Issuu

Emmanouil Moulos

Sr. Mechanical Engineer, Dipl. (MSc @ NTUA)

Welded pipework Estimation Manual in man-hours per ton units© An open source estimation guide analysing 38 pipe sizes through 4,390 different thicknesses of standard and non-standard sec tions

Tendering is an art for the estimator, budget for the management and target for the construction

Title Welded pipework Estimation Manual in man-hours per ton units©

Author Emmanouil Moulos Mechanical Engineering on Energy, MSc (NTUA) Mechanical Engineering on Energy, BSc (TEI of Athens)

emmoulos@gmail.com

Graphics Stavros Moulos Graphics Art Designer @ University of Applied Sciences of Athens

Editing Maria Eleni Moulou Political Scientist (AUT), MA @ University of Westminster

First Edition Athens, March 2022 ISBN 978-618-205-251-8

Vatatzi 55, 114 73 Athens Τel.: +30210 6431108 e-mail: ocelotos@ocelotos.gr www.ocelotos.gr

All rights are reserved. Copying, storing and distribution of the present work, in whole or in parts, is prohibited without the written concept of the writer. Anyone making use of the information contained in this book does so at his/her own risk and assumes any and all resulting liability arising therefrom. While every precaution has been taken in the preparation of this document, the publisher and the author assume no responsibility for errors or omissions, or for damages resulting from the use of information contained in this document. In no event shall the publisher and the author be liable for any loss of profit or any other commercial damage caused or alleged to have been caused directly or indirectly by this document.

To my wife Sofia. She brought up three wonderful children back home at a time when I was delivering projects wandering around the world

Preface

After ten years of persistent efforts, my dream came true. In late 2017, I finally had my first book in hand, the “Tenders Cookbook”, and it was precisely 35 years after my bachelor’s degree graduation. But the book turned out to be far too long. That was because it covered all the construction practices that I have experienced. To make it handy, it was necessary to omit many topics as its size was far too big, and that’s when I felt the urge to write this one.

This book aims to present data inaccessible to the public and concern piping estimation work in man-hours per ton as a measuring units system. Its unique open-source structure makes it easy to track or reconstruct the norms used, allowing the creation of tailor-made solutions that can fit any project. In the end, this book further considers the new generation of engineers entering the construction scene and the technological evolution of their era.

Emmanouil Moulos Senior Mechanical Engineer, Dipl. (MSc)

Preface •

Ever since I was a junior engineer, it was a dream of mine to publish a book. I desired the content of this book to include my fieldwork sub-contracting experience of that time, gathering all the reliable knowledge and data I have accumulated since then in one place.

Preface �� 5 Contents �� 7 Index of Tables ��9 Index of Charts ��10 1. NOTATIONS ��11 2. ESTIMATION UNITS CONVERSION ��12 3. MAN-HOUR NORMS �� 13 3.1..Introduction �� 13 3.2.. Construction standards & process considered �� 13 3.3.. Norm factors development for each pipe diameter size [1] �� 15 3.4.. Overhead factors [2] ��15 3.5.. Material factors (CS and Alloys) [2] ��16 3.6.. The welding complexity factors ��16 3.7.. Examples of the overall Nt factor use ��17 3.8.. Statistical core data considered in the charts ��17 3.9.. The Charts ��18 3.10.. Pipe data table headers description ��19 3.11.. Pipe man-hour norms (MH table) ��21 3.11.1.. Conditions ��21 3.11.1.1... Included ��21 3.11.1.2. Excluded ��21 3.11.1.3. Remarks �� 22 3.11.1.4. How the tables of para. (3.11) work �� 22 3.11.1.5. Controls summary of the method �� 24 3.11.2. Pipe sections data �� 25

