) 17

Rectangular chestsVertical Tanks (VT) 35

RECTIFIERelectrical plant bulks 11

Rectifierelectrical plant bulks 11

Recuperative thermal oxidizerFlares (FLR) 9

Red herring 40Redundancy

introduction 32simple radial system 32spot network system 32

REFINERStock Treatment (ST) 9

RefinersStock Treatment (ST) 9

Refit 40REFORMER

Furnaces, Process Heaters (FU) 41Refrigeration Units (RU) 20

CENT-COMPR 6centrifugal compression 6MECHANICAL 6mechanical compression 6

Registered bond 40Regression analysis 40Relations 7Relationship of Database 7Relief

standard equations for pipe diameter 45REMARKS Relation 1, 10Remote shop

materials 40REMOVAL

demolition - site development 3Reorganization 40REPGRP Relation 1, 14Report groups 8

21

Reportingengineering 57power distribution 36project definition 39project schedule

barcharts 11workforce 43

Rescheduling 40Residual assets 40Residual theory of dividends 41Resins

demineralizer 8packing materials 67

Resistance temperature detectorinstrumentation plant bulks 7

Resource 41Resource based duration 41Resource leveling 41Resurfacing

site development 14RETAIN

earthwork - site development 6Retaining wall

earthwork - site development 6Retrofit 41Return on net working capital 41Return on net worth 41Return on total assets 41Revamp 41Reverse osmosis systems

HORIZ-DRUM, Horizontal Tanks (VT) 2Reversible hammermill

Crushers (CR) 6REV-HAMR

Crushers (CR) 5Revolving credit 42Reynolds number

Agitated Tanks (AT) 21Ribbon blenders

SPIRAL RIBMixers (MX) 30

Rietz single screwONE SCREW (HE) 24

Rights offering 42Ring granulator

Crushers (CR) 7Rings

Inert 2Intalox saddle 3introduction 2Pall, packing materials 3Raschig, packing materials 3Saddle type 2

RIP-ROCKearthwork - site development 8

Risk averter 42Risk neutral 42Risk-adjusted discount rate 42Risk-free interest rate 42

22

Risk-seeker 42Rock excavation

earthwork - site development 8Rod charger

Mills (M) 8Rod crushers

Crushers (CR) 8ROD MILL

Mills (M) 8Rod mill

Mills (M) 8ROD-CHARGR

Mills (M) 8ROG 42ROLL RING

Crushers (CR) 7ROLLER

Conveyors (CO) 8Mills (M) 8

Roller conveyorConveyors (CO) 9

Roller millMills (M) 8

Roofingsteel plant bulks 17

ROTARYBlenders (BL) 25Crushers (CR) 4Feeders (FE) 14Piston, Other Positive Displacement Pumps

(P) 23piston, other positive displacement pumps

(P) 23Rotary breaker

Crushers (CR) 6Rotary double-cone

Blenders (BL) 25Rotary drum

Blenders (BL) 25Rotary drum cooker-cooler

Drum Dryers (DD) 11Rotary Dryers (RD) 16

Conical rotary vacuum 13DIRECT 13INDIRECT 13Jacketed rotary vacuum 14JAC-VACUUM 13VACUUM 13

Rotary vane feederFeeders (FE) 14

ROTARYBOWLBlenders (BL) 26

ROT-BLOWERFans, Blowers (FN) 12

ROTY-DISKFilters (F) 12

ROTY-DRUMFilters (F) 13

RTABLE 1

Index (G6)

RTABLE Relation 16, 23RTD 9

resistance temperature detector 7Rubber

linings 6, 9Packing, Linings (PAK, LIN) 9

Run 42Runs of pipe

piping plant bulks 3

SS BELTCONV

Conveyors (CO) 10S INCLINE

Conveyors (CO) 11S VERTICAL

Conveyors (CO) 10S VIBRATRY

Conveyors (CO) 11Saddle

Berl 4Intalox 3, 4packing 2

Safety stock 43Sale and leaseback 43Sale of assets 43Sales force composite method for

