02 BOPs / Woods D.R 2008 rules-of-thumb-in-Engineering-practice (epdf.tips)

D.4 Detailed Equipment Cost Data Based on Equipment Type 381

= 0.90 for the range 15–120. Factor: FOB materials, q 1.00; field erected package, q 1.54.

Blowers, centrifugal, cast iron, 28 kPa g, motor and drive. FOB cost = $760 000 at inlet gas flow rate = 30 Nm3/s with n = 0.61 for the range 12–70. L+M* = 2–2.5. L/M = 0.25–0.53. Factors: pressure 28 kPa, q 1.00; 7 kPa, q 0.30; 14 kPa, q 0.45; 50–70 kPa, q 1.75; 140–200 kPa, q 4.5. Factors: including motor and drive, q 1.00; excluding motor and drive, q 0.63. Alloy factors: cast iron, q 1.00; fiberglass, q 2.6; s/s, q 2.6.

Blowers, rotary lobe, cast iron, 70 kPa g, drip proof motor and drive; single stage. FOB cost = $25 000 at drive power = 30 kW with n = 0.55 for the range 4–60. L+M* = 2–2.5. L/M = 0.25–0.53. Factors: one stage, q 1.00; two stage, q 2.7.

Blowers, rotary sliding vane, 275 kPa g, with lubricator, coupling and base but excluding motor and drive. FOB cost = $30 000 at inlet gas flow rate = 0.1 Nm3/s with n = 0.40 for the range 0.01–0.4. L+M* = 2.0–2.5. L/M = 0.25.

Compressors, centrifugal, I 7 MPa, cast steel with drip proof induction motor, starter, base plate, gearing and lube system. FOB cost = $1 350 000 at drive power = 1000 kW with n = 0.90 for the range 2–4000. FOB cost = $10 300 000 at drive power = 10 000 kW with n = 0.71 for the range 8000–25 000. L+M* = 1.3–2.15. L/M = 0.37–0.38. Alloy factors: cast steel, q 1.00; s/s, q 2.5; nickel, q 5.0. Factor, motor drive, q 1.00; turbine drive, q1.0.

Compressors, centrifugal, 7 MPa, cast steel with base plate, excluding motor, starter, gearing and lube system. FOB cost = $875 000 at drive power = 1000 kW with n = 0.53 for the range 500–4000. L+M* = 1.3–2.15. L/M = 0.37–0.38. Factors: exit pressure, 7 MPa, q 1.00; 1.7 MPa, q 0.8; 14 MPa, q 1.15; 34 MPa, q 1.43; 48 MPa, q 1.51.

Compressors, axial 15-stage with steam turbine drive, base plate and lubrication. FOB cost = $20 000 at drive power = 10 000 kW with n = 1.33 for the range 4000– 20 000. FOB cost = $18 000 at inlet gas capacity = 100 Nm3/s with n = 0.91 for the range 30–300. L+M* = 1.3–2.15. L/M = 0.37–0.38.

Compressors, helical screw with drip proof motor, starter, base plate, gearing and lube system. FOB cost = $475 000 at drive power = 300 kW with n = 0.77 for the range 100–600 and at inlet gas capacity = 1 Nm3/s with n = 0.85 for the range 30–300. L+M* = 1.3–2.15. L/M = 0.37–0.38.

Compressors, reciprocating, I 7 MPa with base plate, drip proof motor, starter, gearing, lube system and aftercooler. FOB cost = $180 000 at drive power = 100 kW with n = 0.79 for the range 1–10 000. L+M* = 2.25–2.82. L/M = 0.34. Alloy factors: cast steel, q 1.00; s/s, q2.5; nickel, q 5.0. Factors: exit pressure, I 7 MPa, q 1.00; 17 MPa, q 1.25; 34 MPa, q 1.5; 41 MPa, q 1.60; 48 MPa, q 1.68; 55 MPa, q 1.78; 62 MPa, q 186; 69 MPa, q 1.95. Drive factors: electric motor, q 1.00; steam turbine, q 1.4; gas engine, q 2.8.

Compressors, reciprocating, I 7 MPa with base plate, starter, gearing, lube system and aftercooler but excluding drip proof motor. FOB cost = $65 000 at drive power = 100 kW with n = 1.04 for the range 10–1000. L+M* = 2. L/M = 0.35.

382 Appendix D: Capital Cost Guidelines

Compressors, reciprocating, 0.86 MPa single stage with base plate, drip proof motor, starter, gearing, and lube system. FOB cost = $65 000 at inlet air flow rate = 0.1 Nm3/s with n = 0.77 for the range 0.002–5. L+M* = 2. L/M = 0.35.