3.11.2.1. Diam. ¼” pipe (OD=13,7mm & DN=8mm) �� 25 3.11.2.2. Diam. 3/8” pipe (OD=17,1mm &DN=10mm) �� 26 3.11.2.3. Diam. ½ ” pipe (OD=21,3mm & DN=15mm) �� 28 3.11.2.4. Diam. ¾ ” pipe (OD=26,7mm & DN=20mm) ��31 3.11.2.5. Diam. 1 ” pipe (OD=33,4mm & DN=25mm) �� 35 3.11.2.6. Diam. 1 ¼ ” pipe (OD=42,2mm & DN 32mm) �� 39 3.11.2.7. Diam. 1 ½ ” pipe (OD=48,4mm & DN=40mm) ��44 3.11.2.8. Diam. 2” pipe (OD=60,3mm & DN 50mm) ��48 3.11.2.9. Diam. 2 ½” pipe (OD=76,1mm & DN=65mm) �� 53 3.11.2.10. Diam. 3” pipe (OD=88,9mm & DN=80mm) �� 58 3.11.2.11. Diam. 3 ½ ” pipe (OD=101,6mm & DN=90mm) ��64 3.11.2.12. Diam. 4” pipe (OD=114,3mm & DN=100mm) ��69 3.11.2.13. Diam. 5” pipe (OD=139,7mm & DN=125mm) �� 74 3.11.2.14. Diam. 6” pipe (OD=168,3mm & DN=150mm) ��81 3.11.2.15. Diam. 8” pipe (OD=219,1mm & DN=200mm) �� 87 3.11.2.16. Diam. 10” pipe (OD=273,0mm & DN=250mm) ��94 3.11.2.17. Diam. 12” pipe (OD=323,8mm & DN=300mm) �� 101 3.11.2.18. Diam. 14” pipe (OD=355,6mm & DN=350mm) ��108 3.11.2.19. Diam. 16” pipe (OD=406,4mm & DN=400mm) ��113 3.11.2.20. Diam. 18” pipe (OD=457,0mm & DN=450mm) ��120 3.11.2.21. Diam. 20” pipe (OD=508,0mm & DN=500mm) ��126 3.11.2.22. Diam. 22” pipe (OD=559,0mm & DN=550mm) �� 132 3.11.2.23. Diam. 24” pipe (OD=610,0mm & DN=600mm) ��138 3.11.2.24. Diam. 26” pipe (OD=660,0mm & DN=650mm) ��144 3.11.2.25. Diam. 28” pipe (OD=711,0mm & DN=700mm) ��148 3.11.2.26. Diam. 30” pipe (OD=762,0mm & DN=750mm) �� 152 3.11.2.27. Diam. 32” pipe (OD=813mm & DN=800mm) ��156 3.11.2.28. Diam. 34” pipe (OD=864,0mm & DN=850mm) �� 161

Contents •

Contents

Welded pipework Estimation Manual in man-hours per ton units © Emmanouil Moulos

3.11.2.29. Diam. 36” pipe (OD=914,0mm & DN=900mm) ��165 3.11.2.30. Diam. 38” pipe (OD=965,0) ��169 3.11.2.31. Diam. 40” pipe (OD=1016,0mm & DN=1000mm) �� 173 3.11.2.32. Diam. 42” pipe (OD=1067,00mm & DN=1050mm) �� 177 3.11.2.33. Diam. 44” pipe (OD=1118,0mm & DN=1100mm) �� 181 3.11.2.34. Diam. 46” pipe (OD=1168,0mm & DN=1150mm) ��184 3.11.2.35. Diam. 48” pipe (OD=1219,0mm & DN=1200mm) ��187 3.11.2.36. Diam. 52” pipe (OD=1321,0mm & DN=1300mm) ��190 3.11.2.37. Diam. 56” pipe (OD=1422,0mm & DN=1400mm) �� 191 3.11.2.38. Diam. 60” pipe (OD=1524,0mm DN=1500mm) ��192 3.12.. Piping man-hour summary for norms in ASME B 36.10 format ��193 3.13..Piping man-hour norms summary vs. their linear weight per meter �197 3.14..Piping man-hour norms summary vs. their pipe wall thickness ��198 3.15..Handling of pipes for an onshore site ��199 3.16..Handling of pipes for an offshore site �� 202 3.17..Pack & dispatch pipe prefabricated spools �� 203