forecasting 43Sales forecast 43Salvage value 43Sand

packing materials 67SAN-FIXED

Agitators (AG) 6Sanitary bulk bag unloader

Feeders (FE) 16Sanitary centrifugal pump

Centrifugal Pumps (CP) 15Sanitary corrugated double pipe exchanger

Heat Exchangers (HE) 26Sanitary counter-rotating agitator

Agitators (AG) 5Sanitary direct steam heat module

Heat Exchangers (HE) 29Sanitary dumper

Feeders (FE) 15Sanitary filter press

Filters (F) 19Sanitary fixed propeller/turbine mixer

Agitators (AG) 6Sanitary floor scale

Scales (S) 21Sanitary flow diversion panel

piping plant bulks 41Sanitary fluming pump

Centrifigal Pumps (CP) 17Sanitary fluming reclaim reel

RECL-REEL 17Sanitary highshear homogenizing agitator

Index (G6)

Agitators (AG) 5Sanitary horizontal conveyor

Conveyors (CO) 10Sanitary incline conveyor

Conveyors (CO) 11Sanitary in-line metal trap

Filters (F) 17Sanitary kettle blender

Blenders (BL) 25Sanitary multi-zone plate+frame exchanger

Heat Exchanger (HE) 27Sanitary pipe filter

Filters (F)SAN-PIPE 18

Sanitary pipe strainerFilters (F) 22

Sanitary piston-type homogenizerMixers (MX) 34

Sanitary portable propellerAgitatators (AG) 7

Sanitary process equipmentAgitators (AG)

COUNT-ROT 5HIGH SHEAR 5SAN-FIXED 6SAN-PORT 7

Blenders (BL)KETTLE 25MSHELSTAG 27ROTARYBOWL 26

Centrifugal Pumps (CP)FLUME PUMP 17SAN-PUMP 15

Conveyors (CO)S BELTCONV 10S INCLINE 11S VERTICAL 10S VIBRATRY 11

Drum Dryers (DD)S-COOKCOOL 11

Feeders (FE)DUMPER 15SACK-DUMP 16SAN-BELT 17SAN-SCREW 16

Filters (F)METAL TRAP 17RECL-REEL 17SAN-PIPE 18SAN-PRESS 19SAN-STRAIN 22

Heat Exchangers (HE)CORRUGATED 26HOT WATER 27MULTI-P+F 27STM-HE-MOD 29

Horizontal Tanks (HT)SAN-TANK 9

Mixers (MX)

