Equipment Costing

Chapter 22 (p558-597) CH EN 4253 Terry A. Ring

6/10th scale up/down Factor
• Used for scaling the total capital cost for a chemical plant of a different size • Cost2/Cost1 = (Capacity2/Capacity1)0.6 • Accounts for economy-of-scale

Plant Cost Index • Marshall and Swift (MS) Equipment Cost Index • Nelson-Farrar (NF) Refinery Construction Cost Index • Engineering News-Record (ENR) Construction Cost Index – Cp(I) = Cp(Ibase)*(I/Ibase) – Cp(Ibase)=FT*Fm*Cbase(Ibase) . CB. = Historical price at Ibase – I is a Cost Index at present time • Chemical Engineering.Accounting for Inflation • Cost to purchase = Base Cost*(I/Ibase) – Base Cost. CE.

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10.62.73 • Sum over all major equipment • Preliminary Estimate (±20%) – Method of Guthrie – Bare module cost. p = pressure factor. Solids&Fluids 3. Fluids 4. m =materials factor – CTCI= ∑ CBM_i • Quote Estimate .Cost Estimate Methods • Order of Magnitude Estimate – Method of Hill • Marshall Swift for I/Ibase • Six Tenths Rule for Production Capacity – CTCI-2 (I)=CTCI-1 (Ibase)*(I/Ibase)* (Capacity2/Capacity1)0. CBM= Cp-base(I/Ibase)[FBM+(FdFpFm-1)] • d= design factor.05*fL-TCI ∑ (Ii/Ibase-i) Cp-i • Lang factors for different types of Plants – Solids -3.6 • Study Estimate (±35%) – Method of Lang • CTCI=1.

depends on type of equipment • Cp(Ibase)=A*(S)b • Cp(Ibase)=exp(Ao+A1[lnS]+A2[lnS]2+…) • Your book gives 2006 base costs • Ibase = 500 (2006) average . S.Purchase Costs for Equipment • Size Factor.

respectively • CB=exp{5.22 • ηM=~90% .2951. S=Q(Head)0.21 FT pump type factor see Table 22.4866+0. FBM=3. Gear. ρ = density • Efficiencies (pump and motor) are a function of flow rate and break horsepower (power without any losses).20 Other types of pumps have different CB formulas – Electric Motor to drive pump – Installation.013141[ln(PC)]+0.0035549[ln(PC)]4} • Cp=FTCB • FT= motor types factor see Table 22. CB=exp(9. etc.0519[ln(S)]2) Cp=FTFMatCB Fm materials factor see Table 22.053255 [ln(PC)]2 +0.5 Base Cost. Plunger) – Centrifugal Pump • • • • • • Size factor. H = head.3 – CBM=FBM*∑CP • Size Factor=Power consumption.000ηpηM) • Q= flow rate. PC=PT/ηp/ηM=PB/ηM=QHρ/(33.028628 [ln(PC)]30.6019[ln(S)] +0.Pumps & Electric Motors • Pump Types (Centrifugal.0.

8 2.5 5. water)/(6. Q Different CB formula for different types of fans CP=FHFM CB FH Head factor see Table 22.Fans • Fan – – – – – Sizing factor is the volumetric flow rate. FBM = 2.350 ηFηM) • ηM =~90%.24 FM material of construction factor • Fiberglass • Stainless steel • Nickel Alloy 1.0 • Motor size by PC=QHt(in.15 • CBM=FBM*∑CP .

PC • Centrifugal (turbo) Blower CB=exp{6.350 ηFηM) – ηM =90% .6547+0. water)/(6.Blowers • Sizing factor is the power consumption. FBM = 2.15 • CBM=FBM*∑CP .7900[ln(Pc)]} • CP=Fm-fansCB • Motor – Motor size by PC=QHt(in.

CB=exp{7. 1.2223+0.Compressors • Compressor types – Centrifugal. 1. 5. CB=exp{7.80[ln(PC)]} – Screw.25 (gas turbine) FMat = 1. PC=PB/ηC • CP=FDriveFMatCB • • • • FDrive =1 (electric motor). 2.0 Nickel Alloy CBM=FBM*∑CP FBM = 2.6084+0.15 .80[ln(PC)]} – Reciprocating. CB=exp{7.15 (steam).7661+0.5 SS.7243[ln(PC)]} • Size factor is the power consumed.0 Carbon steel.

