Equipment Costing

Chapter 22 (p558-597)
CH EN 4253
Terry A. Ring
 6/10 scale up/down Factor
th

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

 Accounting for Inflation
Cost to purchase = Base Cost*(I/I base)
Base Cost, CB, = Historical price at Ibase
I is a Cost Index at present time
Chemical Engineering, CE, 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)
 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)0.6
Study Estimate (35%)
Method of Lang
CTCI=1.05*fL-TCI (Ii/Ibase-i) Cp-i
Lang factors for different types of Plants
Solids -3.10, Solids&Fluids 3.62, Fluids 4.73
Sum over all major equipment
Preliminary Estimate (20%)
Method of Guthrie
Bare module cost, CBM= Cp-base(I/Ibase)[FBM+(FdFpFm-1)]
d= design factor, p = pressure factor, m =materials factor
CTCI= CBM_i
Quote Estimate
 Purchase Costs for Equipment
Size Factor, S, 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
 Pumps & Electric Motors
Pump Types (Centrifugal, Gear, Plunger)
Centrifugal Pump
Size factor, S=Q(Head)0.5
Base Cost, CB=exp(9.2951- 0.6019[ln(S)] +0.0519[ln(S)]2)
Cp=FTFMatCB
Fm materials factor see Table 22.21
FT pump type factor see Table 22.20
Other types of pumps have different C B formulas
Electric Motor to drive pump
Size Factor=Power consumption, P C=PT/p/M=PB/M=QH/(33,000pM)
Q= flow rate, H = head, = density
Efficiencies (pump and motor) are a function of flow rate and break horsepower
(power without any losses), respectively
CB=exp{5.4866+0.013141[ln(PC)]+0.053255 [ln(PC)]2 +0.028628 [ln(PC)]3-
0.0035549[ln(PC)]4}
Cp=FTCB
FT= motor types factor see Table 22.22
M=~90%
Installation, etc, FBM=3.3
CBM=FBM*CP
 Fans
Fan
Sizing factor is the volumetric flow rate, Q
Different CB formula for different types of fans
CP=FHFM CB
FH Head factor see Table 22.24
FM material of construction factor
Fiberglass 1.8
Stainless steel 2.5
Nickel Alloy 5.0
Motor size by PC=QHt(in. water)/(6,350 FM)
M =~90%, FBM = 2.15
CBM=FBM*CP
 Blowers
Sizing factor is the power consumption, P C
Centrifugal (turbo) Blower
CB=exp{6.6547+0.7900[ln(Pc)]}
CP=Fm-fansCB

Motor
Motor size by PC=QHt(in. water)/(6,350 FM)
M =90% , FBM = 2.15
CBM=FBM*CP
 Compressors
Compressor types
Centrifugal, CB=exp{7.2223+0.80[ln(PC)]}
Reciprocating, CB=exp{7.6084+0.80[ln(PC)]}
Screw, CB=exp{7.7661+0.7243[ln(PC)]}
Size factor is the power consumed, PC=PB/C
CP=FDriveFMatCB
FDrive =1 (electric motor), 1.15 (steam), 1.25 (gas turbine)
FMat = 1.0 Carbon steel, 2.5 SS, 5.0 Nickel Alloy
CBM=FBM*CP
FBM = 2.15
 Heat Exchangers
Types of Heat exchangers
Floating, CB=exp{11.667-0.8709[ln(A)]+0.09005[ln(A)]2}
Fixed Head, CB=exp{11.0545-0.9228[ln(A)]+0.09861[ln(A)]2}
U-tube, CB=exp{11.147-0.9186[ln(A)]+0.09790[ln(A)]2}
Kettle, CB=exp{11.967-0.8709[ln(A)]+0.09005[ln(A)]2}
Thermosiphon, CB=
Double pipe, CB=exp{7.1248-0.16[ln(A)]}
Size Factor is HX area, A
CP=FpFMatFLCB
Pressure Factor, Fp= 0.9803+0.018(P(psig)/100)+0.0017(P(psig)/100) 2
Not for double pipe
Materials Factor, Fmat=a+(A/100)b, a & b from Table 22.25
a1.0 note error in first row of Table 22.5
Tube Length Factor FL= 1.25 for 8 ft, 1.0 for 20 ft. on a sliding scale
CBM = FBM*CP, FBM=3.17 (S&T), 1.80 (DP), 2.17 (Fin/Fan)
 Fired Heaters
Size Factor is the heat duty, Q
CB=exp{0.08505+0.766[ln(Q)]}
CP=FPFMatCB
FP=0.986-0.0035(P(psig)\500)+0.0175(P/500) 2
Fmat=1.4 Cr-Mo alloy steel, 1.7 for stainless
steel
CBM = FBM*CP, FBM=2.19
 Pressure Vessels
Storage Tanks
Distillation Towers
Tray
Packed
Absorber Towers
Stripping Towers
 Pressure Vessels
Sizing Factor is the weight of steel, W
Horizontal Vessels, 1,000<W<920,00 lb
CB=exp{8.717-0.2330[ln(W)]+0.4333[ln(W)] 2}
Vertical Vessels, 4,200<W<1,000,00 lb
CB=exp{6.775-0.18255[ln(W)]+0.02297[ln(W)] 2}
Add Platform Costs,
Horizontal, 3<Di<12 ft
CPL=1580(Di)0.20294
Vertical, 3<Di<21 ft
CPL=258.1(Di)0.7396(L)0.70684
Weight, W=(Di+ts)(L+0.8Di)tss
C=FMCB+CPL
FM= materials factor see Table 22.26
Installation, etc, FBM=4.16 (V), 3.05 (H)
CBM=FBM*CP
 Hoop Stress Calc for thickness, ts
Design Pressure is function of operating pressure, Po
For Po> 1,000psig use Pd=1.1Po
For Po< 1,000psig but not for vacuum
Pd=exp{0.60608+0.91615[ln(Po)]+0.0015655[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, corrosion
Different calculation for vacuum vessels
Also account for leakage when vacuum vessel is used
 Distillation Towers
Pressure vessel with plates or packing and additional
nozzles and manholes
Tray Cost
CT=NTFNTFTTFTMCBT
NT= no. trays
FNT= 1 for NT>20 otherwise FNT=2.25/(1.0414NT)

FTT = tray type, 1.0 sieve, 1.87 bubble cap

FTM= Materials, f(D)
Carbon Steel FTM=1.0
316 SS FTM=1.401+0.0788 Di
Installation, etc, FBM=4.16
CBM=FBM*CP
 Packed Distillation Column
Pressure vessel with platforms plus
packing
Packing Cost basis is volume of packing, VP
C=VpCPK+CDR
CPK= is installed cost per unit volume
Distributors cost, CDR
 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