Piping Esitml

KBR
ONSHORE ESTIMATING DEPARTMENT

PIPING/INSULATION DESK MANUAL
OWNER: GREG MINICONE

ISSUE DATE: APRIL 3, 2000
UPDATED: JULY 2002
TABLE OF CONTENTS
I.
INTRODUCTION
II.
CODE OF ACCOUNT NARRATIVES
III.
PIPING ESTIMATING GUIDELINES

A.
Demolition
B.
U/G Pipe
C.
A/G Pipe
D.
Insulation
E.
Paint
F.
Pipeline
G.
Qualifications & Backup
H.
Crew Mix
I.
Procurement
IV.
TECHNICAL STANDARDS AND REFERENCES

A.
Piping Flexibility
STANDARD FORMS
VI.
PIPING ESTIMATING SOFTWARE
1
1442-0001
INTRODUCTION
The purpose of the PIPING DISCIPLINE MANUAL is to define procedures and job
descriptions and to maintain consistency in the production of the piping portion of detailed
conceptual, lump sum, and definitive estimates. It is intended to set forth correct piping
procedures, material pricing requirements, take off theory, and application of correct workhours. The information should serve as a guideline for an estimate's technical content.
This is to be a working" discipline manual; its organization parallels the activities of a
typical project. First, the estimator must identify the major areas of the project (i.e., scope,
drawings, specifications, dates, etc.). Then, activity responsibility must be determined
within each code of account (i.e., labor, purchasing, shop fabrication, field run, etc.). Once a
plan has been established, the quantity survey begins. After the takeoff has been completed
with work-hours, material dollars, and qualifications, the chief estimator then reviews the
estimate. Technical content, accuracy, and historical comparisons are performed. After
these adjustments, the estimate is turned over to the principal estimator. The estimate then
proceeds through the formal reviewing process to completion.
This manual also has typical details and standards that may be used when no other
drawings or definitions pertinent to the project are available.
Additionally, each piping estimator has the responsibility to suggest ways to revise and
update the manual. The ultimate responsibility for the accuracy of this manual belongs to
the chief piping estimator.
Always be mindful that we are all working together and toward the same goal, any
information that the estimator receives that is beneficial to the other estimators should be
shared. It is also the responsibility of the estimator to communicate with the estimators in
other disciplines to assure uniformity of the estimate.
Finally, the estimator must ask questions if uncertain about a particular situation. He must
be willing to seek advice from those with experience and to research and be able to support
any assumptions that are made. All-important aspects of the piping estimate should be
clarified in writing in the estimate qualifications.
1
1442-0002
K e llo g g B r o w n & R o o t
PIPING
PROJECT CODE OF ACCOUNTS
A H a llib u r to n C o m p a n y
D--DEMOLITION - All work required for dismantling or removal of any existing piping and insulation
systems to clear site of decommissioned systems. These accounts are to include transportation or disposal
costs, if required. For relocation accounts, only the dismantling portion of the work is to be included in this
section. Any new work subsequent to the dismantling activities is to be included in the respective section .
D43 DEMO FOR DISPOSAL - PIPING - Use this account only if the item is not to be salvaged or
relocated. This account includes demolition and disposal of existing piping systems including fittings,
flanges, manual valves, and in-line instruments. Removal techniques may include cold or hot cutting. The
sale of scrap or other credits related to this activity are included in this account. Quantities are measured as
center to center lengths of pipe removed (LF or LM).
D46 DEMO FOR DISPOSAL - INSULATION - Use this account only if the item is not to be salvaged
or relocated. This account includes demolition and disposal of existing insulation, other than asbestos
containing materials. Asbestos abatement costs are included in other accounts. The sale of scrap or other
credits related to this activity are included in this account. Quantities are measured as lengths of insulation
removed (LFI or LMI).
D53 DEMOLITION FOR SALVAGE PIPING - Use this account only if the item is to be salvaged.
This account includes the demolition and salvage of existing piping systems including fittings, flanges,
manual valves, and in-line instruments. Removal techniques may include cold or hot cutting. The sale of
scrap or other credits related to this activity are included in this account. Quantities are measured as center
to center lengths of pipe removed (LF or LM).
D56 DEMOLITION FOR SALVAGE INSULATION - Use this account only if the item is to be
salvaged. This account includes the demolition and salvage of existing insulation, other than asbestos
containing materials. Asbestos abatement costs are included in other accounts. The sale of scrap or other
credits related to this activity are included in this account. Quantities are measured as lengths of insulation
removed (LFI or LMI).
D63 DEMOLITION FOR RELOCATION - PIPING - Use this account only if the item is to be
relocated. This account includes only the removal for relocation of existing piping systems including
fittings, flanges, manual valves, and in-line instruments. Removal techniques may include cold or hot
cutting. For costs to relocate and reinstall the item, use the appropriate control code as though the item was
new. Quantities are measured as center to center lengths of pipe removed (LF or LM).
D66 DEMOLITION FOR RELOCATION - INSULATION - Use this account only if the item is to be
relocated. This account includes only the removal for relocation of existing insulation, other than asbestos
containing materials. Asbestos abatement costs are included in other accounts. For costs to relocate and
reinstall the item, use the appropriate control code as though the item was new. Quantities are measured as
center to center lengths of insulation removed (LF or LM).
D97 SCAFFOLDING - Cost of scaffolding including rental and purchase of materials, and labor
for storage, erection and dismantling.
Quantities will be Lot (LOT).
D98 -CONCEPTUAL DESIGN ALLOWANCE - For estimating use only. The intent of the conceptual
design allowance is to provide for the normal growth of engineered and bulk material quantities during the
engineering design process. These historical percentages are based on the level of definition at the time of
quantity development. These percentages are reflected in real quantities so that the estimate reflects the
actual quantities installed. This allowance is not intended to be a source to cover out-of-scope cost.
D99 -CONSTRUCTION PRACTICES ALLOWANCE - For estimating use only. The intent of the
construction practice allowance is to provide for the material cost only associated with additional material
consumed due to normal construction practice. There will be no labor or man-hours associated with this
code. This allowance also covers standard waste and is not intended to cover out-of-scope costs.
- 1 -Page 1 of 8
PIPING
U4 UNDERGROUND PIPE These accounts are for all labor and material required for
underground process and drainage piping systems. Costs shall include, but not be limited to, pipe,
fittings, flanges, coatings, trench excavation, backfill, sand bedding, kicker blocks, shoring, and
dewatering.
All excavation trenching and backfill shall be performed with due care around/under cables,
pipes, or adjacent structures; protecting and supporting of these items may be required.
Waste or over-excavation shall not constitute additional quantities.
The cost also includes additional excavation and subsequent backfill for working space and
for temporary supporting of trench sides. Trenches shall be excavated in accordance with safety
practices.
Trenches shall be kept free from water to ensure work can proceed.
Work shall include repair of internal and external coatings on metallic systems.
Costs to supply labor and material to repair these coatings shall be included in these accounts
Quantities are measured center-to-center through fittings, flanges, valves, and
other in-line devices. At bends, measurement shall be to the intersection point,
branches are measured from the outer wall of the main pipe. Material handling,
unloading / storage of materials, and clean-up to be included in the appropriate
account.
U41 PRESSURE PIPE LESS THAN 12- All costs of piping materials, fabricating, placing,
and testing of Underground piping up to and including 10 in pressure flow service including pipe,
fittings, valves, and other items and appurtenances. Specialty items, such as hydrants and monitors
are included in this account. Pipe bollards are not included in these accounts and shall be included
in concrete accounts, C. Quantities are measured as center to center lengths of pipe installed
(LF or LM).
U42 PRESSURE PIPE 12 & LARGER All costs of piping materials, fabricating, placing,
and testing of Underground piping 12 & larger pipe in pressure flow service including pipe,
fittings, valves, and other items and appurtenances. Specialty items, such as hydrants and
monitors are included in this account. Pipe bollards are not included in these accounts and shall
be included in concrete accounts, C. Quantities are measured as center to center lengths of pipe
(LF or LM).
U43 GRAVITY PIPE LESS THAN 12- All costs of piping materials, fabricating, placing,
and testing of underground piping up to and including 10 in gravity flow service including pipe,
fittings, valves, and other items and appurtenances. Quantities are measured as center to center
lengths of pipe installed (LF or LM).
- 2 -Page 2 of 8
PIPING
U44 GRAVITY PIPE 12 & LARGER All costs of fabricating, placing, and testing of
underground piping 12 & larger pipe in gravity flow service including pipe, fittings, valves, and
other items and appurtenances. Quantities are measured as center to center lengths of pipe
installed (LF or LM).
U45 MANHOLES - All material and labor costs for installing precast manholes, catch basins,
and sumps. Costs for excavation and backfill shall be included. Quantities are measured as each
installation (EA).
Concrete or precast costs for these items will be included with concrete accounts.
U90 PUMP AND BAIL - All material and labor costs for normal pump and/or bailing of all
excavated trenches. Quantities will be for all u/g piping measured as total (LOT).
U98 -CONCEPTUAL DESIGN ALLOWANCE - For estimating use only. The intent of the
conceptual design allowance is to provide for the normal growth of engineered and bulk material
quantities during the engineering design process. These historical percentages are based on the
level of definition at the time of quantity development. These percentages are reflected in real
quantities so that the estimate reflects the actual quantities installed. This allowance is not
intended to be a source to cover out-of-scope cost.
Quantities will be (LF or LM).
- 3 -Page 3 of 8
PIPING
L01 PIPELINE These accounts are for work required for all costs to supply and install crosscountry product pipelines. Costs shall include, but not be limited to, pipe materials, pipe coatings,
clearing, grade & surveys, ditching & trenching, field bending, alignment, welding, testing,
drying, and purging. Where routings require installation in and/or under waterways, adequate
anchoring costs shall be included.
Also includes routing surveys, clearing of right-of-way, removal of landscaping, bedding,
backfill, final
grading to final elevations, replacement of disturbed areas to its original condition
and the installation of pipeline markers and warning signs. For aboveground
Transmission lines, sleepers and supports area included in this account. All excavation,
Trenching, and backfill shall be performed with due care around/under cables,
pipes, or adjacent structures; protecting and supporting of these items may be
Required. Waste in bulk shall not constitute additional quantities. The cost also includes
Additional excavation and Subsequent backfill for working space and for temporary supporting of
trench sides. The area shall be kept free from water to ensure work can proceed.
Quantities are measured center-to-center through fittings, flanges, valves, and
other in-line devices. At bends, measurement shall be to the intersection point;
Branches are measured from the outer wall of the main pipe. Material handling,
Unloading / storage of materials, and clean-up to be included in the appropriate
account. Costs for permanent roads are included in the Site Preparation accounts.
Bidders shall store all materials at the site. Pipe and fittings will be manufactured with external
coatings. Costs to supply labor and material to repair these coatings shall be included in these
accounts.
L13 ROAD CROSSINGS All costs associated with pipeline installation at road crossings to
include casing installation, testing, and markers and/or warning signs.
Crossings will be concrete box culverts with 12 thick walls, as required by specification.
L14 RIVER CROSSINGS All costs associated with pipeline installation at river crossings.
Crossing may be open cut submerged or bored, as required by specification.
CATHODIC PROTECTION All costs of installing, terminating, and testing a
Complete cathodic protection system for pipelines.
NOTE:
If other ELECTRICAL work is included in this contract, the CATHODIC
PROTECTION shall be in ACCOUNT CODE E.
Also note that, if desired, account 0601 can be divided, as further breakdown,
Into:
L01
L02
L03
L04
L11
L13
L14
L15
Permanent materials
Survey, clear, grade right-of-way
String, weld, & lower in
Ditching and trenching
Clean, test, & finals clean up
Road crossings
River crossings
Specialty items.
- 4 -Page 4 of 8
PIPING
P ABOVEGROUND PIPE All cost of pipe materials, labor, temporary materials, and
permanent materials, and consumables required to install aboveground piping systems as defined
by engineering documents and specifications. Material handling, unloading/storage of materials,
and clean up to be included in these accounts.
Rates shall include, but not be limited to, supply materials, labor costs to fabricate and erect pipe,
fittings, flanges, valves, in-line instruments, and specialty items. All work activities required to
insure complete installation of piping systems shall include, but not be limited to, lifting,
installation, weld out, mechanically connect, hydrotest, and support piping systems. Work for
activities in these accounts shall be through mechanical completion. Costs to be separated by size
and material type.
Costs to perform non-destructive examination (radiography, hardness, etc.), post weld heattreating, steam blow, and chemical cleaning shall be included in these accounts.
Costs to supply, erect, and maintain scaffolding, according to project safety requirements, shall be
included in these accounts.
Quantities are to be measured center to center through fittings, flanges, valves, and other in-line
devices. At bends, measurement shall be to the intersection point. Branches are measured from
the outer wall of the main pipe.
Waste shall not constitute additional quantities.
P11 SPOOL FABRICATION 2 & less Quantity reflects the supply of piping material and
field shop fabrication of welded pipe spools for process and utility service sizes 2 & less. Pipe
spools will be installed in account P31. Quantities are measured as center to center lengths of
pipe fabricated (LF. Or LM.).
P12 SPOOL FABRICATION 2-1/2 thru 10 Quantity reflects supply of piping materials
and field shop fabrication of welded pipe spools for process and utility service sizes 2-1/2
through 10. Pipe spools will be installed in account P32. Quantities are measured as center to
center lengths of pipe fabricated (LF. or LM.).
P13 SPOOL FABRICATION 12 and Larger Quantity reflects supply of piping materials
and field shop fabrication of welded pipe spools for process and utility lines in sizes 12 and
larger. Pipe spools will be installed in account P33. Quantities are measured as center to center
lengths of pipe fabricated (LF. or LM.).
P31 SPOOL ERECTION 2 & less Quantity reflects pipe spool erection of welded pipe
spools for process and utility service sizes 2 & less. Outside fabrication cost of spools will be
included in this account. In the event pipe spools are fabricated at a field shop, material cost will
not be included in this account. Erection labor rates to include but not limited to valve handling,
specialty handling, bolting, and welding.
Quantities are measured as center to center lengths of pipe installed (LF or LM).
P32 SPOOL ERECTION 2-1/2 thru 10 Quantity reflects pipe spool erection of welded
pipe spools for process and utility service sizes 2-1/2 through 10. Outside fabrication cost of
spools will be included in this account. In the event pipe spools are fabricated at a field shop,
material cost will not be included in this account. Erection labor rates to include but not limited to
valve handling, specialty handling , bolting, and welding.
- 5 -Page 5 of 8
PIPING
P33 SPOOL ERECTION 12 and Larger Quantity reflects pipe spool erection of welded
pipe spools for process and utility lines in sizes 12 and larger. Outside fabrication cost of spools
will be included in this account. In the event pipe spools are fabricated at a field shop, material
cost will not be included in this account. Erection labor rates to include but not limited to valve
handling, specialty handling, bolting, and welding.
P41 FIELD RUN 2 & LESS Quantity reflects the material and labor cost of all pipe
systems to be field run in place for process and utility lines sizes 2 and less. Erection labor rates
to include but not limited to valve handling, specialty handling, bolting, and welding.
P42 FIELD/RACK RUN 2-1/2 thru 10 Quantity reflects the material and labor cost of all
pipe systems to be field run in pipe racks for process and utility lines in sizes 2-1/2 through 10.
Erection labor rates to include but not limited to valve handling, specialty handling, bolting, and
welding.
P43 FIELD/RACK RUN 12 and Larger Quantity reflects material and labor cost of all pipe
systems to be field run in Pipe racks for process and utility lines in sizes 12 and larger.
Erection labor rates to include but not limited to valve handling, specialty handling, bolting, and
welding.
P51 DELUGE SYSTEMS Quantity reflects labor and material cost of deluge pipe systems.
P67 PIPE SPECIALTIES Used only for material cost of pipe mechanical specialties. Such
devices shall include, but not be limited to strainers, traps, hoses, paddle blinds, expansion joints,
etc. Quantities are measured as each (EA)
P68 ERECTION MATERIALS Used only for material cost of bolts, nuts, & gaskets.
P69 VALVES Used only for material cost of all manual valves. Supply of RSV and actuated
valves are included in the instrument account.
P71 TESTING All labor & material costs required to perform visual, mechanical, and pressure
test of piping systems as defined by engineering documents, specifications, and applicable codes.
Work shall include provision and subsequent removal of all temporary supply lines, pressure
sources, and test water. Costs shall include completion of punch list check out.
Quantities are measured as lot (LOT)
P72 TIE-INS AND HOT TAPS All labor cost associated with tie-ins.
Quantities are measured as each (EA)
P73 OTHER SERVICES All costs associated with X-raying, stress relieving, pipe.
Quantities are measured as each (EA)
P75 PIPE CLEANING All costs associated with cleaning and pickling pipe.
Quantities are measured as Lot (LOT)
- 6 -Page 6 of 8
PIPING
P81 SHOP PIPE SUPPORTS All costs associated with the supply, fabrication, and
attachment of pipe supports, plates, shoes, guides, hangers, angles, and springs in an outside pipe
fabrication shop.
Quantities are measured as lot (LOT)
P82 PIPE SUPPORTS All costs associated with the supply, fabrication, and erection of pipe
supports, plates, shoes, guides, hangers, angles, and springs by the field erection crews.
Quantities are measured as center to center lengths of pipe installed (LF. or LM.).
P97 SCAFFOLDING - Cost of scaffolding including rental and purchase of materials, and labor
P98 -CONCEPTUAL DESIGN ALLOWANCE - For estimating use only. The intent of the
conceptual design allowance is to provide for the normal growth of engineered and bulk material
quantities during the engineering design process. These historical percentages are based on the
level of definition at the time of quantity development. These percentages are reflected in real
quantities so that the estimate reflects the actual quantities installed. This allowance is not
intended to be a source to cover out-of-scope cost.
Quantities will be (LF. or LM.).
NOTE:
1.)
Process EQUIPMENT NDT, preheat services or post weld heat treatment is

