DIRECT FIXED COST

ESTIMATES
ESTIMATE METHODS FOR
AUXILIARIES AND SPECIFIC
COMPONENTS

AUXILIARY FACTILITIES
AS LISTED IN THE TEXT:

GENERAL CATEGORIES
PLANT UTILITY SYSTEMS

STEAM
WATER
http://www.syska.com/
AIR
Energy/images/StPOWER
Joes-Boiler-plnt.jpg
NATURAL GAS

MINOR UTILITIES

FIRE SYSTEMS
INERT GASES

WASTE DISPOSAL

SEWERS
HAZARDOUS MATERIAL
TREATMENT SYSTEMS

DISTRIBUTION &
TRANSPORTATION SYSTEMS

ROADS
RAILS
DOCKS

http://www.smvrhm.org/2misc/un
k-boxcar-loading.jpg

ESTIMATE FACTORS
DEPEND ON TYPE OF FACILITY

AUXILIARY PROCESSES CAN BE

COMPLICATED
EXAMPLE OF WASTE TREATMENT
PROCESS

PIPING SYSTEM COST

ESTIMATES

ESTIMATES DEPEND ON
FOLLOWING FACTORS
TYPE OF SYSTEM

http://www.welcoser
WELDED
vices.com/pic3b.jpg
SCREWED
SWAGED FLANGES
WELDED FLANGES

MATERIALS OF CONSTRUCTION
SEE TABLE 12-2 FOR ALTERNATE
TYPES

PIPING DESIGN CRITERIA

MAXIMUM VELOCITIES

DIAMETER IS GENERALLY SET TO MEET

PROJECT CRITERIA
SEE TABLE 12.3 AND NOTE LIMITS AS A
FUNCTION OF VISCOSITY

SPECIFIED PRESSURE DROP (SEE MEMO

CTA-02)

USE SPECIFIC EQUATIONS FOR LAMINAR,

TURBULENT, COMPRESSIBLE AND
INCOMPRESSIBLE FLOW.
CHOOSE MORE CONSERVATIVE (LARGER
DIAMETER) WHEN COMPARING RESULTS
FROM VARIOUS MODELS
AVOID SONIC VELOCITY (VALVES ARE PRIMARY
SOURCES)

OTHER CONSTRAINTS
CODES
ASME B31.3 PROCESS PLANT PIPING
ASME B31.1 STEAM PIPING

SYSTEM CURVES

PRESSURE DROP IN FLUID FLOW

LINES (TOTAL HEAD)
USING EQUIVALENT LENGTHS REQUIRE
SOME IDEA OF THE ROUTING.
FACTORS IN CRANE OR CAMERON.

www.fluidedesign.com/downlo
ad-free/chapter4-extract.pdf

PIPING INSTALLATION OPTIONS

OVERHEAD PIPING SYSTEMS

ARE EASIER TO MAINTAIN

RUN PIPING IN RACKS

MINIMUM SIZE IS GENERALLY
2"(NOM) TO ALLOW REASONABLE
SPAN OF ABOUT 25 FT
RACK PIPING LAYOUT SHOULD
ISOLATE INCOMPATIBALE
MATERIALS
USE STRUCTURAL STEEL IN
BUILDINGS
http://www.sococo.co.uk/petro-chemical.htm

SUBSURFACE PIPING
GENERALY LOCATED IN
TRENCHES

DOES NOT INTERFERE

WITH MOST SURFACE
OPTIONS
CAN LIMIT SPREAD OF
LEAKS WHEN FLUIDS
FLOW INTO TRENCHES
TRENCHES MUST BE
PERIODICALLY DRAINED
HAVE MIXED EFFECTS IN
FIRES

MANY PLANTS HAVE A

COMBINATION OF
OVERHEAD AND
SUBSURFACE PIPING
http://www.nasm.si.edu/udvarhazy/bts/goo
d_place/hazy_4.jpg

DETAILED PIPING DESIGN

FACTORS

ATTEMPT TO MAINTAIN CONSTANT

VELOCITIES THROUGH SYSTEMS FOR
PURPOSES OF EFFICIENCY
USE WELDED WHERE LEAKS OF
HAZARDOUS MATERIALS WOULD BE
POSSIBLE
FLANGED FITTINGS ARE USED WHERE
LINES MIGHT BE FREQUENTLY OPENED
FOR MAINTENANCE
LINES 2-3"(NOM) IN DIAMETER MAY BE RUN
IN THE FIELD. LARGER SHOULD BE
FABRICATED IN SHOP.