23

HIGH SPEED 32PISTON HOM 34RIBBON 32, 33, 34SHEAR HOM 35


AIR DIAPH 26ROTARYLOBE 25

Scales (S)SAN-FLOOR 21

Vertical Tanks (VT)SAN-TANK 40

Sanitary ribbon blenderMixers (MX) 32, 33, 34

Sanitary rotary bowl blenderBlenders (BL) 26

Sanitary screw feederSAN-SCREW 16

Sanitary shear pump homogenizerSHEAR HOM 35

Sanitary vertical conveyorConveyors (CO) 10

Sanitary vertical cylindrical vesselVertical Tanks (VT) 40

Sanitary vibratory conveyorConveyors (CO) 11

Sanitary, multi-shell, staggered blenderBlenders (BL) 27

SAN-PIPEFilters (F) 18

SAN-PRESSFilters (F) 19

SAN-PUMPCentrifugal Pumps (CP) 15

SAN-SCREWFeeders (FE) 16

SAN-TANKHorizontal Tanks (VT) 9Vertical Tanks (VT) 40

Saranlined steel pipe 58

SAWTOOTHCrushers (CR) 5

SC 43SCAFFOLD

civil plant bulks 5Scaffolding

civil labor 5construction overhead 62

Scales (S) 17BEAM SCALE 19BELT 19BENCH 19FULL-FRAME 19SEMI-FRAME 19TANK SCALE 20TRACK 20TRUCK 20

Scan 43

24

Scheduling 43S-COOKCOOL

Drum Dryers (DD) 11Scope 44Scraped surface crystallizer

Crystallizers (CRY) 2SCRAPER LR

piping plant bulks 35Screen bowl

Centrifuges (CT) 5SCREEN-BWL

Centrifuges (CT) 5Screens (VS) 19

BAR 29HUMMER 28LD STOCK 29ONE DECK 28PRESSURE 29SIFTER-1 28SIFTER-2 28SIFTER-3 28THREE DECK 28TWO DECK 28

SCREWConveyors (CO) 8

Screw heaterone screw thermascrew 24two screw thermascrew 24

SCROLLFilters (F) 14

Scroll conveyorCentrifuges (CT) 4

Scroll discharge centrifugal filterFilters (F) 14, 16

SCROLL-CONCentrifuges (CT) 4

SEALCOATsite development 14

Seasonal dating 44Secondary markets 44Security 44SEEDING

landscaping - site development 11Seismic data 15Select 44SELF-SUPP

Flares (FLR) 3, 7SEMI-FRAME

Scales (S) 19Semivariable costs 44Sensitivity analysis in cash budgeting 44Sensor loop descriptions

pressure 10Separation Equipment (SE) 19

OIL-WATER 25PULP STOCK 23, 24WATER-CYCL 24

Septic tankdrainage - site development 4

Index (G6)

SEPTIC-TNKdrainage - site development 4

Sequence 44SEWAGE

Filters (F) 14Sewage filter

Filters (F) 14Shaker type filters

Dust Collectors (DC) 6SHEAR HOM

Mixers (MX) 35Shell and head design

towers 6SHELL+TUBE

Heat Exchangers (HE) 24SHORING

earthwork - site development 8SIDEWALKS

site development 14SIDING

railroads - site development 17steel plant bulks 17

Siding and roofingsteel plant bulks 17

SIDING-HVYrailroads - site development 17

Sievemolecular, packing materials 67

Sieve trays 3SIFTER-1

Screens (VS) 28SIFTER-2

Screens (VS) 28SIFTER-3

Screens (VS) 28SIGMA

Mixers (MX) 30SIGNAL

railroads - site development 17Signal wire

instrumentation plant bulks 3Silencers

CYLINDER, Vertical Tanks (VT) 11, 40HORIZ-DRUM, Horizontal Tanks (HT) 2

Silica gelpacking materials 67

S-IMPACTCrushers (CR) 6

Simple radial, redundancy 32SIMPLEX


SINGLE 1-SAir Compressors (AC) 4

SINGLE 2-SAir Compressors (AC) 4

SINGLE ATMDrum Dryers (DD) 11

Single Diameter Towers (TW) 12

Index (G6)

DC HE TW 23PACKED 16TRAY STACK 23TRAYED 20TS ADSORB 26

Single roll crushersCrushers (CR) 4

SINGLE STGEjectors (EJ) 3

SINGLE VACDrum Dryers (DD) 11

Sinking fund 45Site development 45Site/office equipment

construction equipment 14SITE-EXCVN

earthwork - site development 8Skirts

towers 5Slippage 45SLURRY


Slurrystandard equations for pipe diameters 44

Small toolsconstruction overhead 61

SnubbersCYLINDER, Vertical Tanks (VT) 11

SODDINGlandscaping - site development 11

Softenersdemineralizers 8packed towers 8, 16water softening systems 8

SOFTENINGWater Treatment Systems (WTS) 8

Softening treatment systemWater Treatment Systems (WTS) 8

Soilsite development

stabilization 6sterilization 11

Solar panelelectrical plant bulks 12

SOLAR-PANLelectrical plant bulks 12

SOLID BOWLCentrifuges (CT) 4

Solvent extraction towers 3Source of funds 45Sources and use of funds statement 45SPAN* 60SPARKLER

Filters (F) 15Spary

chambers, washers (DC) 10Special reports 45Speculative motive for holding cash 45