Included with specific equipment.
- 7 -Page 7 of 8
PIPING
VCOATINGS AND COVERINGS - All costs to supply and install coatings and insulation for process
and utility piping systems are included in these accounts. Material handling, unloading / storage of
materials, disposal of wastes, and clean-up are to be included in the appropriate account.
V11 PAINT PIPING All costs to apply pipe coatings defined by engineering documents, specifications,
and applicable codes. Costs shall include supply of bulk paint materials, solvents, thinners, and disposal of
waste materials. Labor costs shall include surface preparation and application of primer and finish coats,
and clean up of work areas.
Quantities are measured as surface area of pipe per coat based on center to center lengths of pipe to be
painted (SF or SM).
Waste does NOT constitute basis for additional quantities. Touch up does NOT constitute basis for
additional quantities.
V21 PIPE INSULATION
INSULATION - All costs to supply and install insulation materials as defined by engineering
documents, specifications, and applicable codes.
Waste does NOT constitute basis for additional quantities.
Material handling, unloading / storage of
Materials, and clean up to be included.
Stop ends where required. Also includes supplying and installation of jacketing, vapor barrier,
insulating coatings, mastic adhesives, rings, banding, clips, springs, and associated
hardware. At bends, measurement shall be to the intersection point; branches are measured from
the outer wall of the main pipe
Quantities are measured center-to-center through fittings, flanges, valves and
other in-line devices (LFI of LMI).
V97 SCAFFOLDING - Cost of scaffolding including rental and purchase of materials, and labor
V98 -CONCEPTUAL DESIGN ALLOWANCE - For estimating use only. The intent of the conceptual
design allowance is to provide for the normal growth of engineered and bulk material quantities during the
engineering design process. These historical percentages are based on the level of definition at the time of
quantity development. These percentages are reflected in real quantities so that the estimate reflects the
actual quantities installed. This allowance is not intended to be a source to cover out-of-scope cost.
Quantities will be (LFI. or LMI.).
V99 -CONSTRUCTION PRACTICES ALLOWANCE - For estimating use only. The intent of the
construction practice allowance is to provide for the material cost only associated with additional material
consumed due to normal construction practice. There will be no labor or man-hours associated with this
code. This allowance also covers standard waste and is not intended to cover out-of-scope costs.
- 8 -Page 8 of 8
KELLOGG BROWN & ROOT ESTIMATING
UNDERGROUND PIPING - U4X