3.18..Valves �� 205 3.18.1.. Conditions �� 205 3.18.1.1.1... Included �� 205 3.18.1.1.2..Excluded �� 205 3.18.1.1.3.. Remarks ��206 3.18.2..Valve installation with unknown size ��206 3.18.3..Valve installation with known size and class �� 207 3.18.4..Valve hydrotesting with unknown size ��210 3.18.5..Valve hydrotesting with known size and class ��211 3.19..Pipe Supports �� 213 4. STATISTICAL DATA ��214 5. REFERENCES �� 215 6. BIBLIOGRAPHY �� 217

Table T.1: Table T.2: Table T.3: Table T.4: Table T. 5-1: Table T. 5-2: Table T. 5-3: Table T.6: Table T.7: Table T.8-1: Table T.8-2: Table T. 8-3: Table T. 9: Table T. 10-1: Table T. 10-2: Table T.11-1: Table T.11-2: TableT.11-1.3: Table T.12-1: Table T.12-2: Table T.12-3: Table T.13-1: Table T.13-2: Table T.14-1: Table T.14-2: Table T.15: Table T.16:

Notations used in the development of the book ��11 Estimation Units conversion �� 12 Welding complexity factors �� 16 Examples of the overall Nt factor use �� 17 Prefabricated pipe norms with reference to the partial weight �� 193 Prefabricated pipe norms with reference to the total weight ��194 ASMEB 36.10 installation norms with reference to the total weight �� 195 Summary of piping man-hours norms vs. their linear weight per meter �� 197 Piping man-hours norms vs. their pipe wall thickness in milimeters ��198 Handling onshore project pipe norms (%) breakdown ��199 Handling onshore project pipes norms per ton and meter �� 200 ASMEB 36.10 Onshore pipe handling norms �� 201 Handling of offshore project pipes norms (%) breakdown ��202 Pipe shop spools pack & dispatch gross norms ��203 ASME B 36.10 Pipe shop spools pack & dispatch norms �� 204 One valve installation norms # valve size unknown �� 206 Two valve flanges connection norms # valve size unknown �� 206 Two valve welded joints connection norms # valve size unknown ��207 One valve installation norms # size & class known ��207 Two valve flanges connection norms # size & class known �� 208 Two valve welded joints connection norms # size & class known �� 209 Site valve hydro-testing norms, with size unknown �� 210 Lab bench valve hydro-testing norms, with size unknown �� 210 Site valve hydro-testing one-by-one norms, with size & class known �� 211 Lab hydraulic bench valve testing norms, with size & class known �� 212 Pipe supports & Valves weight statistical data �� 214 Manual SMAW Pipe Welding Versus Orbital GTAW comparison chart [3] �� 215

Index of Tables •

Index of Tables

Index of Charts

Welded pipework Estimation Manual in man-hours per ton units © Emmanouil Moulos

Chart No 1: Number of Joints/DN size for 100 m of pipe �� 18 Chart No 2: Number of Inches/DN to be Welded (WIDs) �� 19 Chart No 3: Prefabrication percentage/DN for Plant Unit �� 19

1. NOTATIONS Table T.1: Notations used in the development of the book meter foot square meters cubic meters Kilogram Man-Hours Carbon Steel Welded Inch Diameter Radiographic Testing Penetrants Testing Magnetic Particles Testing Ultrasonic Testing Positive Materials ID Temp. Indicator/Thermo Well Blasting & Painting Front End Engineering Design General Arrangement Issued For Construction

IFD IFQ IFR ISO LDT MTO BOQ BOM NDT NDE P&ID PFD UFD WBS DBM EHT FAT SAT

Issued For Design Issued For Quotation Issued For Review Isometric Line Designation Table Material Take Off Bill of Quantities Bill of Materials Non Destructive Testing Non Destructive Examination Process Instruments Diagram Process Flow Diagram Utility Flow Diagram Work Breakdown Structure Design Basis Memorandum Electrical Heat Tracing Field Acceptance Test Site Acceptance Test