25

SPHEREVertical Tanks (VT) 21

SPHEROIDVertical Tanks (VT) 23

Spheroidshemispheriod 23hortonspheriod 23

SPHOS 40, 41SPIRAL PLT

Heat Exchangers (HE) 25SPIRAL RIB

Mixers (MX) 30Spiral ribbon mixer

SPIRAL RIBMixers (MX) 30

Spot networkpower distribution 32

SPRAYDryers (D) 10

Sprinkler systemSPRNK 3, 36

SQL 45S-ROLL-HVY

Crushers (CR) 5S-ROLL-LT

Crushers (CR) 4, 5S-ROLL-MED

Crushers (CR) 5SRSC 5SRST 5SS 45STABILIZE

earthwork - site development 6Stable dollar dividend policy 46STACK

Stacks (STK) 10Stacks (STK) 21

height calculation 2STACK 10thickness 4

Stainless steelcasting materials 65clad plate materials

BS 22DIN 46

packing materials 67STAIR

steel plant bulks 15Stairs

steel plant bulks 15Standard basis 46Standard horizontal tube evaporator

Evaporators (E) 6STAND-HOR

Evaporators (E) 6Standpipe

SPHOS 40STAND-VERT

Evaporators (E) 5

26

Start float 46Starting activity 46Start-to-start lag 46Start-up 56

disciplines and wage ratesJP 9US 3, 11

STATICMixers (MX) 30

Stationpotential measurement test

electrical plant bulks 11STATIONARY

Kneaders (K) 28Statutory consolidation 46Statutory merger 46Steam

plant, Water Treatment Systems (WTS) 8standard equations for piping

diameters 44Steam Boilers (STB) 20

BOILER 4field erected 4packaged boiler 4STM BOILER 4

Steam turbine 9Steel

boxes 16casting materials 64chutes 16columns, beams, bracing 2, 16elevated access platforms 13fabricated plate items 16fireproofing for existing stuctural steel 2gallery structure 14grate 15ladders 15mill building 12open structure 2pipe rack 6siding and roofing 17stairs 15transfer tower 15

STEEL-Hpiling - site development 16

STERILIZElandscaping - site development 11

Stirred vesselsagitated open tanks

Agitated Tanks (AT) 12STM BOILER

Steam Boilers (STB) 4Stock dividend 46Stock markets 47Stock pumps

high density 24low consistency 14

Stock right 47Stock split 47

Index (G6)

Stock Treatment (ST) 14DEFLAKE-CN 10DEFLAKE-DK 9REFINER 9

Stockholders_quity 47Stone

packing materials 66Stoneware

packing materials 66STOPS

railraods - site development 17STORAGE

Flares (FLR) 10Vertical Tanks (VT) 25

Stripping towers 3STRIP-SOIL

earthwork - site development 9STRUC-EXC

earthwork - site development 9Structure

open, steel plant bulks 2Structures

civil plant bulks 3Sub-critical activity 47SUBDRAIN

drainage - site development 4Subordinated debenture 48SUBPAVING

site development 14Subproject 48Subscription price 48Substations

power distributionmain 31unit 31

SUBSTN STL 14SUBTYPE

database relation attributes 46, 47, 48, 49, 50, 51, 52, 53

Successor 48SUC-HEATER

Heat Exchangers (HE) 25Summary funds statement 48Summary reports

code of accounts 5Sump pit

drainage - site development 4SUMP-PIT

drainage - site development 4Super-critical activity 48Support personnel 56SURF-ANODE

electrical plant bulks 11SW 48Swing jaw crusher

Crushers (CR) 4SWING-HAMR

Crushers (CR) 6Switch board 16

Index (G6)

Symbolprocess equipment 6

SYNCHRONElectrical Motors (MOT) 3

Synchronous motors 3System base indices, cost reporting 39

TTake-off 48Tank containment

civil 5TANK SCALE

Scales (S) 20TAR-CHIP

site development 14Target finish ©roject 49Target finish šctivity 48Target start šctivity 49Taxes and permits

code of accounts 6, 30TC 7, 9TC16 5TEFC 49TEFC (totally-enclosed fan-cooled)

Electrical Motors (MOT) 3Teflon

lined steel pipe 58Teflon sheet lining 63Telescoping gas holder

Vertical Tanks (VT) 30Tellerettes H.D. 67TEMA 49TEMA-EXCH

Heat Exchangers (HE) 14Temperature swing adsorbtion unit 26Temporary construction 49Tender offer 49Terminal warehouse receipt 49Test borings

earthwork - site development 6Test station

electrical plant bulks 11TEWAC 49TEWAC (totally enclosed water cooled)