CHECK LIST
GENERAL NOTES
PAGE 1
GENERAL
1. READ THE PROJECT SCOPE, SPECIFICATIONS AND ALL RELATED DOCUMENTS. ALL DRAWINGS SHOULD BE
CAREFULLY EXAMINED FOR LEGENDS, NOTES & DETAILS. THESE CAN PROVIDE VALUABLE INFORMATION FOR THE
THE TAKE-OFF EFFORT.
2. ON THE "PIPING ESTIMATE INPUT" SHEETS THE FOLLOWING ENCODERS TO BE USED AND INPUTED IN LINE "1$"
AND COLUMN 54.
" P " PRESSURE SYSTEMS
" G " GRAVITY SYSTEMS
2. THE CHECK LIST(S) INCLUDES ALL ACTIVITIES NEEDED FOR A PARTICULAR SYSTEM AND TYPE OF MATERIALS.
CARE MUST BE EXERCISED SO WE DO NOT INCLUDE ANY OF THESE ACTIVITIES, IN THE ESTIMATE,
IF THEY ARE NOT SPECIFICALLY REQUIRED BY THE JOB SCOPE AND/OR THE PROJECT SPECIFICATIONS.
THE FOLLOWING LISTED ITEMS ARE SOME EXAMPLES OF THE ABOVE.
FIRE PROTECTION GRAVEL AT FIRE HYDRANTS
FIRE PROTECTION GUARD POSTS
UTILITIES PIPE AND FITTING RESTRAINMENT
ALL DOPE & WRAP OF PIPE AND FITTINGS
2. UNDERGROUND MATERIAL AND LABOR TAKE-OFFS TO BE IN DETAIL UNLESS SPECIFICALLY INSTRUCTED.
3. INDIVIDUALS SHOULD FAMILIARIZE THEMSELVES WITH THE MATERIAL REQUIREMENTS, TYPE OF END
CONNECTIONS, & THE CONSTRUCTIBILITY OF THE MATERIALS REQUIRED.
4. IT IS VERY IMPORTANT THAT YOU CONVEY TO OTHER DISCIPLINES THE EXTENT OF THEIR SCOPE OF WORK
SHOWN ON UNDERGROUND PIPING DRAWINGS. COMMUNICATIONS IS THE SECRET AND COLOR CODING THE
DRAWINGS IS A FAIL SAFE METHOD.
5. ON THE U/G PIPING CHECK LISTS THERE ARE ITEMS LISTED THAT NEED TO BE INCLUDED IN OTHER DISCIPLINES
ESTIMATES, THESE ARE SHOWN BY DISCIPLINE IDENTIFICATION LETTER. QUANTITIES AND A DESCRIPTION,
OF THESE ITEMS, MUST BE GIVEN TO THE RESPONSIBLE DISCIPLINE ESTIMATOR.
6. FOR ALL MATERIAL TYPES, THAT REQUIRE FIELD FABRICATION, USE THE FOLLOWING CAPS ENCODERS.
P40 PIP - FOR MATERIALS
P10 PSE - FOR FIELD FABRICATION
P40 PSE - FOR PIPE LAY
7. CHECK YOU ESTIMATE RUN AND VERIFY THAT THE FOLLOWING UNITS HAVE BEEN USED.
FOR PIPE MATERIALS - LFP
FOR FIELD FABRICATION - LF.
FOR PIPE LAY - LF
8. ALLWAYS USE THE APPROPRIATE SERVICE DESIGNATION OR ASSIGN A SERVICE DESIGNATION. ON YOUR CAPS
SHEETS USE THE 1$ LINE AND COLUMNS 9 THRU 13. THIS WILL SORT THE MATERIALS AND LABOR BY SERVICE.
THE FOLLOWING ARE SOME EXAMPLES OF SERVICE DESIGNATIONS.
FW - FIRE WATER
SA- SANITARY SEWER
PS - PROCESS SEWER
CHS - CHEMICAL SEWER
MW - MILL WATER
SS - STORM SEWER
9. ALL SYSTEMS REQUIRE TESTING. UNLESS OTHERWISE DETERMINED IN THE PROJECT SPECS, THE STANDARD
APPROACH TO GRAVITY PIPE TESTING IS "STAND PIPE/INFILTRATION" METHOD. USE 6% OF DIRECT MAN HOURS,
EXCLUDING TRENCHING. FOR PRESSURE PIPING USE 8% OF THE DIRECT MANHOURS.
10. SOME ACTIVITIES ARE NOT APPLICABLE TO CERTAIN MATERIAL TYPES. CHECK JOB SPECIFICATIONS
FOR REQUIREMENTS.
11. DIAPER GROUT JOINTS ARE OPTIONAL FOR CONCRETE OR CLAY PIPE. CHECK JOB SPECIFICATIONS
FOR REQUIREMENTS.
12. DOPE & WRAP FOR FITTINGS INCLUDES THE ADJACENT WELDS. SEE "AREA OF PIPE AND FITTINGS
- EXTERNAL COATING" CHART.
13. CONSIDERATION SHOULD BE GIVEN TO ADDING MATERIAL DOLLARS AND MHRS FOR THE REPAIR OF
OF VENDOR FURNISHED DOPED AND WRAPPED PIPE.
14. JACK AND BORING OPERATIONS, REQUIRE EXCAVATION AND BACKFILL, FOR SETTING THE MACHINE AT THE
PROPER ELEVATION.
15. JACK AND BORING MACHINE REQUIRES A GRAVEL/ROCK FOUNDATION. DEPTH OF THE FOUNDATION
TO BE FURNISHED BY THE SUBCONTRACTOR. MATERIALS AND INSTALLATION BY B&R.
16. JACK AND BORING MACHINE REQUIRES SETTING AND REMOVAL ,IN TRENCH, EACH DAY OF OPERATION(S).
SUB-CONTRACTOR WILL FURNISH THE DURATION IN MEN DAYS. EQUIPMENT AND LABOR FOR SETTING,
THE BORING MACHINE, TO BE FURNISHED BY KELLOGG BROWN & ROOT.
17. FOR EXCAVATION AND BACKFILL, CONSIDERATION SHOULD BE GIVEN TO THE REMOVAL (SPOIL) OF EXTRA
SOIL DUE TO THE VOLUME OF PIPE AND SAND BEDDING.
UNDGR1.XLS
UNDERGROUND PIPING - 04X

CHECK LIST
GENERAL NOTES
PAGE 2
18. EXCAVATION AND BACKFILL QUANTITIES, NEAR OR UNDER BUILDING OR EQUIPMENT FOUNDATIONS
CAN BE EXCLUDED FROM THE 04XX ACCOUNTS, IF MASSIVE EXCAVATION IS REQUIRED AND DEPTH IS
ADEQUATE FOR THE INSTALLATION OF THE PIPE.
19. CONTAMINATED SOIL SHOULD BE SPOILED AND NEW PURCHASED SOIL IS TO BE USED. CHECK JOB
REQUIREMENTS. COST FOR DISPOSAL OF CONTAMINATED SOIL, AT SPECIAL LANDFILLS, TO BE INCLUDED
AS A SUBCONTRACT PRICE.
20. MATERIAL SQUARE FOOTAGE, FOR SHORING, SHOULD BE BASED ON A 1/3 OF THE SQUARE FOOTAGE REQUIRED.
(MATERIALS CAN BE REUSED A MAXIMUM OF THREE TIMES). THE FOLLOWING UNITS TO BE USED FOR SHORING.
SHORING LABOR - SF
SHORING MATERIAL - SF.
21. THE MATERIAL COST, OF ALL UNDERGROUND COMPONENTS,SHOULD BE INCLUDED PER SYSTEM. FOR DETAIL
INFORMATION SEE UNDERGROUND "CHECK LIST".
22. FOR ADDITIONAL MATERIAL COST OF BOLTS & GASKETS, AS REQUIRED BY THE SPECIFICATIONS, SHOULD
BE INCLUDED AS ONE LINE ITEM, SIMILAR TO THE P68 ACCOUNT FOR ABOVEGROUND PIPE.
UNDGR1.XLS

CHECK LIST
SEWERS & DRAINS
SYSTEM
MATERIALS
ITEM
PIPE
FITTING
JOINT (OPTIONAL)
PIPE
CLAY
FITTING
JOINT (OPTIONAL)
AREA DRAINS
PIPE
FLOOR DRAINS FRP HAND LAY-UP PIPE
EQUIPMENT DRAINS
JOINT
JOINT
PIPE
PVC
PIPE
CHEMICAL
FITTING
CEMENT JOINT JOINT
JOINT
PVC
PIPE
PUSH-ON JOINTS FITTING
JOINT
PIPE
FRP
FITTING
JOINT
JOINT
PIPE
POLYETHYLENE PIPE
OR
FITTING
POLYPROPYLENE JOINT
JOINT
PIPE
PIPE
D&W
D&W - REPAIR
CARBON STEEL PIPE
WITH
FITTING HANDLE
DOPE & WRAP
FITTING
JOINT
JOINT
JOINT
WELD
PIPE
PIPE
PIPE ENCASEMENT
CARBON STEEL FTTNG ENCASEMENT
WITH
PIPE
EXTRUDED
FITTING HANDLE
POLYETHYLENE FITTING
ENCASEMENT
JOINT
JOINT
JOINT
WELD
PIPE
PIPE
D&W (OPTIONAL)
D&W - REPAIR (OPT)
STAINLESS
PIPE (OPTIONAL)
STEEL
JOINT
FITTING HANDLE
JOINT
JOINT (OPTIONAL)
FITTING (OPTIONAL)
WELD
P - PIPE
M - MECHANICAL
I/E - INSTR./ELECTR.
S/C - SUBCONTRACT
STORM
PROCESS
SANITARY
OILY/WATER
RCP
ACTIVITY
MATL
LAY
HANDLE
DIAPER GROUT JOINT
LAY
HANDLE
GROUT JOINT
SPOOL FABRICATION
LAY
BUTT-WRAP
BOLT-UP
FIELD FABRICATION
LAY
HANDLE
SOCKETWELD - CHEM
BOLT-UP
LAY
HANDLE
PUSH-ON
LAY
HANDLE
SOCKETWELD - CHEM
BOLT-UP
FIELD FABRICATION
LAY
HANDLE
FUSION WELD
BOLT-UP
FIELD FABRICATION
LAY
FOR PIPE ONLY
FOR PIPE ONLY
GEEB TESTING
P
P
P
P
P
P
V
DOPE & WRAP

ERECTION BUTTWELD
BOLT-UP
DOPE & WRAP JOINT
X-RAY
FIELD FABRICATION
LAY
POLYETHYLENE
POLYETHYLENE
GEEB TESTING
HEAT SHRINK SLEEVE

ERECTION BUTTWELD
BOLT-UP
HEAT SHRINK SLEEVE
X-RAY
FIELD FABRICATION
LAY
FOR PIPE ONLY
FOR PIPE ONLY
GEEB TESTING
ERECTION BUTTWELD
BOLT-UP
DOPE & WRAP JOINT
DOPE & WRAP FTTG
X-RAY
C - CIVIL
V - VENDOR
FABR
P
P
P
P
P
P
V
P
V - S/C
P
V
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
P
P
P
P - S/C
P
P
P
P
PAGE 3
LABOR OTHER
EQUIP
P
P
V
P
P
S/C
P
P
P
EQUIP
NONE
P
P
P
P
P - S/C
P
P
V
P
P
P
EQUIP
NONE
P
P
P
P
EQUIP
P - S/C
P
S/C
P
P
P
V
P
P
P
S/C
P
P
EQUIP
P
NONE
P
P
P
P - S/C
UNDGR1.XLS

