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detailing.
2. Materials: The cost of all bought out materials , i.e. pipe flanges, fittings, valves, expansion units, etc.
3. Fabrication: The cost of site fabrication , off- site fabrication, done in a
shop away and adjacent to site.
4. Erection: The cost of erecting on-site fabricated pipe work and pressure testing. This includes
preliminaries, variation orders and error
rectification if any.
Economic
Fluid Velocity (ft/s)
Pipe diameter d (in)
Pressure drop available(Ib/in2) / 100 ft
Remark
Pump discharge pipe
(d/3 + 5) ft/s2.0
Pump suction pipe
(d/6 + 1.3) ft/s0.4
Steam or gas line
20 d ft/s0.5
For liquids, a velocity in excess of 20 ft/s should never be specified in order to avoid erosion of the pipe.
On suction lines to the pump, the pressure drop should always be less than 50% of the total head
developed by the pump.
7. Suggested Steam Pipe Velocities in Pipe Connecting Steam Turbines
SERVICE - STEAM TYPICAL RANGE -ft/s
Inlet to turbine 100 - 150
Exhaust, non-condensing 175 - 200
Exhaust - condensing 400 500
8. Relative Economics of Various Materials of Construction
S.No. Material Connection Factor
1
Carbon steel (C.S.), A-53,
seamless Welded 1.00
2
Carbon steel (C.S.), A-53,
welded galvanised Screwed 0.84
3 Wrought iron, galvanised Screwed 1.61
4Unplasticised polyvinyl
chlorideSock, weld 1.79
5 Carbon steel, lead lined Flanged 4.11
6 Carbon steel, PVC lined Flanged 4.76
7 Stainless steel Welded 15.00
9. Material Estimation
There are three main topics of pipe work estimation as mentioned below:
S.No. Stage Accuracy Basis
1 Preliminary +/- 25% Based on %age of total plant cost
2 First control +/- 20 % Based on completed P and Is etc.
3 Second control +/- 10 %Final P and I , all pipe work details, drawings,
material list etc.
10. Fabrication Cost Estimation
The contents of fabrication cost estimation comprise the following:
1. Fabrication
2. Fabrication / Welding
3. Welding
4. Supports
11. Erection Cost Estimation
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The contents of fabrication cost estimation comprise the following:
1. Erection
2. Supports
3. Testing of completed pipelines
12. Rates for Fabrication and Erection
The schedule of rates under the fabrication and erection work are established in man hours which
should be representative of the gang time to complete the operation. The type of rate will depend on the
client and contractor relationship on the basis of the contractors tenders.
The rates shall be included or excluded, allowances for construction plant, tools, tackle and
consumables.
Typical rates for various piping materials are enclosed for reference. These include labour, consumables,
tools, tackles and overheads.
13. Typical Rates for Fabrication, Erection and Testing of Pipelines for Costing with
Example
a) Mild steel (MS), B and C class piping: Rs. 45/- per inch dia per metre
length.
b) SS 304 piping ( Sch 5): Rs. 90/- per inch dia per metre length.
c) PVC Piping: Rs.45/- per meter length.
d) Cu Piping: Rs. 100/- per inch dia metre.
e) Pipe fitting reducer, bend etc.
SS 304: Rs. 125/- per inch dia
MS: Rs. 60/- per inch dia
Copper: Rs.140/- per inch dia
f) Fabrication and erection of MS supports= Rs. 4500/- per MT.
Q. Find out the labour cost for making a MS reducer of 2" x 4" size?
Ans: MS Reducer 2" x 4" = 4 x60 = Rs.240/- (Considering 4" dia)
Q. Find out the labour charges for fabrication and erection of a MS pipeline of 50 NB (2") MS B or MSC of 400 m length fabrication and erection?