1. NOTATIONS •

m ft Sqm or m2 Cum or m3 Kgr Mhrs CS WID RT PT MT UT PMI TI/TW B&P FEED GA IFC

2. ESTIMATION UNITS CONVERSION For the metric to imperial system estimation calculations apply the factors below.

Welded pipework Estimation Manual in man-hours per ton units © Emmanouil Moulos

Table T.2: Estimation Units conversion

Kgrs x 0,4536 = Lbs Kgrs / Mhrs x 2,2046 = Lbs /Mhrs Kgrs / m x 0,67197 = Lbs / ft Kgrs / sqm x 0,2048 = Lbs /sqft Kgrs / cum x 2,2046 = Lbs /cum Kgrs / weld x 2,2046 = Lbs /weld Kgrs / ton x 2,2046 = Lbs / ton kWh / kgrs x 0,4536 = kWh / Lbs Lit x 0,2642 = U.S. gal

mm x 0,03937 = inch m x 3,281 = ft sqm x 10764 = sq ft cum x 35,32 = cuft 1000 cum = 35320 cuft Mhrs / m x 0,3048 = Mhrs / ft Mhrs / sqm x 0,0929 = Mhrs /sqft Mhrs / cum x 0,02831 = Mhrs /cuft

3. MAN-HOUR NORMS 3.1. Introduction This book covers all those occasions by which the piping work quotation can be requested per ton unit.

costs to complete the estimation in the safest way possible. 2)

And this can occur under two significant extreme variations. One with the detailed materials list available, and the other without the material list. The estimators` risks on these two variants in detail could be: 1)

The detailed materials list is available: Under this option, where all the project materials are known, the estimator apart the manhour norms should also add the necessary overhead and indirect

The materials list is not provided: If this is the case, all the risk falls onto the estimators’ shoulders, especially when the available quantities refer to a unit (1 Kgr or 1 ton). Practically, when this type of quotation is requested, the bid evaluation work concerns the estimator’s historic data and not the project specifications and details. And this is the second gap that this book attempts to fill to assist in securing this type of estimate.

In response to these risks above, a database of 38 pipe sizes (from DN ¼” to 60”) is presented below, developed through 4,390 different thicknesses, including standard and non-standard pipe sections.

The international standards that support the method below are: • • • • • • •

ASME IX ASME B31.1 ASME B31.2 ASME B31.3 ASME B31.4 ASME B31.5 ASME B31.8

Welding & Brazing Qualification, Power Piping, Fuel Gas Piping, Chemical Plant and Petroleum Refinery Piping, Liquid Petroleum Transportation Piping Systems, Refrigeration Piping, Gas Transmission and Distribution Systems,

The construction work activities considered for the development of the estimation method of this book are the following: 1) 2) 3)

Delivery of the pipe materials on site (Excluded, see para. 3.15, 3.16 & 3.17), Unloading, Sorting, and Storing of the materials, spreading the deliverables by size and type, (Excluded, see para. 3.15, 3.16 & 3.17 Delivery inspection before the release of the construction materials. (Excluded)

The points of such assessment are: a. Traceability of heat numbers and Markings, b. Bevel end damage, c. Flange face damage, d. Thread damage, e. Pipe body damage, f. Flange face cover, g. Pipe ends cover, h. Valve ends cover. 4)

Blast & Paint of the straight pipes, which are to be sent directly to the project area for installation, up to the final coat (Excluded),

3. MAN-HOUR NORMS • 3.1. Introduction

3.2. Construction standards & process considered

Welded pipework Estimation Manual in man-hours per ton units © Emmanouil Moulos

Shop Fabrication for the fittings & part of the straight pipes (Included), a. Pipe cutting by checking: Specifications, Traceability tags, External roundness, Internal roundness, Wall thickness, Spool tag number, Cutting length, Squareness of cut & Correct set-up. b. Edge preparation, by checking: Bevel angle, Root face & Correct set-up. c. Fit-Up, by checking: Alignment, Correct root gap, Bevel angle, Stub-In or Stub-Out branch, Orientation, TIG for tacking, TIG rods specified, Bullet materials correct (if applied). d. Welding by checking: Approved WPS/PQR, Root face-visual check, Travel Speed, Voltage/Ampere, Portable oven usage, Inter-pass cleaning, PMI on welds, PWHT & BHN on welds, RT requirements.