CHECK LIST
SEWERS & DRAINS
SYSTEM
STORM
PROCESS
SANITARY
OILY/WATER
AREA DRAINS
FLOOR DRAINS
EQUIPMENT DRAINS
MATERIALS
DOUBLE WALL
CONTAINMENT
CARBON STEEL
WITH
DOPE & WRAP
DOUBLE WALL
CONTAINMENT
CARBON STEEL
WITH
EXTRUDED
POLYETHYLENE
ENCASEMENT
PER JOB
REQUIREMENTS
PER JOB
REQUIREMENTS
ALL
MATERIALS
ALL
ROAD CROSSINGS
R/R CROSSINGS
(AREAS WHERE)
(EXCAVATION NOT)
(ALLOWED)
P - PIPE
O - OPTIONAL
CASING
CARBON STEEL
ITEM
PIPE
PIPE
D&W
D&W - REPAIR
PIPE
FITTING HANDLE
FITTING
JOINT - CARRIER
JOINT - CLOSURE
JOINT
JOINT
WELD
SPECIAL
ACTIVITY
SHOP FABRICATION
LAY
FOR PIPE ONLY
FOR PIPE ONLY
GEEB TESTING
MATL
V
FABR
PAGE 4
LABOR OTHER
V
P
V
P
P
P
EQUIP
NONE
P
P
P
P
P
P - S/C
P
DOPE & WRAP

P
ERECTION BUTTWELD
ERECTION BUTTWELD
BOLT-UP
DOPE & WRAP JOINT
P
X-RAY
S/C
UNLOAD, INSPECT &
STORE PIPE
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
P
PIPE ENCASEMENT
POLYETHYLENE
V
FTTNG ENCASEMENT POLYETHYLENE
P
P
PIPE
GEEB TESTING
P
EQUIP
FITTING HANDLE
NONE
FITTING
HEAT SHRINK SLEEVE
P
P
JOINT - CARRIER
ERECTION BUTTWELD
P
JOINT - CLOSURE
ERECTION BUTTWELD
P
JOINT
BOLT-UP
P
JOINT
HEAT SHRINK SLEEVE
P
P
EQUIP
WELD
X-RAY
S/C
P - S/C
SPECIAL
UNLOAD, INSPECT &
P
STORE PIPE
WALL INSERT
SHOP FABRICATION
V
V
WALL INSERT
FIELD FABRICATION
P
P
WALL INSERT
INSTALL
P
WALL INSERT
TILE REPAIR
M - S/C
M - S/C
WALL PENETRATION SHOP FABRICATION
V
V
WALL PENETRATION FIELD FABRICATION
P
P
WALL PENETRATION INSTALL
P
WALL PENETRATION TILE REPAIR
M - S/C
M - S/C
TESTING
AS REQUIRED
P
P
TRENCH
EXCAVATION
P
TRENCH
BACKFILL - SOIL
P
P
TRENCH
BACKFILL - SAND
P
P
TRENCH
SPOILS
P
TRENCH
SHORING
P
P
TRENCH
DEWATERING
P
P
JACK & BORE
PIPE CASING
C-S/C
PIPE CASING
FABRICATION
P
JOINTS
BUTTWELD
P
EXTERNAL COATING PIPE
V
INTERNAL COATING (IF REQUIRED)
V
EXTERNAL COATING JOINT
P
P
INTERNAL COATING (IF REQUIRED)
P
P
END CLOSURES
INSTALL
P
P
IF REQUIRED
CASING VENT
FIELD FABRICATION
P
IF REQUIRED
INSTALL
P
BORING MACHINE
EXCAVATE TRENCH
C
BORING MACHINE
BACKFILL TRENCH
C
BORING MACHINE
INSTALL IN TRENCH
C
BORING MACHINE
REMOVE FM TRENCH
C
BORING MACHINE
CRUSHED ROCK PAD
C
C
M - MECHANICAL
C - CIVIL
UNDGR1.XLS
S/C - SUBCONTRACT
V - VENDOR

CHECK LIST
SEWERS & DRAINS
SYSTEM
MATERIALS
LEACH FIELD
(SANITARY SEWER)
VITRIFIED CLAY
MANHOLE
CATCH BASIN
PRE-CAST
RCP
MANHOLE
CATCH BASIN
CAST IN-PLACE
CONCRETE
CONCRETE
LIFT STATION
PRE-CAST
PIPING
PER JOB
REQUIREMENTS
CONCRETE
LIFT STATION
CAST IN-PLACE
PIPING
PER JOB
REQUIREMENTS
MISCELLANEOUS
CULVERTS
(STORM DRAINAGE)
P - PIPE
MATERIALS
ALL
ALL
ITEM
PIPE
PIPE
GRAVEL
DISTRIBUTION BOX
TOP W/ COVER
CONE
SHELL
CONCRETE BASE
INTERNAL GROUT
PIPE
TOP W/ COVER
CONE
SHELL
CONCRETE BASE
INTERNAL GROUT
PIPE
TOP W/ COVER
SHELL
CONCRETE BASE
PUMP
INSTRUMENTATION
PIPE FAB
PIPE ERECTION
FTTG HANDLE
JOINT
TOP W/ COVER
SHELL
CONCRETE BASE
PUMP
INSTRUMENTATION
PIPE FAB
PIPE ERECTION
FTTG HANDLE
JOINT
FLOOR DRAINS
JOINT
CLEAN-OUTS
JOINT
P-TRAP
JOINT
ALL
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
LAY
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
HANDLE & SET
AS REQUIRED
HANDLE & SET
AS REQUIRED
HANDLE & SET
AS REQUIRED
ALL
C - CIVIL
V - VENDOR
MATL
FABR
PAGE 5
LABOR OTHER
P
P
P
C
P
P
P
C
C
P
C
C
C
C
C
C
P
P
C
M
I/E
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
C
C
C
M
I/E
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
P
P
P
P
P
P
C
P
P
P
C
C
P
C
C
C
C
C
C
P
P
C
M
I/E
C
C
C
M
I/E
P
P
P
P
P
P
C
UNDGR1.XLS

CHECK LIST
FIRE PROTECTION
SYSTEM
MATERIALS
FIRE PROTECTION
C900 PIPE
ITEM
PIPE - PVC
FITTING - D.I.
JOINT - PIPE
JOINT -FTTG
PIPE (OPTIONAL)
FITTING (OPTIONAL)
THRUST BLOCK
MEGA-LUGS
(PIPE RESTRAINMENT)
PIPE
FITTING
JOINT - PIPE PO
DUCTILE IRON
JOINT - PIPE MJ
INTERNALLY LINED JOINT -FTTG
PIPE (OPTIONAL)
CARBON STEEL
WITH
DOPE & WRAP
CARBON STEEL
WITH
EXTRUDED
POLYETHYLENE
ENCASEMENT
CARBON STEEL
INTERNALLY LINED
ACTIVITY
LAY
HANDLE
BOLT-UP MJ
POLYETHYLENE
ENCASEMENT
POLYETHYLENE
ENCASEMENT
INSTALL
INSTALL
LAY
HANDLE
MATL
FABR
P
P
PAGE 6
LABOR OTHER
P
P
NONE
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
BOLT-UP MJ
BOLT-UP MJ
POLYETHYLENE
P
ENCASEMENT
FITTING (OPTIONAL)
POLYETHYLENE
P
ENCASEMENT
THRUST BLOCK
INSTALL
P
RODDING/CLAMPS
INSTALL
P
COATING (ROD/CLAMP)APPLY (OPTIONAL)
P
PIPE
FIELD FABRICATION
P
PIPE
LAY
D&W
FOR PIPE ONLY
V
D&W - REPAIR
FOR PIPE ONLY
P
PIPE
GEEB TESTING
FITTING
HANDLE
FITTING
DOPE & WRAP FTTGS
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
WELD
X-RAY
S/C
THRUST BLOCK
AS REQUIRED
P
PIPE
FIELD FABRICATION
P
PIPE
LAY
PIPE & FITTING
POLYETHYLENE SLV
P
PIPE
GEEB TESTING
FITTING
HANDLE
FITTING
HEAT SHRINK SLEEVE
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
JOINT
HEAT SHRINK SLEEVE
P
WELD
X-RAY
S/C
THRUST BLOCK
AS REQUIRED
P
INTERNAL LINER
PIPE & FITTINGS
V
FIELD WELD
INTRNL LINER REPAIR P - S/C
P
P
P
P
P
P
P
P
EQUIP
NONE
P
P
P
P
P & S/C
P
P
ALL OTHER ACTIVITIES SEE CARBON STEEL THIS PAGE
P
P
EQUIP
NONE
P
EQUIP
P
P
P
P
P & S/C
P
P - S/C
P - PIPE
M - MECHANICAL
S/C - SUBCONTRACT
C - CIVIL
V - VENDOR
UNDGR1.XLS

CHECK LIST
FIRE PROTECTION
SYSTEM
FIRE PROTECTION
MATERIALS
MATERIALS
ALL
ITEM
FIRE HYDRANT
ACCESSORIES
CONCRETE BASE
GRAVEL
JOINT
JOINT
VLV INDICATOR POST
VALVE
VALVE JOINT
JOINT
VALVE BOX
VALVE
VALVE JOINT
VALVE JOINT
FIRE MONITOR
JOINT
JOINT
SPRAY/FOAM NOZZLE
JOINT
HOSE HOUSE
CONCRETE BASE
INSULATION FLG KIT
JOINT
CATHODIC PROTECT
VALVE
JOINT
JOINT
HOSE & REEL
GUARD POST (PIPE)
ROAD CROSSINGS
R/R CROSSINGS
(AREAS WHERE)
(EXCAVATION NOT)
(ALLOWED)
P - PIPE
O - OPTIONAL
CASING
CARBON STEEL
TESTING
TRENCH
TRENCH
TRENCH
TRENCH
TRENCH
TRENCH
JACK & BORE
PIPE CASING
JOINTS
EXTERNAL COATING
INTERNAL COATING
EXTERNAL COATING
INTERNAL COATING
END CLOSURES
IF REQUIRED
CASING VENT
IF REQUIRED
BORING MACHINE
BORING MACHINE
BORING MACHINE
BORING MACHINE
BORING MACHINE
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
MATL
INSTALL
INSTALL
INSTALL
PLACE
BOLT-UP
BOLT-UP MJ
INSTALL
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
BOLT-UP
BOLT-UP MJ
INSTALL
BOLT-UP
INSTALL
INSTALL
INSTALL
BOLT-UP
PROVIDE COUNT
OF JOINTS
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
INSTALL
P
P
C
P
AS REQUIRED
EXCAVATION
BACKFILL - SOIL
BACKFILL - SAND
SPOILS
SHORING
DEWATERING
PIPE CASING
FABRICATION
BUTTWELD
PIPE
(IF REQUIRED)
JOINT
(IF REQUIRED)
INSTALL
FIELD FABRICATION
INSTALL
EXCAVATE TRENCH
BACKFILL TRENCH
INSTALL IN TRENCH
REMOVE FM TRENCH
CRUSHED ROCK PAD
C - CIVIL
V - VENDOR
FABR
P
P
C
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
C
P
P
E
P
P
C
P
E
P
P
P
C
P
P
P
P
PAGE 7
LABOR OTHER
P
P
P
P
C
P
P
P
P
P
P
P
S/C
P
P
V
V
P
P
P
P
P
P
P
P
P
P
P
C
UNDGR1.XLS