Compressors, reciprocating, 3.5 MPa double stage with base plate, drip proof motor, starter, gearing, intercooler and lube system. FOB cost = $100 000 at inlet air flow rate = 0.1 Nm3/s with n = 0.53 for the range 0.03–0.2. L+M* = 2. L/M = 0.35. Factors: two stage, q 1.00; three stage, q 1.7.

Compressor station, centrifugal or reciprocating, installed station, compressor, electric motor. TM cost = $2 850 000 at drive power = 1000 kW with n = 0.65 for the range 150–2500 and $18 000 000 at drive power = 10 000 kW with n = 0.70 for the range 3000–13 000.

Compressor station, reciprocating, installed station, compressor, gas engine. TM cost = $4 000 000 at drive power = 1000 kW with n = 0.75 for the range 150–2500 and $40 000 000 at drive power = 10 000 kW with n = 0.70 for the range 3000– 13 000.

Compressor station, centrifugal or reciprocating installed station, compressor, steam or gas turbine. TM cost = $2 850 000 at drive power = 1000 kW with n = 0.65 for the range 150–2500 and $26 000 000 at drive power = 10 000 kW with n = 0.70 for the range 3000–13 000. 2.25–2.82. L/M = 0.34. Alloy FOB cost factors: c/s q 1.00; nickel q 5.0; s/s q 2.5.

Section 2.2

Gas Moving: Vacuum Service

Rotary vane vacuum pump, 10–15 kPa-abs, drip proof motor, base plate, gearing and reservoir. FOB cost = $22 000 at free air displacement = 170 dm3/s with n = 0.38 for the range 3–1670. L+M* = 1.7–2.1. L/M = 0.1–0.15.

Rotary liquid piston vacuum pump, 10–15 kPa-abs, with base plate and reservoir but excluding motor. FOB cost = $103 000 at actual free air displacement = 1700 dm3/s with n = 0.73 for the range 83–5000. L+M* = 1.7–2.1. L/M = 0.1–0.15. Dry reciprocating vacuum pump, cast iron with TEFC motor, base plate V-belt drive. FOB cost = $12 700 at ratio of gas capacity (kg/h)/absolute pressure (kPa-abs) = 1 with n = 0.66 for the range 0.1–80. L+M* = 1.7–2.1. L/M = 0.1–0.15. Dry reciprocating vacuum pump, cast iron with base plate, V-belt drive but excluding motor. FOB cost = $27 000 at drive power = 10 kW with n = 0.88 for the range 4–80 and at inlet gas capacity = 100 dm3/s with n = 0.69 for the range 3–1200. L+M* = 1.7–2.1. L/M = 0.1–0.15.

Steam ejector system, single stage, 6–40 kPa-abs, steam pressure 0.7 MPa, ejector only. FOB cost = $4750 at the ratio of the gas capacity (kg/h)/the absolute pressure (kPa) = 10 with n = 0.45 for the range 0.015–750. L+M* = 1.7–2.1. L/M = 0.1–0.15.

Steam ejector system, two stage with barometric condenser, 1.3–13 kPa-abs, steam pressure 0.7 MPa, and 29 hC water including two ejectors, barometric condenser and interstage piping. FOB cost = $23 000 at the ratio of the gas capacity

D.4 Detailed Equipment Cost Data Based on Equipment Type 383

(kg/h)/the absolute pressure (kPa) = 10 with n = 0.39 for the range 0.7–20. L+M* = 1.7–2.1. L/M = 0.1–0.15.

Steam ejector system, multistage with barometric condensers, 0.07–27 kPa-abs, steam pressure 0.7 MPa, and 29 hC water including two ejectors, barometric condenser and interstage piping. FOB cost = $28 500 at the ratio of the gas capacity (kg/h)/the absolute pressure (kPa) = 10 with n = 0.24 for the range 0.8–80. L+M* = 1.7–2.1. L/M = 0.1–0.15. Alloy factors: cast iron, q 1.00; c/s, q1.30; s/s, q 2; Hastelloy, q 3.0. Factors, barometric condensers, q 1.0; surface or shell and tube indirect contact condensers, q 1.25.

Rotary piston oil-sealed vacuum pump, 0.015 kPa-abs, with base plate, drip proof motor, belt guard and drive. FOB cost = $10 000 at free air displacement = 17 dm3/ s with n = 0.55 for the range 0.3–1700. L+M* = 1.7–2.1. L/M = 0.1–0.15.

Generalized vacuum pump including TEFC motor, base plate and belt drive. FOB cost = $50 000 at the ratio of the gas capacity (kg/h)/the absolute pressure (kPa) = 10 with n = 0.64 for the range 0.01–500. L+M* = 1.7–2.1. L/M = 0.1–0.15.