Ans: 2 x 400 x 45 = Rs.36,000/-
Typically the quantum of pipe fabrication, erection and testing of pipe work shall be expressed as shown
below:
1. MS B and C class piping : 12450 inch m tr
2. SS 304 piping : 2850 inch mtr
3. PVC piping : 285 inch mtr
4. Cu piping: 695 inch mtr
14. Typical Calculation for Piping Cost
Raw material Factors SS Condensortube
CopperCondensor tube
Sheet width mm
Raw material base
rateRs/kg 78.50 140.00
Packing and
forwardingRs/kg 1.00 0.79 1.40
Conversion Rs/kg 40.00 50.00
Excise % 16.00 19.09 30.62
Sales tax/ VAT % 4.00 5.53 8.88
Insurance % 0.20 0.29 0.46
Transportation Rs/kg 2.00 2.00
Total Cost Rs/kg 146.19 233.37
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Modvat Benefit Rs/kg 19.09 30.62
Cost to Co. Rs/kg 127.11 202.74
Rs/mtr 93.81 246.74
15. General Scope of Work for Piping Fabrication and Erection
Fabrication, cutting, welding, assembly in position as per drawing.
All raw material i.e. pipe, reducers, bends, flanges, sockets etc. and
hardware i.e. nut, bolts, gaskets etc. shall be supplied by client.
Fitment includes assembly of fittings i.e. flanges, bends, valves, reducer, fabrication of tees, fitment ofnon return va lve, valves, gaskets, nut bolts, sockets for pressure gauges fabrication and fitment of
thermowell, etc. Pipe work shall be carried out as per piping drawings/ specifications/ instructions given
to construction engineer.
After assembly, complete pipeline to be welded by taking necessary
precautions to avoid stresses. If stresses developed , those are to be
removed and w elded as per standard practice and instructions of the
site co-ordinator.
One in-position weld is allowed for line which cannot be welded on
ground.
After welding , finishing and grinding , pipeline to be hydraulically tested at pressure specified in the
order.
After hydraulic testing, pipeline to be painted with redoxide ( one coat).
After painting, pipeline to be assembled in position and with necessary
clamps and supports.
16. List of Tools, Tackles and Machinery Required to Carry Out the Piping Works
To be arranged by contractor:
1. Rectifier
2. H.F. unit
3. Transformer
4. Grinders- AG7
5. Winch 5 MT
6. Chain block 3 MT 11 mtr. Lift
7. Ropes / pulleys
8. FF2 grinder
9. Hacksaw/Files etc. and other tools and tackles.
10. Pipe voice
11. G Q 4 Grinder
12. Abrasive cutting machine
13. Gas cutting
17. Contractor Manpower List of Piping, Fabrication and Erection
For piping, fabrication and erection:
1. Experienced Mechanical Engineer as in-charge
2. Supervisor3. Highly skilled fitter for SS 304
4. Highly skilled fitter for MS B and C class piping and fabrication
5. Welders for SS TIG, Welders for SS Tacking, Welders for MS Tacking
6. Helpers/Riggers
18. Additional Cost Information
Piping cost may v ary between 20 to 66 %.
Piping cost may be a headache to the estimator as he/she is asked to
give the cost even before engineering and execution.
The estimator needs to convert the preliminary flow sheet into a fair
approximation of an actual design.
The estimator should have the skill to draw quick and rather accurate
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free hand isometric sketches, which will be of inestimable value.
19. Methods used for Estimation
Piece by piece method ( Detailed costing)
Finagling factor ( 40 % of equipment cost)
N system.
20. N System
The N system is based on the fact w hich has been tested many times, that the costs of strings of pipes of
different sizes but of the same material and class of pipe bear constant relations to each other. The Nsystem was introduced by R.A. Dickson (Chem. Eng. Nov 1947, PP 121-123)
21. How to use the N System
Step I : Calculate the cost of the reference sizes of the strings of pipe in question.
StepII : Then use the N factors to get the cost of the same string in the required size.
Continued to Costing of Pipelines - 2
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Design Detail Considerations for
Piping Supports
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Important Definitions &
Considerations in Piping
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