CHECK LIST
UTILITIES
SYSTEM
UTILITIES
MATERIALS
ITEM
PIPE
PIPE
FITTING
JOINT - PIPE
JOINT - FTTG
PIPE
PVC
FITTING
PUSH-ON JOINT JOINT - PIPE
JOINT - FTTG
PIPE
FITTING
DUCTILE IRON
JOINT - PIPE PO
INTERNALLY LINED JOINT - PIPE MJ
JOINT - FITTING
PIPE (OPTIONAL)
PVC
CHEMICAL
CEMENT JOINT
FITTING (OPTIONAL)
C900 PIPE
PIPE - PVC
FITTING - D.I.
JOINT - PIPE
JOINT - FTTG
PIPE
FITTING
JOINT - PLAIN
JOINT - PLAIN
JOINT - FLANGED
JOINT - FLGD MJ
PIPE
PIPE
FRP
FITTING
JOINT
JOINT
PIPE
POLYETHYLENE PIPE
OR
FITTING
POLYPROPYLENE JOINT
JOINT
CONCRETE
STEEL
CYLINDER
PIPE
P - PIPE
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
FIELD FABRICATION
LAY
HANDLE
SOLVENT CEMENT
SOLVENT CEMENT
LAY
HANDLE
-NONE-NONELAY
HANDLE
- NONE BOLT-UP MJ
BOLT-UP MJ
POLYETHYLENE
ENCASEMENT
POLYETHYLENE
ENCASEMENT
LAY
HANDLE
MATL
P
FABR
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
P
P
P
P
P
P
BOLT-UP MJ
LAY
HANDLE
SEAL WELD
DIAPER GROUT
BOLT-UP
BOLT-UP MJ
FIELD FABRICATION
LAY
HANDLE
SOCKETWELD - CHEM
BOLT-UP
FIELD FABRICATION
LAY
HANDLE
FUSION WELD
BOLT-UP
C - CIVIL
V - VENDOR
PAGE 8
LABOR OTHER
P
P
P
P
P
P
P
P
P
P
P
P & S/C EQUIP
P
UNDGR1.XLS

CHECK LIST
UTILITIES
SYSTEM
UTILITIES
(PRESSURE)
(PIPING)
MATERIALS
ITEM
ACTIVITY
MATL
FABR
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
D&W
FOR PIPE ONLY
V
D&W - REPAIR
FOR PIPE ONLY
P
CARBON STEEL PIPE
GEEP TESTING
WITH
FITTING
HANDLE
DOPE & WRAP
FITTING
DOPE & WRAP FTTGS
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
WELD
X-RAY
S/C
SPECIALTY HANDLE SAME AS A/G
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
PIPE & FITTING
POLYETHYLENE SLV
P
CARBON STEEL PIPE
GEEB TESTING
WITH
FITTING
HANDLE
EXTRUDED
FITTING
HEAT SHRINK SLEEVE
P
POLYETHYLENE JOINT
ERECTION BUTTWELD
ENCASEMENT
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
JOINT
HEAT SHRINK SLEEVE
P
WELD
X-RAY
S/C
INTERNAL LINER
PIPE & FITTINGS
V
CARBON STEEL FIELD WELD
INTERNALLY LINED
PIPE
PIPE
STAINLESS STEEL FITTING
JOINT
JOINT
WELD
SPECIALTY HANDLE
PIPE
PIPE
PVC
FITTING
JOINT
JOINT
SPECIALTY HANDLE
P - PIPE
M - MECHANICAL
S/C - SUBCONTRACT
FIELD FABRICATION
P
LAY
HANDLE
ERECTION BUTTWELD
BOLT-UP
X-RAY
S/C
SAME AS A/G
FIELD ASSEMBLY
P
LAY
HANDLE
CHEMICAL SOCKETWELD
BOLT-UP
SAME AS A/G
C - CIVIL
V - VENDOR
PAGE 9
LABOR OTHER
P
P
P
EQUIP
NONE
P
P
P
P
P - S/C
P
P
EQUIP
NONE
P
EQUIP
P
P
P
P
P & S/C
P - S/C
P
P
NONE
P
P
P - S/C
P
P
NONE
P
P
UNDGR1.XLS

DEMOLITION
1.0
GENERAL
=
Thoroughly read and understand scope of work and specifications as applies to
demolition - highlight pertinent items and any unusual requirements and pass these
items on to assigned project estimator.
2.0
QUANTITY TAKEOFF
=
Quantify piping for removal by a centerline to centerline takeoff, by type of material.
=
Indicate type of demolition (disposal, salvage, relocation, etc.)
=
Highlight all piping on all demolition drawings that indicate demolition.
Input or Import the data into CAPS.
=
1
1442-0010

UNDERGROUND PIPE
1.0
GENERAL
Thoroughly read and understand the scope of work and specifications as applies to
underground piping. Highlight pertinent items and any unusual requirements and
pass these items on to assigned project estimator.
2.0
MATERIAL AND LABOR TAKEOFF

Determine if, drawings or electronic data ( IPMS, Engineering Input Form, etc. ) will be
provided. If drawings are provided, check drawings against drawing transmittal.
Count all fittings and pipe appurtenances per checklist.
Quantify labor activities for each type of construction, i.e. push-on, weld, or
mechanical joints (see checklist).
Calculate excavation and backfill for each trench operation. Use common trench if
lines are routed adjacently.
Allow for hand excavation where machine use is inappropriate or dangerous.
Quantify shoring if required.
Quantify shore box use if application is appropriate.
=
=
=
=
=
=
=
=
=
=
=
=
DRAWING TAKEOFF
Quantify underground pipe by centerline takeoff by piping system and spec.
Count all fittings and pipe appurtenances per checklist.
Highlight all piping on all drawings that indicate underground pipe.
Quantify labor activities for each type of construction, i.e. push-on, weld, or
mechanical joints (see checklist).
Count manhole and catch basins by size and depth. Advise civil estimator of the
number of foundations for catch basins and manholes.
Calculate excavation and backfill for each trench operation. Use common trench if
lines are routed adjacently.
Allow for hand excavation where machine use is inappropriate or dangerous.
Quantify shoring if required.
Quantify shore box use if application is appropriate.
1
1442-0011
PIPING ESTIMATING CHECKLIST
UNDERGROUND PIPING
a. Drains, sewers (storm, sanitary, process)
b. Pressure drains
c. Fire systems
d. Type of pipe - C.S., Bondstrand, Concrete (RCP), Fiberglass, PVC
e. Excavation requirements, depths, slope, backfill, bedding, shoring, dewatering
f.
Take-off by system (firewater, drains, storm sewer, process, etc.)
g. Testing is normally 6% of pipe erection work hours
h. Bolts, nuts, gaskets, supports
i.
Dope and Wrap
1. U/G pipe should be taken off by systems (Sanitary sewer, Storm sewer, Firewater,
etc.) and put into the estimate this way with detail subtotal cards following each
system. Comment cards should be used to designate each system.
2. The material and installation cost for pipe, fittings, valves, precast manholes, precast
catch basins, thrust blocks, hydrostatic testing, excavation and backfill should be
included per system.
3. If manholes, catch basins and seal slabs are to be poured in place, the civil estimators
will be responsible for installation. Pipe estimators need to, check with the civil
estimators to, be sure they are taking care of these items.
4. An erection material line needs to be put in the U/G account. This covers the cost of
bolts, gaskets, dope and wrap material, rods, lead, etc. Quantities will be in lump sum
(LS) dollars. This card will be similar to the P68 account for aboveground pipe.
UNDERGROUND GRAVITY SYSTEMS
1. Line sizes
2. Sewer identification i.e., process, sanitary, and numerical identification (line number).
3. Material specifications
4. Manhole locations, and number.
5. Dimensional ponds, lagoons, setting basins, oxidation ponds, and other field
construction equipment.
6. Any tie-in points including existing line size and material of construction.
7. Finished grade elevation.
8. Curbed, diked, and paved areas.
9. Valves
10. Liquid seal, and vent requirements.
1
1442-0012
PIPING ESTIMATING CHECKLIST - Continued
11. Liquid conveying trenches and open ditches.

UNDERGROUND PRESSURE SYSTEMS
1. Line sizes.
2. Identification of flowing media (i.e., air, process, steam, etc.), and numerical
identification.
3. Material specifications.
4. Material specifications of above-grade piping connections.
5. Any existing tie-in points including line size, material of construction, and condition of
any tap required (wet or dry).
6. Cathodic protection requirements.
7. Hydrant, and monitor specifications and location.
8. Deluge house and hose house location.
9. Manual actuating fire protection system.
2
1442-0012

CHECK LIST
SEWERS & DRAINS
SYSTEM
MATERIALS
LEACH FIELD
(SANITARY SEWER)
VITRIFIED CLAY
MANHOLE
CATCH BASIN
PRE-CAST
RCP
MANHOLE
CATCH BASIN
CAST IN-PLACE
CONCRETE
CONCRETE
LIFT STATION
PRE-CAST
PIPING
PER JOB
REQUIREMENTS
CONCRETE
LIFT STATION
CAST IN-PLACE
PIPING
PER JOB
REQUIREMENTS
MISCELLANEOUS
CULVERTS
(STORM DRAINAGE)
P - PIPE
MATERIALS
ALL
ALL
ITEM
PIPE
PIPE
GRAVEL
DISTRIBUTION BOX
TOP W/ COVER
CONE
SHELL
CONCRETE BASE
INTERNAL GROUT
PIPE
TOP W/ COVER
CONE
SHELL
CONCRETE BASE
INTERNAL GROUT
PIPE
TOP W/ COVER
SHELL
CONCRETE BASE
PUMP
INSTRUMENTATION
PIPE FAB
PIPE ERECTION
FTTG HANDLE
JOINT
TOP W/ COVER
SHELL
CONCRETE BASE
PUMP
INSTRUMENTATION
PIPE FAB
PIPE ERECTION
FTTG HANDLE
JOINT
FLOOR DRAINS
JOINT
CLEAN-OUTS
JOINT
P-TRAP
JOINT
ALL
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
LAY
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
CUT HOLE & GROUT
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
INSTALL
INSTALL
INSTALL
INSTALL
INSTALL
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
HANDLE & SET
AS REQUIRED
HANDLE & SET
AS REQUIRED
HANDLE & SET
AS REQUIRED
ALL
C - CIVIL
V - VENDOR
MATL
FABR
PAGE 5
LABOR OTHER
P
P
P
C
P
P
P
C
C
P
C
C
C
C
C
C
P
P
C
M
I/E
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
C
C
C
M
I/E
SEE APPROPRIATE
MATERIALS AND
ACTIVITIES PER
PAGE 3
P
P
P
P
P
P
C
P
P
P
C
C
P
C
C
C
C
C
C
P
P
C
M
I/E
C
C
C
M
I/E
P
P
P
P
P
P
C
UNDGR1.XLS