Oil diffusion vacuum pump, complete unit. FOB cost = $4200 at free air displacement = 1.4 m3/s with n = 0.22 for the range 0.007–1.4 and n = 0.89 for the range 1.4–17. L+M* = 1.7–2.1. L/M = 0.1–0.15.

Section 2.3

Liquid

Pumps, centrifugal, AVS, 1800 rpm, 15 m head, radial flow, cast iron with housing, impeller, mechanical seal, base plate, coupling but excluding motor. Four correlations are available. FOB cost = $7000 at drive power = 16 kW with n = 0.26 for the range 0.2–16 and n = 0.43 for the range 16–400; or FOB cost = $9500 at rated capacity 8.3 L/s with n = 0.34 for the range 1–500; or FOB cost = $10 000 at product of (capacity, m3/s) and (head, m)0.5 = 10 with n = 0.34 for the range 1–300, or FOB cost = $15 000 at the product of (capacity, m3/s)0.6 and (head, m)2.5 = 5000 with n = 0.34 for the range 1000 to 30 000. L+M* = 1.47. L/M = 0.28. Alloy factors: cast iron, q 1.00; c/s. 1.3; bronze, q1.5; 316 s/s alloy, q 1.9; clad, q 1.4; 304 s/s alloy, q 1.9; nickel, q 3.0; monel, q 3.0; Alloy 20, q 1.9; Hastelloy C, q 2.8; titanium, q 9.5. Pressure factors: suction pressure, 1.1 MPa, q 1.00; 3.5 MPa, q 1.6; 7. MPa, q 2.0. Type factors: self priming, q 1.5; heavy duty, q 1.10; closed impeller, q 1.15. Stage factors: single stage, q 1.00; two stage, q 1.3; three stage, q1.4; four stage, q 1.5; five stage, q 1.7; six stage, q 1.9.

Pumps, centrifugal, AVS, 1800 rpm, 15 m head, radial flow, cast iron with housing, impeller, mechanical seal, base plate, coupling, and TEFC motor. Three correlations are available. FOB cost = $9500 at drive power = 23 kW with n = 0.29 for the range 1–23 and n = 0.79 for the range 23–250; or FOB cost = $12 700 at rated capacity 16.7 L/s with n = 0.59 for the range 0.5–500 or FOB cost = $10 000 at the product of (capacity, L/s) and (head, m) = 1000 with n = 0.29 for the range 100– 1000 and n = 0.75 for the range 1000–100 000. L+M* = 1.47. L/M = 0.4. Alloy factors: cast iron, q 1.00; c/s. 1.3; bronze, q 1.28; 316 s/s alloy, q 1.93; clad, q1.45; 304 s/s alloy, q 1.9; nickel, q 3.5; monel, q 3.2; Alloy 20, q 2.3; Hastelloy C,

384 Appendix D: Capital Cost Guidelines

q 2.95; titanium, q 9.0. Pressure factors: suction pressure, 1.1 MPa, q 1.00; 3.5 MPa, q 1.5; 7 MPa, q 1.9. AVS, q 1.00; APS, q1.6.

Pumps, centrifugal, heavy duty, non-clog, 1800 rpm, cast iron with base plate, coupling and mechanical seal excluding motor. FOB cost = $9000 at drive power = 19 kW with n = 0.11 for the range 0.8–19 and n = 1.10 for the range 19–150. L+M* = 2.3. L/M = 0.15.

Pumps, in-line, API-610: vertical, 1.1 MPa, cast iron with base plate, coupling, TEFC motor. FOB cost = $8000 at drive power = 11 kW with n = 0.28 for the range 0.5–122 and n = 0.58 for the range 11–60 or FOB cost = $20 000 at the product of (capacity, L/s) and (head, m) = 2,000 with n = 0.17 for the range 100–1000 and n = 0.75 for the range 1000–100 000. L+M* = 1.72. L/M = 0.15. Alloy FOB cost factors: cast iron q 1.00; cast steel q 1.3; s/s q 1.6; s/s clad q 1.3. Pressure factors: 1.1 MPa, q 1.00; 3.6 MPa, q 1.5; 7 MPa, q 1.92.

Pumps, axial flow: steel, with impeller, mechanical seal, base plate, coupling, and TEFC motor. Three correlations: FOB cost = $150 000 at flow rate = 0.67 m3/s with n = 0.03 for the range 0.06–0.67 and n = 0.65 for the range 0.67–17 or FOB cost = $76 000 at the product of (capacity, L/s) and (head, m) = 1000 with n = 0.79 for the range 100–100 000 or FOB cost = $76 000 at drive power = 10 kW with n = 0.79 for the range 1–1000. L+M* = 2.0. L/M = 0.2. Factors: axial flow, q 1.00; mixed flow, q 1.6.

