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

Accounting for Inflation

Cost to purchase = Base Cost*(I/Ibase)
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 CB formulas

Electric Motor to drive pump

Installation, etc, FBM=3.3 CBM=FBM*CP

Size Factor=Power consumption, PC=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)]30.0035549[ln(PC)]4} Cp=FTCB FT= motor types factor see Table 22.22 M=~90%

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 Stainless steel Nickel Alloy 1.8 2.5 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, PC 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

Not for double pipe

Pressure Factor, Fp= 0.9803+0.018(P(psig)/100)+0.0017(P(psig)/100)2

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 Vertical Vessels, 4,200<W<1,000,00 lb Add Platform Costs,
Vertical, 3<Di<21 ft
CPL=1580(Di)0.20294

CB=exp{8.717-0.2330[ln(W)]+0.4333[ln(W)]2}

CB=exp{6.775-0.18255[ln(W)]+0.02297[ln(W)]2} Horizontal, 3<Di<12 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 NT= no. trays
CT=NTFNTFTTFTMCBT

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