CHECK LIST
FIRE PROTECTION
SYSTEM
MATERIALS
FIRE PROTECTION
C900 PIPE
ITEM
PIPE - PVC
FITTING - D.I.
JOINT - PIPE
JOINT -FTTG
PIPE (OPTIONAL)
FITTING (OPTIONAL)
THRUST BLOCK
MEGA-LUGS
(PIPE RESTRAINMENT)
PIPE
FITTING
JOINT - PIPE PO
DUCTILE IRON
JOINT - PIPE MJ
INTERNALLY LINED JOINT -FTTG
PIPE (OPTIONAL)
CARBON STEEL
WITH
DOPE & WRAP
CARBON STEEL
WITH
EXTRUDED
POLYETHYLENE
ENCASEMENT
CARBON STEEL
INTERNALLY LINED
ACTIVITY
LAY
HANDLE
BOLT-UP MJ
POLYETHYLENE
ENCASEMENT
POLYETHYLENE
ENCASEMENT
INSTALL
INSTALL
LAY
HANDLE
MATL
FABR
P
P
PAGE 6
LABOR OTHER
P
P
NONE
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
BOLT-UP MJ
BOLT-UP MJ
POLYETHYLENE
P
ENCASEMENT
FITTING (OPTIONAL)
POLYETHYLENE
P
ENCASEMENT
THRUST BLOCK
INSTALL
P
RODDING/CLAMPS
INSTALL
P
COATING (ROD/CLAMP)APPLY (OPTIONAL)
P
PIPE
FIELD FABRICATION
P
PIPE
LAY
D&W
FOR PIPE ONLY
V
D&W - REPAIR
FOR PIPE ONLY
P
PIPE
GEEB TESTING
FITTING
HANDLE
FITTING
DOPE & WRAP FTTGS
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
WELD
X-RAY
S/C
THRUST BLOCK
AS REQUIRED
P
PIPE
FIELD FABRICATION
P
PIPE
LAY
PIPE & FITTING
POLYETHYLENE SLV
P
PIPE
GEEB TESTING
FITTING
HANDLE
FITTING
HEAT SHRINK SLEEVE
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
JOINT
HEAT SHRINK SLEEVE
P
WELD
X-RAY
S/C
THRUST BLOCK
AS REQUIRED
P
INTERNAL LINER
PIPE & FITTINGS
V
FIELD WELD
P
P
P
P
P
P
P
P
EQUIP
NONE
P
P
P
P
P & S/C
P
P
P
P
EQUIP
NONE
P
EQUIP
P
P
P
P
P & S/C
P
P - S/C
P - PIPE
M - MECHANICAL
S/C - SUBCONTRACT
C - CIVIL
V - VENDOR
UNDGR1.XLS

CHECK LIST
FIRE PROTECTION
SYSTEM
FIRE PROTECTION
MATERIALS
MATERIALS
ALL
ITEM
FIRE HYDRANT
ACCESSORIES
CONCRETE BASE
GRAVEL
JOINT
JOINT
VLV INDICATOR POST
VALVE
VALVE JOINT
JOINT
VALVE BOX
VALVE
VALVE JOINT
VALVE JOINT
FIRE MONITOR
JOINT
JOINT
SPRAY/FOAM NOZZLE
JOINT
HOSE HOUSE
CONCRETE BASE
INSULATION FLG KIT
JOINT
CATHODIC PROTECT
VALVE
JOINT
JOINT
HOSE & REEL
GUARD POST (PIPE)
ROAD CROSSINGS
R/R CROSSINGS
(AREAS WHERE)
(EXCAVATION NOT)
(ALLOWED)
P - PIPE
O - OPTIONAL
CASING
CARBON STEEL
TESTING
TRENCH
TRENCH
TRENCH
TRENCH
TRENCH
TRENCH
JACK & BORE
PIPE CASING
JOINTS
EXTERNAL COATING
INTERNAL COATING
EXTERNAL COATING
INTERNAL COATING
END CLOSURES
IF REQUIRED
CASING VENT
IF REQUIRED
BORING MACHINE
BORING MACHINE
BORING MACHINE
BORING MACHINE
BORING MACHINE
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
MATL
INSTALL
INSTALL
INSTALL
PLACE
BOLT-UP
BOLT-UP MJ
INSTALL
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
BOLT-UP
BOLT-UP MJ
INSTALL
BOLT-UP
INSTALL
INSTALL
INSTALL
BOLT-UP
PROVIDE COUNT
OF JOINTS
HANDLE
BOLT-UP
BOLT-UP MJ
INSTALL
INSTALL
P
P
C
P
AS REQUIRED
EXCAVATION
BACKFILL - SOIL
BACKFILL - SAND
SPOILS
SHORING
DEWATERING
PIPE CASING
FABRICATION
BUTTWELD
PIPE
(IF REQUIRED)
JOINT
(IF REQUIRED)
INSTALL
FIELD FABRICATION
INSTALL
EXCAVATE TRENCH
BACKFILL TRENCH
INSTALL IN TRENCH
REMOVE FM TRENCH
CRUSHED ROCK PAD
C - CIVIL
V - VENDOR
FABR
P
P
C
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
C
P
P
E
P
P
C
P
E
P
P
P
C
P
P
P
P
PAGE 7
LABOR OTHER
P
P
P
P
C
P
P
P
P
P
P
P
S/C
P
P
V
V
P
P
P
P
P
P
P
P
P
P
P
C
UNDGR1.XLS

CHECK LIST
UTILITIES
SYSTEM
UTILITIES
MATERIALS
ITEM
PIPE
PIPE
FITTING
JOINT - PIPE
JOINT - FTTG
PIPE
PVC
FITTING
PUSH-ON JOINT JOINT - PIPE
JOINT - FTTG
PIPE
FITTING
DUCTILE IRON
JOINT - PIPE PO
INTERNALLY LINED JOINT - PIPE MJ
JOINT - FITTING
PIPE (OPTIONAL)
PVC
CHEMICAL
CEMENT JOINT
FITTING (OPTIONAL)
C900 PIPE
PIPE - PVC
FITTING - D.I.
JOINT - PIPE
JOINT - FTTG
PIPE
FITTING
JOINT - PLAIN
JOINT - PLAIN
JOINT - FLANGED
JOINT - FLGD MJ
PIPE
PIPE
FRP
FITTING
JOINT
JOINT
PIPE
POLYETHYLENE PIPE
OR
FITTING
POLYPROPYLENE JOINT
JOINT
CONCRETE
STEEL
CYLINDER
PIPE
P - PIPE
M - MECHANICAL
S/C - SUBCONTRACT
ACTIVITY
FIELD FABRICATION
LAY
HANDLE
SOLVENT CEMENT
SOLVENT CEMENT
LAY
HANDLE
-NONE-NONELAY
HANDLE
- NONE BOLT-UP MJ
BOLT-UP MJ
POLYETHYLENE
ENCASEMENT
POLYETHYLENE
ENCASEMENT
LAY
HANDLE
MATL
P
FABR
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
NONE
P
P
P
P
P
P
P
P
P
BOLT-UP MJ
LAY
HANDLE
SEAL WELD
DIAPER GROUT
BOLT-UP
BOLT-UP MJ
FIELD FABRICATION
LAY
HANDLE
SOCKETWELD - CHEM
BOLT-UP
FIELD FABRICATION
LAY
HANDLE
FUSION WELD
BOLT-UP
C - CIVIL
V - VENDOR
PAGE 8
LABOR OTHER
P
P
P
P
P
P
P
P
P
P
P
P & S/C EQUIP
P
UNDGR1.XLS

CHECK LIST
UTILITIES
SYSTEM
UTILITIES
(PRESSURE)
(PIPING)
MATERIALS
ITEM
ACTIVITY
MATL
FABR
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
D&W
FOR PIPE ONLY
V
D&W - REPAIR
FOR PIPE ONLY
P
CARBON STEEL PIPE
GEEP TESTING
WITH
FITTING
HANDLE
DOPE & WRAP
FITTING
DOPE & WRAP FTTGS
P
JOINT
ERECTION BUTTWELD
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
WELD
X-RAY
S/C
SPECIALTY HANDLE SAME AS A/G
PIPE
FIELD FABRICATION
P
P
PIPE
LAY
PIPE & FITTING
POLYETHYLENE SLV
P
CARBON STEEL PIPE
GEEB TESTING
WITH
FITTING
HANDLE
EXTRUDED
FITTING
HEAT SHRINK SLEEVE
P
POLYETHYLENE JOINT
ERECTION BUTTWELD
ENCASEMENT
JOINT
BOLT-UP
JOINT
DOPE & WRAP JOINTS
P
JOINT
HEAT SHRINK SLEEVE
P
WELD
X-RAY
S/C
INTERNAL LINER
PIPE & FITTINGS
V
CARBON STEEL FIELD WELD
INTERNALLY LINED
PIPE
PIPE
STAINLESS STEEL FITTING
JOINT
JOINT
WELD
SPECIALTY HANDLE
PIPE
PIPE
PVC
FITTING
JOINT
JOINT
SPECIALTY HANDLE
P - PIPE
M - MECHANICAL
S/C - SUBCONTRACT
FIELD FABRICATION
P
LAY
HANDLE
ERECTION BUTTWELD
BOLT-UP
X-RAY
S/C
SAME AS A/G
FIELD ASSEMBLY
P
LAY
HANDLE
CHEMICAL SOCKETWELD
BOLT-UP
SAME AS A/G
C - CIVIL
V - VENDOR
PAGE 9
LABOR OTHER
P
P
P
EQUIP
NONE
P
P
P
P
P - S/C
P
P
EQUIP
NONE
P
EQUIP
P
P
P
P
P & S/C
P - S/C
P
P
NONE
P
P
P - S/C
P
P
NONE
P
P
UNDGR1.XLS