PIPING QUALITY CHECKS

RADIOGRAPHY REQUIREMENTS

RANGE FROM 0% ON LOW RISK SYSTEMS TO

100% ON HIGH RISK
5% RANDOM A TYPICAL INTERMEDIATE VALUE.
THERMAL AND MECHANICAL STRESS
CONSIDERATIONS

EXPANSION MUST BE CONSIDERED AND

SYSTEMS DESIGNED TO HAVE ZERO
STRESS ON EQUIPMENT NOZZLES

NPSH MAY BE A FACTOR WHEN DESIGN FOR

PUMP INLETS. SEE PERRY'S FOR GUIDELINES
AVOID VAPOR TRAPS IN EQUIPMENT PIPING
CONTROL VALVES SHOULD BE ISOLATED TO
ALLOW REMOVAL FOR MAINTENANCE
WITHOUT SHUTTING DOWN THE SYSTEM

VALVE DESIGN CRITERIA

DEPEND ON MEDIA AND

SERVICE

POSITIVE SHUTOFF - GATES,

PLUG, BALL
GASES - GATES FOR SHUTOFF,
BUTTERFLYS FOR THROTTLING
CHECK VALVES - PREVENT
BACKFLOW AND SHOULD BE
INSTALLED AFTER ROTATING
EQUIPMENT

http://www.valvediagno
stics.com/media/pictur
s/gate.gif

http://www.offshore247.com/n
ews/article.asp?Id=3226

http://www.valvediagnostics.c
om/media/pictures/check.gif

RELATIVE COSTS FOR PIPING

SEE FIGURES 12-4 THROUGH 12-12

PIPING COSTS ARE LOWEST FOR
SCREWED PIPING, BUT THIS IS
GENERALLY LIMITED TO 6 DIAMETER OR
LESS
STRAIGHT RUN PIPE IS GENERALLY FIELD
FABRICATED IN 20 FT SECTIONS

AUTOMATIC WELDING MACHINES FOR FIELD

INSTALLATIONS ARE AVAILABLE FOR STRAIGHT
RUNS
SCREWED CONNECTIONS CAN ALSO BE
INSTALLED IN LONGER SECTIONS

OTHER PIPING COST FACTORS

PIPE WITH BENDS, FITTINGS, VALVES,

MULTIPLE CONNECTIONS IS TYPICALLY
FABRICATED IN A SHOP
THE SHOP CAN BE LOCATED IN THE FIELD
FOR PIPE UNDER 1 FT IN DIAMETER
LARGE PIPE FABRICATIONS ARE
COMPLETE IN A SHOP WITH AUTOMATED
WELDERS
http://home.iprimus.com.au/jackdo
g/lockseam22.jpg
http://www.alibaba.com/catal
og/11115924/Quality_Pipe_
Fittings_Elbow_Bend_Tee_
Flange_Reducer.html

SPECIFIC EXAMPLE
Cl2 PLANTS
PRODUCTION ECONOMICS FOR DIAPHRAGM Cl2
Cl2 Capacity
Cl2 Production

ST/Y
ST/Y

275000
275000

450000
450000

1100000
1100000

Investment ($US millions)

Battery Limits

208

330

662

Off-Sites
Total Fixed Capital

100
308

158
487

317
978

PRODUCTION ECONOMICS FOR MEMBRANE Cl2

Cl2 Capacity
Cl2 Production

ST/Y
ST/Y

250000
250000

450000
450000

1100000
1100000

Investment ($US millions)

Battery Limits

DATA
FROM T. PAVONE
Off-Sites
Total Fixed Capital

221

350

702

93
314

148
497

297
999