Pumps, peripheral/turbine: steel with impeller, mechanical seal, base plate, coupling, TEFC motor. Two correlations: FOB cost = $11 000 at drive power = 10 kW with n = 0.48 for the range 1–500 or at the product of (capacity, L/s) and (head, m) = 600 with n = 0.48 for the range 300–10 000. L+M* = 1.8. L/M = 0.4–0.41. Alloy factors: steel, q 1.00; cast iron, q 0.6; bronze fitted, q 0.65; all bronze, q 1.00; s/s, q 1.6.

Pumps, reciprocating: piston or plunger type, cast iron, 1.1 MPa suction pressure, 150–300 rpm with the exit pressure I 7 MPa with base plate, gears and TEFC motor. FOB cost $25 000 at drive power = 5 kW with n = 0.16 for the range 0.5–5 and n = 0.59 for the range 5–200. L+M* = 2.4. L/M = 0.3. Alloy factors: cast iron q 1.00; cast steel q 1.8; s/s q 2.4; nickel alloy q 5.0.

Pumps, reciprocating: piston or plunger type, cast iron, 1.1 MPa suction pressure, 150–300 rpm with the exit pressure I 7 MPa with base plate, gears excluding TEFC motor. FOB cost = $12 500 at drive power = 10 kW with n = 0.52 for the range 0.5–200. L+M* = 2.3. L/M = 0.25–0.4. Alloy factors: cast iron, q 1.0; c/s, q 1.55; s/s, q 2.1. Suction pressure factors: 1.1 MPa, 1.00; 3.5 MPa, q 1.2; 7 MPa, q 1.4; Exit pressure factors, I 7 MPa, q 1.00; 35–70 MPa, q 2.5.

Pumps, reciprocating metering pumps: 316 s/s with drive, base plate, gears and TEFC motor. FOB cost = $14 200 at drive power = 1 kW with n = 0.85 for the range 0.2–3. L+M* = 1.5. L/M = 0.3. Alloy factors: 316 s/s, q 1.00; cast steel, q 0.64; cast iron, q 0.5. Discharge pressure factors: 1.1 MPa, q 1.00; 3.5 MPa, q 1.37; 7 MPa, q 1.79.

Pumps, diaphragm: cast iron with drive, base plate, gears and TEFC motor. FOB cost $7000 at a drive power = 10 kW with n = 0.43 for the range 6–300 or at the

D.4 Detailed Equipment Cost Data Based on Equipment Type 385

product of (capacity, L/s) and (head, m) = 600 with n = 0.43 for the range 400– 20 000. L+M* = 1.6 -2.3. L/M = 0.15.

Pumps, diaphragm: 316 s/s with PTFE diaphragm, drive, base plate, gears and TEFC motor. FOB cost = $18 000 at drive power = 1 kW with n = 0.67 for the range 0.2–3. L+M* = 1.5. L/M = 0.3. Alloy factors: 316 s/s, q 1.00; cast steel, q 0.64; cast iron, q 0.5. Discharge pressure factors: 1.1 MPa, q 1.00; 3.5 MPa, q 1.37; 7 MPa, q 1.79.

Pumps, rotary screw moyno: cast iron with pump, base plate, V-belt drive but excluding motor. FOB cost $10 000 at flow rate = 5.5 L/s with n = 0.5 for the range 1–5.5 and n = 0.6 for the range 5.5–25. L+M* = 1.6–2.2. L/M = 0.15. Factor: without motor, q 1.00; with TEFC motor, q 1.2.

Pumps, gear: cast iron with base plate, gear reducer and open drip proof motor. FOB cost = $6000 at flow rate = 10 L/s with n = 0.43. L+M* = 1.6–2.3. L/M = 0.15. Alloy factors: cast iron q 1.00; 316 s/s q 2.4; glass lined q 3.6; bronze q 1.4. Pump only, q 0.30.

Pumps, sliding vane: cast iron with pump, base plate, hear box or coupling but excluding motor. FOB cost $10 000 at a capacity = 10 L/s with n = 0.75 for the range 0.4–120. L+M* = 1.6–2.3. L/M = 0.15. Factor: without motor, q 1.00; with motor, q 1.7.

Pumps, Archimedes screw: c/s with 38h inclination with shaft and flights, upper and lower bearing mounts, V belt drive and TEFC motor excluding concrete channel and influent and effluent basins. FOB cost $160 000 at drive power = 10 kW with n = 0.58 for the range 0.6–100. L+M* = 1.7–2.1. L/M = 0.3–0.41.