ABOVEGROUND PIPE
1.0
GENERAL
=
aboveground piping - highlight pertinent items and any unusual requirements and
pass these items on to assigned project estimator.
2.0
MATERIAL TAKEOFF
=
When valves are a responsibility of the contractor, the valve takeoff must come from
P&ID's. Highlight each valve on P&ID. If valves are furnished by others, the takeoff
from ortho's or isometrics is sufficient. Attention must always be given to vent and
drain valves. When the valve count has been completed, it should be forwarded to
purchasing for inquiry.
=
When making material takeoff, highlight everything--plans, elevations, etc. --whether
it be on isometrics or orthographics. Outside shop fabrication - if critical services exist,
(i.e., chrome, heavy wall, C.S., or exotic materials), these lines should be considered a
priority item. If schedule or estimate time frame is a concern, takeoff of critical lines
should be forwarded as soon as possible to fabrication specialist, or procurement for
outside pricing.
=
The P&ID should be marked up as the line by line takeoff occurs. This may flag an
early problem. If working from ISO's, an early decision will be made as to the
verification required back to the ortho's.
=
When P&IDs, orthos, or isos are not available back check line list for scope
completeness.
==
3.0
MATERIAL PRICING
=
When time permits, all pricing for alloy materials should be solicited by outside
suppliers.
=
In-house pricing, with appropriate discounts, is available for all field run carbon steel
materials.
=
All shop fabrication information should be supplied to the fabrication specialist for
outside pricing.
=
Apply normal percentages for erection materials, specialties, and hanger materials
when detail information is not available.
4.0
MISCELLANEOUS
=
Refer to checklists for additional items to consider.
1
1442-0015
CHECKLIST
The following is a list of items to be followed when an estimator is assigned to a project
estimate.
1. Obtain and read scope of work and understand the responsibility matrix. It is
important that all task force members understand the scope and responsibility for the
project.
2. Determine if, drawings or electronic data ( IPMS, Engineering Input Form, etc. ) will
be provided. If drawings are provided, check drawings against drawing transmittal.
3. Identify material specifications pertinent to underground piping, aboveground piping,
insulation and paint. If these are not available, immediately notify the project
estimator and determine if they will be available.
4. Determine what the estimate milestone dates are (i.e., review dates, date that detail
information is due to the project estimator, subcontractor bid due dates, etc.)
5. Review piping estimate manpower needs with the Chief Estimator based on these
considerations:
A. OUTSIDE SHOP FABRICATION
B. PRICING REQUIREMENTS
C. ESTIMATE SCHEDULE
6. Identify outside shop fabrication requirements.
7. Determine how many cost/schedule areas the estimate is to be divided into. Also,
identify what the parameters for the cost/schedule areas are. The project estimator
will provide this information.
8. Determine if any additional engineering is required before the estimate can be
completed (i.e., are utility systems engineered?).
9. Determine cleaning, pickling, stress relieving, and radiographic inspection
requirements.
10. Determine fabrication requirements (i.e., field shop, outside shop).
11. Determine paint labor (i.e., subcontract or direct, are spools blasted & primed).
12. Determine whether insulation is subcontract or direct.
13. It is important that the piping estimator review drawings of other disciplines to assure
complete coverage of project scope.
14. Establish a tentative appointment to review estimate with Chief Estimator to allow
adequate time to make changes prior to turnover of estimate disk to Project Estimator.
1
1442-0006
PIPING ESTIMATING GUIDELINES - Continued
The following piping related items are significant enough to be addressed to assure
consistency in our work. Make a habit of checking specifications and/or construction needs
for any requirements of these items.
COTTON BALL PIPE CLEANING
1.
Mechanical polishing of internal surfaces of piping is always required on the approach

piping of paper machines. This is usually large diameter stainless that is acid washed
by the fabricator after fabrication. The shop cost is to be included in the fabrication
account; however, some field cleaning is always needed no matter how good a job the
fabricator does. The smoothness of the pipe is checked in the field by rubbing the
interior surface with cotton balls. Any cotton snagged on the metal indicates an area
requiring more cleaning. All scratches left by the workers has to be polished out.
To accomplish this, the pipe is lifted and trial fit in place. Since access to the welds is
normally not permitted through the headbox, the entire section is laid on the operating
floor for welding and cleaning. Input of triple the work hour rates for handling of
spools in this system will generate adequate hours for the field to complete this work.
STEAM BLOW
2.
Whenever a major steam system is in the estimate scope, work hours and materials for
steam blow are required and should be input into the other services account, 1773. For
every high pressure main steam header, include materials and labor for 200 feet of
pipe, the same size as the header, one valve, and target plate materials.
Also, include work hours for four men for four blows for 24 hours each to monitor the
blow out process.
For low and intermediate pressure headers include enough pipe material and labor to
route the blow out line twenty feet above the highest rack level. Add 100 work hours
for assistance.
3.
On paper machines, add fifty feet of pipe on each dryer section and thirty work hours
for assistance.
4.
Workhours for pipe fitter assistance on pump alignments should be included in the
spool erection account. The pump alignment count need only be by size for rotating
and reciprocating pumps, compressors, and turbines. Small, metering type pumps do
not require alignment.
5.
Turn around time for valve inquiries: Suppliers are quoting as a courtesy and often
have difficulty with the information that is forwarded to them from the RFQ package.
The estimator may need to do some extra PC work to make a better package for them
2
1442-0006
to respond to. If it takes a day or two to edit some valve data to our current report,
then that may pay off in a faster response. This may also be beneficial by serving as a
double check on coding work.
FIREWATCH
6.
There seems to be several methods to calculate firewatch on estimates. Again, in order

to maintain consistency; start with the following basis for areas requiring firewatch
hours.
a. Use one weld every fifteen feet times 30% of the weld rate for the average size
pipe in each account. This is low for small sizes but will average out based on the
percentage of welding being higher for small pipe.
ESTIMATE FILING
After an estimate is completed, follow the KB&R Estimating file protocol to save electronic
files generated during the estimate.
ESTIMATE TO P.E.
On all Estimates involving the same company, it is important to insure that the estimator
use any labor rates and pricing from previous estimates, particularly if the current estimate
is an update of a previous effort. This may cause some extra work, but many times the
estimate is scrutinized for inconsistencies. The ESP template provided by the Project
Estimator (P.E.), should contain any final factors used at the time the previous estimate was
completed.
When the ESP template is turned over to the P.E., give him a copy of your nd a copy of the
piping system summaries. Remember that the estimator should look over the P.E.'s
combined estimate for correct totals and units. If this is not practical, the copies will be a
welcome reassurance to the P.E. in that eleventh hour crunch. Also, it is nice to have a pipe
only" Estimate for review time.
To assure all the information in the understood and included by the project estimator, the
piping estimator is to provide the following to the P.E. at the time the file is turned over:
1. A copy of `CODES.DIR' file (highlight any changes you have made).
2. A copy of the PERCENTAGE, ALLOWANCES, AND FACTORS from your template
(again, highlight all changes).
3. A copy of the OVERALL SUMMARIES report.
3
1442-0006
Make sure that this printed information is the latest and matches that on the ESP piping
template. At this point, the P.E. can get the templates combined and give a printout back to
the estimator to confirm completeness of the Estimate.
Certain statistics should be prepared for department reviews.
The following list should be ready for discussion at reviews:
1. Average pipe size - aboveground and underground
2. Percentage of C.S. pipe to total pipe (w/o D.A.).
3. Percentage of alloy pipe to total pipe (w/o D.A.).
4. Percentage of fabricated pipe to total pipe (w/o D.A.).
5. Percentage of field run pipe to total pipe (w/o D.A.).
6. Percentage of insulated pipe to total pipe (w/o D.A.).
7. Percentage of small bore pipe to total pipe (w/o D.A.).
8. Percentage of P67, P68, P71, P81 and P82 accounts.
9. Percentage on P98 and P97 accounts.
10. If time permits, a written comparison of current job to past similar projects.
Prepare qualifications on a daily basis. See Qualifications & Backup" in this manual.
4
1442-0006
REVIEW HINTS
The following is a list of items that are frequently brought up during the review cycle of the
estimate:
1. Type of drawings used to determine quantities;
2. Basis of pricing;
3. Average pipe size;
4. Purchasing responsibility;
5. Labor responsibility;
6. Missing information;
7. Events that cloud the accuracy of the estimate;
8. Assumptions and reasons why assumptions were made;
9. Sources of vendor quotes;
10. Reasons for unit work hour deviations from the norm;
11. Percentages used in respective accounts;
12. Outside shop fabrication or field shop fabrication or field run pipe;
13. Basis of piping take-off (line by line, quantities provided, etc.);
14. Basis of paint and insulation take-off;
15. Unique site conditions or plant requirements;
16. Line list;
17. Small bore piping quantity/large bore piping quantity ratio;
18. Inter-discipline checks;
19. Predominant pipe metallurgy;
20. Insulation requirements (hot/cold, single/double layer, material type, jacketing).
21. Special conditions that, cause a deviation from normal procedures.
5
1442-0006
TO:
PROJECT MANAGER or
PROJECT CONTROL MANAGER
DATE: DDMMMYY
FROM:
PIPING DESIGN WORK GROUP LEADER
PAGE: 1 of ??
SUBJECT:
PROJECT XXXX - PROJECT NAME

ESTIMATE RISK ASSESSMENT MEMORANDUM
This memorandum constitutes an assessment of the risks associated with the Class M" MTO estimate for the subject
project. Information contained herein was developed with input from the following groups:
Piping Design
Systems Engineering
Piping Specifications
A.
MTO BASIS
1.
P&ID's Issue "R" and Issue "1" received from Systems Engineering, as identified on the attached "Definitive
Estimate P&ID Basis, dated DDMMMYY.
2.
Conceptual MTO of all aboveground (A/G) lines identified on the P&ID's utilizing the current Plot Plan and
preliminary planning studies, where available.
3.
MTO from preliminary underground (U/G) planning drawings.
4.
Piping Specifications as of DDMMMYY.
5.
Class M Piping MTO plan for the Definitive estimate, from (Name of Work Group Leader), dated DDMMMYY.
B.TAKEOFF METHODOLOGY
1.
The shop/field fabrication philosophy used for the MTO consisted of the following:
a.
Shop Fabrication
(1) All A/G material types 2" and larger (except PVC, threaded piping, and cement lined firewater piping).
(2) All configured U/G cooling water piping and cooling water piping over 24".
b.
Field Fabrication
(1) All U/G material (except cooling water piping mentioned above).
(2) All material types 1-1/2" and smaller.
(3) All yard rack pipe.
(4) All PVC and threaded pipe.
(5) All A/G cement lined firewater piping.
2.
Takeoff was performed for the pipe, flanges, and fittings in accordance with the Estimate MTO Plan. The
MTO's were performed using KELWAY "EE" input forms. The data was entered into the material control
system.
3.
The U/G MTO was extracted from the current PDS model (unchecked state as of DDMMMYY) and entered
directly into the material control system.
4.
All MTO data was segregated within the material control system on a unit level, design area, service, line
number, and sheet basis.
5.
This data is further identified by material type, point of fabrication, A/G and U/G, coating and insulation
systems.
6.
Process steam trap quantities are provided as part of Systems Engineering SP listing. These trap quantities
are in addition to the traps defined by Piping Design as part of the steam trace takeoff effort.
7.
Manholes and catch basins are quantified and typically priced as "precast" items using local vendor quotes
per Company standards.