0 for 20 ft.018(P(psig)/100)+0.9228[ln(A)]+0.17 (Fin/Fan) .09790[ln(A)]2} Kettle. FBM=3.147-0. CB= Double pipe. CB=exp{11.0545-0. A • CP=FpFMatFLCB • – Not for double pipe – Pressure Factor. Fmat=a+(A/100)b.8709[ln(A)]+0.80 (DP).0017(P(psig)/100)2 • • • Materials Factor. 1. CB=exp{11. 2.09005[ln(A)]2} Fixed Head. Fp= 0.8709[ln(A)]+0. CB=exp{11.1248-0.0 note error in first row of Table 22. CB=exp{11.25 for 8 ft.9186[ln(A)]+0.967-0.9803+0.09861[ln(A)]2} U-tube. on a sliding scale CBM = FBM*CP.17 (S&T). a & b from Table 22.667-0. CB=exp{7.Heat Exchangers • Types of Heat exchangers – – – – – – Floating.5 Tube Length Factor FL= 1.16[ln(A)]} • Size Factor is HX area. 1.25 a≥1.09005[ln(A)]2} Thermosiphon.

Q • CB=exp{0.986-0. FBM=2.7 for stainless steel • CBM = FBM*CP.Fired Heaters • Size Factor is the heat duty.08505+0. 1.4 Cr-Mo alloy steel.0035(P(psig)\500)+0.766[ln(Q)]} • CP=FPFMatCB • FP=0.0175(P/500)2 • Fmat=1.19 .

Pressure Vessels • Storage Tanks • Distillation Towers – Tray – Packed • Absorber Towers • Stripping Towers .

16 (V).000<W<920.8Di)tsρs • C=FMCB+CPL • FM= materials factor see Table 22.18255[ln(W)]+0.20294 CB=exp{8.4333[ln(W)]2} CB=exp{6. 3. 3<Di<21 ft • CPL=1580(Di)0. – Vertical.000. etc.775-0. 4.Pressure Vessels • Sizing Factor is the weight of steel. W • Horizontal Vessels. 1.717-0.200<W<1.00 lb • Vertical Vessels.00 lb • Add Platform Costs. 3<Di<12 ft • CPL=258.2330[ln(W)]+0.70684 • Weight.05 (H) – CBM=FBM*∑CP .02297[ln(W)]2} – Horizontal.1(Di)0. W=π(Di+ts)(L+0.26 – Installation. FBM=4.7396(L)0.

000psig use Pd=1. corrosion Different calculation for vacuum vessels – Also account for leakage when vacuum vessel is used .000psig but not for vacuum Pd=exp{0.1Po – For Po< 1. ts • Design Pressure is function of operating pressure.0015655[ln(Po)]2} • • • • • • • Thickness (Hoop Stress Calculation) ts= PdDi/(2SE-1.2 Pd) S = max allowable stress for steel is f(T) E = weld efficiency (fraction) Minimum wall thickness for given diameters May add extra thickness for wind stresses.Hoop Stress Calc for thickness. Po – For Po> 1.60608+0.91615[ln(Po)]+0.

f(D) – Carbon Steel FTM=1. trays CT=NTFNTFTTFTMCBT • FNT= 1 for NT>20 otherwise FNT=2. FBM=4.87 bubble cap • FTM= Materials.0 sieve. 1.Distillation Towers • Pressure vessel with plates or packing and additional nozzles and manholes • Tray Cost • NT= no. 1. etc.0 – 316 SS FTM=1.401+0.0788 Di • Installation.16 – CBM=FBM*∑CP .0414NT) • FTT = tray type.25/(1.

VP • C=VpCPK+CDR • CPK= is installed cost per unit volume • Distributors cost. CDR .Packed Distillation Column • Pressure vessel with platforms plus packing • Packing Cost basis is volume of packing.

Absorbers/Strippers • Pressure Vessel plus platforms and packing • Separate costs for blowers • Separate costs for motors .

Other process equipment • Different sizing factors • Different basis cost equations • Same methods used for cost calculation .

Other Process Equipment • Various Size Factors • Table 22.32 .

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