Section 2.4

Gas-Liquid (Two-phase Flow)

Cost as a pipe, Section 2.7, plus the necessary auxiliaries, such as gas injection and fluid pumping as required for the application. Costs for some configurations are given in Section 6.5.

Section 2.5

Pumping Slurries: Liquid–Solid Systems

Cost as a pipe, Section 2.7, plus the necessary auxiliaries, such as fluid pumping as required for the application.

Section 2.6

Solids

Belt conveyors: belt speed 1 m/s handling solids of density 1.6 Mg/m3 with steel welded frame, head and tail pulley, troughing idlers, roller bearings, cold rolled steel shafters, four ply, 28 oz belt excluding motor, drive and supports. FOB cost = $21 000 for the product of (solids capacity, Mg/h) q (length, m)2.5 = 106 with n = 0.20 for the range 5000–5 q 107. L+M* = 1.7–2.7. L/M = 0.3.

386 Appendix D: Capital Cost Guidelines

Bucket elevators: handling solids of density 1.6 Mg/m3 with single vertical leg, casing, chain or belt, sprockets, malleable iron buckets, roller bearings, screw takeup, boot and head excluding motor and drive. FOB cost = $25 000 for the product of (solids capacity, Mg/h) q (vertical lift, m) = 500 with n = 0.50 for the range 10–3000. L+M* = 1.9–2.35. L/M = 0.44. Discharge factors: centrifugal discharge of chain-bucket, q 1.00; centrifugal discharge belt, q 1.25; continuous discharge, q 1.25.

Screw conveyors: c/s with trough, cover, screw flights, bearings, inlets and outlets excluding motor, drive and supports. FOB cost = $36 000 for the product (solids capacity, Mg/h) q (length, m) = 5000 with n = 0.46. L+M* = 1.6–2.4. L/M = 0.25. Alloy factors: c/s, q 1.00; s/s, q 3.5.

Oscillating conveyors: excluding motor and drive. FOB cost = $6500 for the product of (width, m)0.75 q (length, m) = 10 with n = 0.93 for the range 2–100. L+M* = 1.7. L/M = 0.25.

Roller conveyors: FOB cost = $600 for the product of (length, m) q (width, cm) with n = 0.90 for the range 10–500. L+M* = 1.65. L/M = 0.3.

Pneumatic conveyors, dilute phase: low pressure or vacuum, c/s duct excluding blower and motor. FOB cost $145 000 for the product of (diameter, m)2 q (length, m) = 2.2 with n = 0.14 for the range 0.18–2.2 and n = 0.38 for the range 2.2–15. L+M* = 2.0. L/M = 0.3. Alloy factors: carbon steel, q 1.00, s/s q 2.23.

Pneumatic conveyors, dense phase: batch, high pressure, with fluidizer only, excluding piping, fittings, switches, air supply and air compressor. FOB fluidizer cost = $40 000 for the product of (diameter, m)2 q (length, m) with n = 0.47 for the range 0.8–7. L+M* = 2.0. L/M = 0.3.

Hoists for medium lift, heavy duty with push trolley, multiple disc brakes including motor and drive. FOB cost = $16 000 for lifting capacity = 2.6 Mg with n = 0.36 for the range 4.5–26 and n = 1.48 for the range 26–45. For motor driven trolley q 1.6.

Hoists for long lift with motor driven trolley, cab or floor controlled, variable speed, mechanical or electric load braking, double reeving, single or twin load hooks, overload relays, AC current. FOB cost = $40 000 for lifting capacity = 3 Mg with n = 0.82 for the range 2–20. For DC current q 1.05. L+M* = 1.5. L/M = 0.22.

Cranes bridge type, with bridge, crane trolley, controls, motors, floor operated at 0.75 m/s, AC current. FOB = $185 000 at lifting capacity = 15 Mg with n = 0.23 for the range 3–15 and n = 0.56 for the range 15–20. L+M* = 1.6. L/M = 0.25. Factors: floor operated, q 1.00; cab operated at 1.5 m/s, q 1.07; AC current, q 1.00; DC current, q 1.07.

Feeder: star or rotary: hot rolled steel excluding motor. FOB cost = $6600 for a diameter = 20 cm with n = 0.52 for the range 15–30. L+M* = 2.0. L/M = 0.3. Alloy factors: hot rolled steel, q 1.00; s/s, q 1.07.

Feeder, apron, with motor and drive excluding hopper. FOB cost = $90 000 for the product of (width, m)2 q (length, m) = 2 m3 with n = 0.18 for the range 0.75–25. L+M* = 2.0. L/M = 0.3.

D.4 Detailed Equipment Cost Data Based on Equipment Type 387

Feeder, vibratory with motor and drive. FOB cost = $27 000 for the product of (width, m) q (length, m) = 1.8 m2 with n = 0.62 for the range 0.4–1.8 and n = 1.1 for the range 1.8–8. L+M* = 2.15–2.65. L/M = 0.28.