Electrical Motors (MOT) 4generated for API 610 pump 5

Text string 49THCPL-WIRE

instrumentation plant bulks 4Thermascrew (Rietz) singel screw (HE) 24Thermocouple

instrumentation plant bulks 7Thermocouple wire

instrumentation plant bulks 4THERMOSIPH

Reboilers (RB) 34Thermosiphon reboilers

Reboilers (RB) 34THICKENER

27

Thickeners (T) 26Thickeners (T) 19

THICKENER 26THIN FILM

Wiped Film Evaporators (WFE) 7This 5, 1THREE DECK

Screens (VS) 28THRM-OX LC

Flares (FLR) 9Tile Chests

Vertical Tanks (VT) 35TILTING

Kneaders (K) 28Time value of money 50Times interest earned 50Titanium

plate materialsBS 21DIN 45

tube materialsASME 14DIN 50JIS 38

Tools, smallconstruction overhead 61

TOP UNLOADCentrifuges (CT) 3

TOPSOILlandscaping - site development 11

Torispherical towers 5Total assets turnover 50Total debt to total assets ratio 50Total float 50Total stockholders_quity 50Towers

absorption 3adsorption 3applications 1, 2appurtenances 6convey transfer, steel plant bulks 15description of 1, 5desorption 3distillation 2ellipsoidal 5elliptical 5extraction 3fractionator 3functions 5hemispherical 5internals 1, 3manholes 5materials of construction 6nozzles 5packings 4shell and head design 6sieve trays 4skirt 5solvent extraction 3

28

stripping 3torispherical 5trays 3

TRACE CNTR 13TRACE PANL 12Tracing

existing equipment 4existing piping run 5piping plant bulks 24

TRACKScales (S) 20

Track scaleScales (S) 20

Track yard sidingrailroads - site development 17

Trade acceptance 50Trailer

construction equipment 5Transaction loans 50Transactional motive for holding cash 50Transfer lines

piping plant bulks 3Transfer tower

steel plant bulks 15TRANSFORM 14Transformer/rectifier

electrical plant bulks 11Transmission line

overhead - electrical plant bulks 5, 16Transmission lines

power distribution 31Travelling bridge crane

Cranes (CE) 13Tray

cable, electrical plant bulks 4Tray Drying Systems (TDS) 16

ATM-SYSTEM 14batch tray 14TURBO 14turbo drying system 14VAC-SYSTEM 14VACUUM 14

TRAY STACKSingle Diameter Towers (TW) 23

TRAYEDDouble Diameter Towers (DDT) 12Single Diameter Towers (TW) 20

Traystower internals 3

Treasury stock 51Tree diagram 51TRENCH

civil plant bulks 5TRENCH-EXC

earthwork - site development 9Trenching

civil 5Trend projection 51TRIPLEX

Index (G6)

Piston, Other Positive Displacment Pumps (P) 21

TRNS-TOWERsteel plant bulks 15

TRUCKScales (S) 20

Truckconstruction equipment 2

Truck scaleScales (S) 20

Trust receipt 51Trustee 51TS ADSORB

Single Diameter Towers (TW) 26T-T 48Tube materials

DINnon-ferrous 50

TUBULARCentrifuges (CT) 5Filters (F) 15

Tubularexchangers (HE) 4

Tubular fabric filtersFilters (F) 15

TURBINECentrifugal Pumps (CP) 14

Turbines (TUR) 9CONDENSING 9GAS 10NON-COND 9non-condensing 9steam turbine 9

TURBOTray Drying Systems (TDS) 14

Turbo drying systemTray Drying Systems (TDS) 14

TURBOEXPANDER 10TURBO-GEN

Electrical Generators (EG) 7TURNOUT

railroads - site development 17TWO DECK

Screens (VS) 28TWO SCREW

Heat Exchangers (HE) 24TWO STAGE

Ejectors (EJ) 3TWO-ROLL

Mixers (MX) 32

UUBC Zone

seismic data 15UK country base

units of measure 39Underground cable duct 12Underwriting syndicate 51Unit cost database 51

Index (G6)

Unit cost library 2Unit substation 51Unit substations

power distribution 31Units of measure

project definition 39Unsecured loan 52UPS

electrical plant bulks 16US country base

units of measure 39Uses of funds 52UTIL PIPE

Piping plant bulks 19Utility headers

piping 19, 50U-TUBE

Heat Exchangers (HE) 11, 12, 13, 37, 38Reboilers (RB) 35, 36Reboilers (RB) - continued. 35, 36