Blasting & Coating for the prefabricated spools up to the final coat (Excluded),

Field installation (Included, but the permanent supports norms that are necessary at this stage are excluded from the scope of this book), a. Pipe cutting by checking: Specifications correct, Traceability tags, External roundness, Internal roundness, Wall thickness, Spool tag number, Cutting length, Squareness of cut & Correct set-up. b. Edge preparation, by checking: Bevel angle, Root face & Correct set-up.

c. Fit-Up by checking: Alignment, Correct root gap, Bevel angle, Stub-In or Stub-Out branch, Orientation, TIG for tacking, TIG rods specified, Bulleted materials correct (if applied). d. Welding, by checking: Approved WPS/PQR, Root face-visual check, Travel Speed, Voltage/Ampere, Portable oven usage, Inter-pass cleaning, PMI on welds, PWHT & BHN on welds, RT requirements. 8)

PWHT and NDTs (Excluded),

Pressure test (Excluded),

10) Touch up (Excluded) 11) Reinstatement (or Lay-Up)(is not included in this book scope) (Excluded), The interface between the Fit-Up and the Welding is the “Tack Welding”. Applying it, the fitter should keep the tacks equal spaced. The minimum number of the tacks shall be: a. Two (2) Tacks: for 2 ½” pipe diameter and smaller, b. Four (4) Tacks: for 3” to 12” pipe diameter, and c. Six (6) Tacks: for 14” and larger pipe diameters. For the root pass the GTAW (TIG) method was selected, followed by SMAW (Electrodes) capping passes for finishing.

3.11.2. Pipe sections data

1,65

1/4

1,85

(f/ton) (18) 4435

% (19) 17,5%

(Mhrs/ton) (20) (21) 1369 1163

4435

17,5%

1359

3465

17,5%

1383

1174

3349

17,5%

1389

1180

3349

17,5%

1389

1180

3063

17,5%

1359

1154

155

287

121

224

117

217

117

217

107

198

(btls/ton) (9) (10) 10 4

0,76

1154

1/4

JIS 20s

2,00

0,76

184

2837

17,5%

1316

1117

1/4

2,11

0,76

184

2837

17,5%

1293

1098

1/4

JIS 40

2,20

0,76

170

2630

17,5%

1327

1127

1/4

STD

2,24

0,76

170

2626

17,5%

1316

1118

1/4

2,24

0,76

170

2626

17,5%

1316

1118

1/4

40s

2,24

0,76

170

2626

17,5%

1316

1118

1/4

2,30

0,76

166

2558

17,5%

1316

1117

1/4

2,31

0,76

165

2549

17,5%

1314

1116

1/4

2,50

0,76

155

2396

17,5%

1291

1097

2324

17,5%

1279

1086

1/4

2,60

0,76

151

1/4

2,77

0,76

144

2216

17,5%

1258

1068

1/4

2,80

0,76

142

2198

17,5%

1254

1065

1/4

2,87

0,76

140

2158

17,5%

1245

1057

1/4

2,90

0,76

139

2142

17,5%

1241

1054

1/4

2,97

0,76

136

2105

17,5%

1233

1047

1/4

3,00

0,76

135

2090

17,5%

1173

996

3. MAN-HOUR NORMS • 3.11. Pipe man-hour norms (MH table)

10s

(f/J) (17) 1

(12) 58

(8) 16

Onshore Installation

1/4

Workshop (%) Prefabrication

1,65

% Prefabrication rate

1,60

100% + 25 % RT 10x40

1/4

Films/Joint 10x40

1/4

Flapper, Φ.125x8

Cutting, Φ.125x7

1,25

Cutting, Φ.125x1,6

JIS 5s

(16) 58

(11) 155

(Kgr/ton) (6) (7) 49 75

Grinding, Φ.125x3,2

1/4

Discs (pcs/ton) (13) (14) (15) 287 12 6

Grinding, Φ. 230x7

(m/J) (5) 0,76

Cutting, Φ. 230x3,2

(nos) (4) 1

Acetylene

Statistics

(mm) (3) 1,24

Oxygen

One Joint Passes (SMAW/SMAW)

(Sch) (2) 5

100% SMAW packed electrodes ARGON-Prefab (CS)

Thickness

(nos) (1) 1/4

100% GTAW filler rod

NPS

Standards

3.11.2.1. Diam. ¼” pipe (OD=13,7mm & DN=8mm)

ISBN 978-618-205-251-8

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