Section 2.7

Ducts and Pipes

Cost of pipes and fittings are usually included in the L+M* factors. For those special cases where estimates are needed just of the pipe:

Ducts:

Installed cost per meter $700 for cross sectional area of 4 m2, n = 0.53; for diameter of 2.3 m, n = 1.08. Alloy cost factor: galvanized q 1.00; aluminum q 2; s/s q 4.3.

Pipes:

FOB cost per meter $80 for 15 cm diameter, n = 1.33 for the range 10–70. L+M* = 13 (including fittings, supports, insulation, labor cost to install 30 valves but excludes cost of valves). Alloy cost factors: c/s q 1.00; c/s galvanized q 0.92; aluminum q 1.82; PVC q 0.9–1.1; 316 s/s q 3.77; 304 s/s q 2.90; monel q 4; nickel q 4.53; c/s glass lined q 3.17; c/s PTFE lined q 3.17.

Section 3.1

Drives

Gas diesel engines FOB cost = $250 000 at 300 kW with n = 0.82 for the range 20–50 000 kW. L+M* = 2.0. L/M = 0.3.

Electric motors, induction, squirrel cage: 3 phase, AC, TEFC, 1800 rpm excluding starter, gearing. FOB cost = $19 000 at drive power = 75 kW with n = 1.1 for the range 0.3–1500. L+M* = 1.36. L/M = 0.58. Factors: 1800 rpm, q 1.00; 900 rpm, q 1.3; 1200 rpm, q 1.5; 3600 rpm, q 1.3. Enclosure factors: TEFC, q 1.00; open drip proof, q 0.7; guarded drip proof, q 0.9; explosion proof, q 1.15.

Electric motors, induction, wound rotor: 3 phase, AC, open drip proof, 1800 rpm, excluding starter. FOB cost = $8000 at drive power = 50 kW with n = 0.93 for the range 8–150. L+M* = 1.6. L/M = 0.58.

Electric motors, synchronous: AC open drip proof, 1800 rpm excluding gears. FOB cost = $380 000 at drive power = 2235 kW with n = 0.96 for the range 350–7000 kW. L+M* = 1.6. L/M = 0.26.

Electric motors, synchronous, open drip proof: AC, 1200 rpm excluding gears. FOB cost = $260 000 at drive power = 2235 kW with n = 0.81 for the range 500–7000 kW. L+M* = 1.3. L/M = 0.26. Factors: 1200 rpm, q 1.00; 900 rpm, q 1.10; 514 rpm, q 125.

Electric motors, gear reduced TEFC: 1800 rpm plus gear reducer to give fixed output rpm. FOB cost = $1800 at drive power = 1.8 kW with n = 0.20 for the range 0.35–1.8 and n = 0.53 for the range 1.8–15. L+M* = 1.67. L/M = 0.26.

Electric motors, variable speed TEFC: 1800 rpm plus V-belt unit for speed control 2/1 to 5/1 at 3480, 520 and 30 rpm. FOB cost = $8000 at the ratio of (drive power

388 Appendix D: Capital Cost Guidelines

at 1800 rpm, kW)/(rpm)0.2 = 1.5 with n = 0.63 for the range 0.35–7.5. L+M* = 1.67. L/M = 0.26.

Drives, gear units: general, single, double, triple reduction on concentric, offset or vertical right angle drives, excluding lubrication system and motor. FOB cost

=$6000 at the product of (drive power at 1800 rpm, kW) q (reduction ratio)0.5

=50 with n = 0.45 for the range 3–50 and n = 0.75 for the range 50–1500. L+M* = 1.5. L/M = 0.2.

Drives, gear units: medium duty, single reduction 20/1 to 50/1 excluding lubrica-

tion system and motor. FOB cost = $5300 at the product of (drive power at 1800 rpm, kW) q (reduction ratio)0.5 = 180 with n = 0.54 for the range 3–180 and n = 1.90 for the range 180–1500. L+M* = 1.5. L/M = 0.2.

Steam turbines: noncondensing, steam 2 MPa, 100–150 hC superheat, backpressure I 0.7 MPa, wheel diameter about 60 cm excluding gears and lubrication. For single valve, single stage, FOB cost = $90 000 at power = 300 kW with n = 0.51 for the range 7–3000. For single valve, multistage, FOB cost = $800 000 at power = 3000 kW with n = 0.46 for the range 700–15 000. For multivalve, multistage, FOB cost = $1 250 000 at power = 3000 kW with n = 0.35 for the range 1500–15 000. L+M* = 1.4–1.5. L/M = 0.26. Factors: steam pressure 2 MPa, q 1.00; 4 MPa, q 1.22; 6 MPa, q 1.50; 14 MPa, q 1.60. Steam superheat: I 50 hC, q 1.08; 50–100 hC, q 0.97; 150–200 hC, q 1.05; i 200 hC, q 1.10. Noncondensing, q 1.00; condensing including condenser and integral piping, q 1.85.