VVAC-SYSTEM

Tray Drying Systems (TDS) 14VAC-TILTNG

Kneaders (K) 28VAC-TRAY

Dryers (D) 9VACUUM

Rotary Dryers (RD) 13Tray Drying Systems (TDS) 14

Vacuum Pumps (VP) 13MECHANICAL 7MECH-BOOST 7WATER-SEAL 7

Vacuum tray batch dryerDryers (D) 9

Value 52Value engineering 52Valve trays 3VANEAXIAL

Fans, Blowers (FN) 12Vaneaxial fan

Fans, Blowers (FN) 12Vapor control flare

Flares (FLR) 10Variable cash budget 52Variable costs 52Variable payment sinking fund 52VARY-SPEED

Electrical Motors (MOT) 5Vendor representatives 52

construction overhead 62VERTICAL

Furnaces, Process Heaters (FU) 41Vertical merger 52Vertical Tanks (VT) 13

CHEST-CYL 37CHEST-MTL 39

29

CHEST-REC 35cone bottom 31CONE BTM 31cone roof (storage) 26CRYOGENIC 28CYLINDER 11flat roof (storage) 25floating roof (storage) 25GAS HOLDER 30high pressure gas/liquid storage 21JACKETED 18lifter roof (storage) 26LIVE BTM 33, 34MULTI WALL 15near-atmospheric liquid storage 25open top (storage) 26PLAST TANK 29plastic storage 29pressure/vacuum service 11SAN-TANK 40SPHERE 21SPHEROID 23STORAGE 25telescoping gas holder 30tile chests 35WOOD TANK 30wooden (storage) 30

Vessel basedesign code

ASME 10BS 22JIS 34

Vesselsagitated open tanks

Agitated Tanks (AT) 11demineralizers (WTS) 8pressure

Agitated Tanks (AT) 8sphere, Vertical Tanks (VT) 21spheroid, Vertical Tanks (VT) 23tray or packed towers 8, 12, 16, 20vacuum

Agitated Tanks (AT) 8VIBRATING

Conveyors (CO) 8Feeders (FE) 15

Vibrating conveyorConveyors (CO) 8

Vibrating feederFeeders (FE) 15

VIBRATORYCentrifuges (CT) 5

Volumetric belt feederFeeders (FE) 14

Volumetric models 15

WWage rates

reporting 43

30

workforces 40, 42Walkways, gallery 15Wall, free standing

fencing - site development 10WASHERS

Dust Collectors (DC) 10WASTE HEAT

Heat Exchangers (HE) 25Water heater

Heat Exchangers (HE) 27Water supply well, cased

drainage - site development 4Water Treatment Systems (WTS) 20

AERATOR 8DEMINERAL 8SOFTENING 8

WATER-CYCLSeparation Equipment (SE) 24

Water-only cyclonesSeparation Equipment (SE) 22, 25

WATER-SEALVacuum Pumps (VP) 7

Water-sealed vacuum pump 7WATER-WELL

drainage - site development 4Weight belt

sanitary 17Weighted cost of capital 53Welding equipment

construction equipment 9, 10WELL HEAD

piping plant bulks 36, 38, 40, 41WELLPOINTS

drainage - site development 5WELLS

drainage - site development 5WFE-SYSTEM

Wiped Film Evaporators (WFE) 7White water filter

Filters (F) 15WHITEWATER

Filters (F) 15Windows NT workstation 53Wiped Film Evaporators (WFE) 15

agitated thin film evaporator 7THIN FILM 7WFE-SYSTEM 7

Wire mesh fencingfencing - site development 10

WOODpiling - site development 16

WOOD TANKVertical Tanks (VT) 30

Work breakdown structure (WBS) 53Work items

concept 49Work load 53Work unit 53Work week adjustments

Index (G6)

workforce 51Workforce

craft names 43craft productivity 50craft wage rates 42crew mix modifications 42multiple workforces 40productivity 40productivity concepts 43reporting 43wage rates 40, 42work items 49work week adjustments 51

Working capital 53Working capital management 53WSHWR 40, 41WT-LOSS

Feeders (FE) 15

YYARD PIPE

piping plant bulks 3Yen

currency base 37Yield to maturity 54

ZZero float 54Zero growth stocks 54Zero-base budgeting 54Zinc

coating - lining 63linings 6

Index (G6)
31

32
Index (G6)