Gas driven turbine: excluding equipment needed for gas supply. FOB cost = $2 000 000 at output power = 5,000 kW with n = 0.8 for the range 1000–30 000. L+M* = 1.4–1.5. L/M = 0.26.

Gas combustion turbines: with inlet air system, compressor, combustion chamber, firing, turbine, starter and exhaust system. FOB cost $4 000 000 at output drive power = 5000 kW with n = 0.55 for the range 650–15 000. L+M* = 1.4–1.5. L/M = 0.26.

Electric power generators: steam raising plus turbines: for steam at 1–1.7 MPa or for gas driven without regenerator. FOB cost $4 800 000 for power output = 10 000 kW with n = 0.73 for the range 3000–50 000. L+M* = 1.6. L/M = 0.25. Factors for steam driven: steam pressure, 1–1.7 MPa, q 1.00; 6 MPa, q 1.3; 17 MPa, q 1.5. Factors for gas driven: without gas regenerator, q 1.00; with regenerator, q 1.25.

AC–DC converters: uni-converter, current single direction; voltage, either. Input 3 phase AC 230/460/575. Nema 1. FOB cost = $40 000 at power = 30 kW with n = 0.61 for the range 10–80. Factors: uni, q 1.00; dual with current and voltage either direction, Nema 1, q 1.1; Nema 12 enclosures, q 1.64.

Section 3.2

Thermal Energy: Furnaces

Box type furnace, fired: horizontal radiant c/s tubes for process service, Field erected cost $1 500 000 at 10 MW heat absorbed, n = 0.87, range 2–100 MW. L+M* = 1.3. L/M = 0.22. Alloy FOB cost factors: c/s q 1.00; Cr–Mo q 1.24;

D.4 Detailed Equipment Cost Data Based on Equipment Type 389

304 s/s q 1.34; 316 s/s q 1.34; Incalloy q 2. Pyrolysis furnace configuration q 1.09; reformer configuration, q 1.34. Pressure factors 3.4 MPa, q 1.05; 7 MPa, 1.15; 15 MPa, q 1.3; 20 MPa, q 1.4.

Cylindrical type furnace, fired: high grade c/s in both radiant and convection sections, vertical, 3.6 MPa, Field erected, $250 000 at 1 MW heat absorbed, n = 0.74, range 0.5–100. L+M* = 1.57–1.62. L/M = 0.22. Alloy FOB cost factors: c/s q 1.00; Cr–Mo q 1.45; s/s q 1.5. Pressure factors: 0.7 MPa, q 0.35; 7 MPa, q 1.15; 10 MPa, q 1.2; Dowtherm, q 1.33.

See also Section 3.12 for costs of steam boilers.

Section 3.3

Thermal Energy: Fluid Heat Exchangers, Condensers and Boilers

Shell and tube: floating head, 1.1 MPa, c/s in c/s shell, bare tube. FOB cost = $70 000 for heat transfer area = 100 m2 with n = 0.71 for the range 20–2000. L+M* = 2.2–2.8. L/M = 0.35–0.37. Alloy FOB factors for tubes in c/s shell: c/s q 1.00; aluminum q 1.2; copper q 1.35; brass q 1.3; Admiralty q 1.5; 70–30 Cu–Ni q 1.7; nickel q 2.8; 316 s/s q 2.4; 304 s/s q 2.0; Monel q 3.0; titanium q 9.0; Inconel q 2.4; Hastalloy C q 8.5. Alloy FOB factors for tubes and shell of 316 s/s q 3; 304 s/s q 2.8; Monel q 4.0; titanium q 13.0. Factors: floating head, q 1.00; fixed head, q 0.85; U-tube, q 0.87; as kettle reboiler, q 1.35.

Spiral plate (Rosenblad): c/s and 350 kPa. FOB cost = $30 000 at heat transfer area = 10 m2 with n = 0.47 for the range 1–100. L+M* = 2.2–2.8. L/M = 0.35–0.37. Alloy FOB factors: c/c in c/c q 1.00; 316 s/s q 2.8.

Spiral tube heat exchanger (Heliflow): c/s tube. FOB cost = $1100 at heat transfer area = 0.7 m2 with n = 0.43 for the range 0.25–0.7 and n = 0.83 for the range 0.7–6. L+M* = 1.53. L/M = 0.35–0.37. Alloy factors: c/s, q 1.0; s/s, q 4.0.

Plate coil, exchanger: c/s plate with double embossed serpentine or header coil on plate. FOB cost = $600 for a surface area = 2.5 m2 with n = 0.38 for the range 0.5–2.5 and n = 1.07 for the range 2.5–10. L+M* = 1.6. L/M = 0.22. Alloy factor: c/s, q 1.00; s/s, q 4.4. Double embossed, q 1.00; single embossed, q 2.8.

Plate and frame heat exchanger: 316 s/s, 0.7 MPa. FOB cost = $120 000 at heat transfer area = 100 m2 with n = 0.65 for the range 10–600. L+M* = 1.53. L/M = 0.35–0.37. Alloy FOB factors: c/s q 0.43; 316 s/s q 1.0; 304 s/s, q 0.95; nickel q 1.1; titanium q 2.6.

Cubic/monolithic heat exchanger: graphite in c/s shell. FOB cost = $14 000 for heat transfer area = 6.5 m2 with n = 0.71 for the range 1–20 m2. L+M* = 2.2–2.8. L/M = 0.35–0.37.

Double pipe heat exchanger: c/s inside c/s with inner tube finned. Total area: bare tube area = 5–10:1. Increase in area by selection of fins and tube length. Duplication of units not allowed in this correlation. FOB cost $30 000 at 3 m2 total heat transfer area, n = 0.14, range 0.1–20. L+M* = 2.57. L/M = 0.35–0.37. Alloy FOB factors in c/s outside jacket: c/s q 1.00; s/s q 1.85–2.65; unfinned central s/s tube q 2.1. Alloy FOB factors for tubes and jacket: s/s q 5.5. Pressure factor: 6 MPa q 1.10; 7 MPa q 1.25.

390 Appendix D: Capital Cost Guidelines

For duplication of units, FOB cost $30 000 at 3 m2 total area with n = 1.23 for sizes i 3 m2.

Air cooled heat exchanger: FOB cost for c/s 1 MPa including bundle, heater, fan, explosion-proof motor, case but excluding foundation, water trim cooler, fireproofing. $70 000 at bare tube heat transfer area = 100 m2, n = 0.39 for range 10–10 000. Finned area: bare area = 16:1. L+M* = 1.6–2.1. L/M = 0.21–0.24. Alloy factors: c/s q 1.00; aluminum q 1.5; Admiralty q 1.08; s/s q 2.85; Monel q 3.2. Pressure factors, 1 MPa q 1.; 1.7 MPa q 1.05; 3 MPa q 1.1; 7 MPa q 1.15. Add water trim cooler, q 1.15–1.2.

Coil heat exchanger in tank: c/s coil excluding tank. FOB cost = $2300 for a heat transfer area = 2.8 m2 with n = 0.62 for the range 0.1–30. L+M* = 2.2–2.8. L/M = 0.35–0.37. Alloy FOB factors: c/s coil q 1.00; s/s q 2.3; glass q 3.5; teflon q 3.0.

Ramen/lamella plate fin heat exchanger: brazed alumina, pressure I 7 MPa. FOB cost = $48 000 for a heat transfer area = 1300 m2 with n = 0.34 for the range 100– 1300 and n = 1.00 for the range 1300 to 10 000. L+M* = 2.2–2.8. L/M = 0.35–0.37. Thermal screw heat exchanger: single screw, c/s with screw and trough but excluding motor and drive. FOB cost = $65 000 for a transfer area = 7.5 m2 with n = 0.13 for the range 1–7.5 and n = 0.78 for the range 7.5–40. L+M* = 1.53. L/M = 0.35–0.37. Related to drying, Section 5.6.

Section 3.4

Thermal Energy: Fluidized Bed (Coils in Bed)

Bayonet heat exchanger: c/s. FOB cost = $930 at heat transfer area = 1.3 m2 with n = 0.25 for the range 0.1–1.3 and n = 1.33 for the range 1.3–12. L+M* = 1.53. L/M = 0.35–0.37.

Section 3.5

Thermal Energy: Static Mixers

See Section 6.6.

Section 3.6

Thermal Energy: Direct Contact L–L Immiscible Liquids

Costs see process vessels, Section 10.1.

Section 3.7

Thermal Energy: Direct Contact G–L Cooling Towers

Cooling tower: induced or forced draft, approach temperature 5.5 hC, wet bulb temperature 23.8 hC, cooling range 5.5 hC. Package with fans, motors, integral piping, erection and labor excluding foundations, basin, water pumps, external and distribution piping. Packed FOB = $1 200 000 for water flow rate = 1000 L/s with n = 1.00 for the range 100–1000 and n = 0.64 for the range