C.MTO RISK CONSIDERATIONS
(Following are examples of typical risk considerations that have been noted in actual risk memos. Risk
considerations are project specific. The intent of these examples is to serve as a "prompt" for items which may
be relevant to the current estimate.)
1.
No sleeving or encasement of U/G lines for any reason is included in the estimate.
2.
Tie-ins are not fully defined and routing is estimated based on "best guess" location information.
3.
A complete set of nomenclature was not available for parity review of design takeoff data. The lack of
complete and accurate nomenclature is also a hindrance in the area of paint and insulation code input and
verification.
4.
The piping takeoff is based on less than 100% of planning drawings and P&ID's are a mixture of revisions.
The standard basis of a FCE is availability of all planning drawings and Issue 2 P&IDs.
5.
The group (contract personnel) performing the takeoff was not familiar with the corresponding takeoff
forms/procedures. This situation creates a continuous learning curve which ultimately affects the degree of
takeoff accuracy, continuity and amount of rework to successfully process the data.
6.
Utility piping such as emergency eyewash stations, utility stations, subheader lines for utility distribution were
not individually taken-off.
7.
No allowances are provided or material identified for temporary facilities or construction services.
8.
Shop/field split is based on 2" and larger welded material (both A/G and U/G) being shop fabricated.
9.
Interconnecting piping for vendor skids is not defined, and subject vendors have not provided requested
material lists to support a computation of basic construction workhours.
10.
Offsites U/G drainage/treatment requirements are not clearly defined and the minimal assumptions made to
determine requirements are subject to change/growth.
11.
The terminal points of the package units are estimated by the envelope size of the unit, and the actual details
of required hook-ups are not available (i.e., API Plan Pumps).
12.
No allowances are made for the risks associated with an early buy function. All blanket orders should be
established with liberal and lengthy return agreements to support normal developmental changes being made
at minimal or no cost.
13.
The Piping specifications were in a constant state of change during the estimate takeoff, i.e., items not in
specification. Additional checking and reviews were required.
14.
The PIMATO/VAMATO MTO is based on approximately 60% Issue R and 40% Issue 1 P&ID's. The quantities
generated by PIMATO for large O.D. lines (over 12") and long runs of pipe (over 100 feet) were reviewed for
accuracy and adjusted if necessary. An estimated 15% of all lines have been checked.
15.
Fittings were taken-off directly from the P&ID's. After comparisons of the ratios of fittings per 100 feet were
made with historical data, additional elbows and fittings were added to the estimate to better reflect historical
ratio's.
16.
Steam tracing has been included in this estimate.
17.
Approximately 2700 3/4" block valves were added to the estimate to account for low-point drains that are not
shown on the P&ID'S. This amount is approximately one low point drain for every 1 line taken-off (based on
historical data). Although the material cost of these valves may be minimal, the impact on Construction
workhours has been found to be significant.
18.
A special effort has been made to accurately identify the Expanded Nomenclature" piping and valves that
does not typically show up on the P&ID's. A detailed MTO of utility stations, sample coolers, pump drains and
cooling water pipe for pump casings, steam trap and steam tracing manifold piping, lube and seal oil piping,
and eye wash and safety shower piping was included in this estimate. Housekeeping drains will not be
required for this project.
19.
Piping associated with the site prep subcontract package has been included in the estimate. Quantities of
related piping has been given to Construction to back-out labor for these materials.
20.
Piping associated with the ISBL ARU unit has been included based on preliminary P&ID's provided by the
vendor.
21.
Manholes and catch basins have been included as a separate line item in the estimate based on quoted prices
for this project. Quantities have been given to Construction to calculate workhours.
22.
The proposed change to sewer pipe from ditches in the OSBL is not included in the estimate.
23.
Piping quantities have been included (for computation of basic construction workhours) for vendor furnished
materials to be installed by the Company in the OSBL unit for the Ethylene and Propylene product lines, and
vendor supplied items 7802U, 8701L, 8703L, 8704L, 8705L, and 8706L.
24.
A definitive estimate (quantitative) review was conducted on DDMMMYY, and included an extensive review
of all items pertaining to the Class M estimate.
25.
All MTO quantities are neat with no contingencies or construction spares applied (other than identified in this
document).
D.AUDIT/CHECK PROCEDURES
1.
All input sheets were reviewed for completeness and compliance with specifications before entry to the
Company material control system.
2.
All output documents were reviewed for completeness and to ensure that every input document created a
corresponding output document.
3.
Data should be compared with other similar in-house projects so that differences can be
investigated/validated.
4.
Nomenclatures, where available, and PDS line number extract reports were reviewed to ensure all lines have
corresponding takeoffs.
5.
Random checks of base document planning drawings and P&ID's were performed to ensure inclusion of all
lines. Random checks of large bore lines with large quantities are reviewed to verify takeoff accuracy.
6.
Statistical reports are reviewed to validate the relationships of piping component quantities (i.e., fittings per
hundred lineal feet).
7.
A review of small bore versus large bore quantities was conducted to ensure completeness of takeoff (as a
ratio).
8.
Orifice flange quantities were checked versus P&ID quantities to ensure takeoff totals represents sets (pairs).
9.
Nomenclature information, where available, was used to check insulation/paint codes assigned to takeoff.
10.
The relationship of projected isometrics versus identified tonnage is investigated and exceptions stated.
11.
Project and department estimate procedure check lists were completed to ensure all basic areas of the
estimate are addressed.
E.TAKEOFF ALLOWANCES
The following factors should be applied to the FCE takeoff quantities to account for takeoff and summarization
accuracy. These factors reflect how accurately the materials were defined based on the quality of the source
documents, equipment data available, and certainty of routing.
These factors provide an assessment of how accurately materials were estimated (measured) based on the quality
of the documents used and amount of checking.
(PROJECT SPECIFIC)
CATEGORY
A/G PIPING
UNIT 01
<1-1/2"
14%
2" - 24"
UNIT 02
UNIT 50
17%
20%
10
15
>26"
U/G PIPING
<1-1/2"
15
18
20
2" - 24"
10
13
15
10
10
10
>26"
PIPING VALVES
F.
GROWTH ALLOWANCES
The following factors should be applied to the FCE quantities to allow for a Systems Engineering assessment of
the potential for change and/or growth within the P&ID's, specifications, and nomenclature information per Systems
Engineering Risk Memo.
CATEGORY
UNIT 01
UNIT 02
UNIT 50
ABOVEGROUND AND UNDERGROUND:

PIPING
<1-1/2"
10%
10%
2" - 24"
10
>26"
PIPING VALVES
G.
SUMMARY - MTO COST RISK

1.
H.
20%
The following items either have not been specifically addressed in the defined MTO or were not included in
the definitive scope of work with an allowance:
a.
Tie-ins are routed to a battery limit only and are not finalized regarding the tie-in sequence and third party
responsibilities.
b.
Utility stations and subheaders are "factorized", but not separately taken-off.
c.
Vendor-provided skids with interconnecting piping are routed to the unit envelope, but actual hookups
are not defined.
d.
API pump/compressor piping plans are not developed completely.
e.
Some percentage of planning release drawings are available at the time of the estimate.
f.
Significant additions (eighteen lines, 6" and larger) were made to P&ID's as late changes, and some lines
are not identified (except in the sense of overall tonnage), although being part of the FCE (eleven lines,
4" and larger).
HI/LO RISK ANALYSIS
ITEM
TAKE-OFF
ALLOW
GROWTH
ALLOW
HIGH/LOW %
U/G PIPING-ALL
A/G PIPING
SHOP FAB
CS >2"
ALLOY >2"
FIELD FAB:
CS <1-1/2"
CS >2"
ALLOY <1-1/2"
ALLOY >2"
PVC/CU
/
/
/
/
/
I.
CTE RECOMMENDATION
Based on a review of the methods used to prepare the Class M cost estimate and the corresponding risk items,
Piping Design makes recommendations against further contingencies to be applied to the estimate. The Work
Group Leader and the CTE sign the written recommendations and attach the Completed Checklist.
WORK GROUP LEADER
CTE

INSULATION
1.0
GENERAL
=
insulation. Highlight pertinent items and any unusual requirements and pass these
items on to assigned project estimator.
=
The insulation specifications must be very carefully read. Often, the insulation is more
expensive than the piping. Omissions are costly; therefore, make all possible double
checks against line list and/or P&ID's.
=
Determine before pipe takeoff is started whether or not valves, flanges, and fittings
receive removable, replaceable covers.
2.0
=
MATERIAL TAKEOFF
A.
B.
C.
D.
LFI-linear feet of pipe to be insulated center line to centerline ( By type and

thickness).
EA-all fittings, flanges, and valves to be covered (see attachment).
Account V99-construction allowance. Recommend a 3% allowance to cover
breakage and damaged material.
Account V98-design allowance should reflect the same percentage as the pipe P98
account.
=
3.0
MATERIAL PRICING
=
When insulation specifications are initially examined, the insulation-pricing technician
should be notified as to the general requirements of the specification. Any special
material requirements may require outside sources.
=
.
Steam Trace
Hot Oil Trace
Glycol Trace
Electric Trace
May require heat transfer cement and channel (see job specification). Insulation OD
must accommodate tracer sizes and number of each.
1
1442-0020

PAINT
GENERAL
=
painting. Highlight pertinent items and any unusual requirements and pass these
items on to assigned project estimator. Check line list to verify all pipe painting.
=
1
1442-0022
METALLIC SURFACE PREPARATION STANDARDS
Solvent Cleaning
SSPC-SP 1
Procedure for removal of detrimental foreign matter such as oil, grease, soil, drawing and
cutting compounds, and other surface contaminants from steel surfaces by the use of
solvents, emulsions, cleaning compounds, steam cleaning, or similar materials and
methods which involve a solvent or cleaning action.
Hand Tool Cleaning
SSPC-SP 2
Procedure for removal of loose mill scale, loose rust, and loose paint by hand brushing,
hand sanding, hand scraping, hand chipping, or other hand impact tools, or by a
combination of the above methods.
Power Tool Cleaning
SSPC-SP 3
Procedure for removal of loose mill scale, loose rust, and loose paint with power wire
brushes, power impact tools, power grinders, power sanders, or by a combination of the
above methods. It is not intended that all mill scale, rust, and paint be removed by this
process; however, loose mill scale, loose rust, loose paint and other detrimental foreign
matter will be removed
White Metal Blast Cleaning
SSPC-SP 5, NACE No. 1
Procedure for removal of all mill scale, rust, rust scale, paint, or foreign matter by the use of
abrasives propelled through nozzles or by centrifugal wheel. Defined as a surface with a
gray-white, uniform metallic color, slightly roughened to form a suitable anchor pattern for
coatings. The surface, when viewed with magnification, shall be free of all oil, grease, dirt,
visible mill scale, rust, corrosion products, oxides, paint, or any other foreign matter. The
color of the clean surface may be affected by the particular abrasive medium used.
1
1442-0036
METALLIC SURFACE PREPARATION STANDARDS - Continued
Near-White Blast Cleaning

Procedure for removal of mill scale, rust, rust scale, paint, or foreign matter by the use of
abrasives propelled through nozzles or by centrifugal wheels All oil, grease, dirt, mill scale,
rust, corrosion products, oxides, paint or other foreign matter shall be completely removed
from the surface except for very light shadows, very slight streaks, or slight discolorations
caused by rust stain, mill scale oxides, or slight, tight residues of paint or coating that may
remain. At least 95 percent of each square inch of surface area shall be free of all visible
residues, and the remainder shall be limited to the light discoloration mentioned above.
Commercial Blast Cleaning
Procedure for removal of mill scale, rust, rust scale, paint, or foreign matter by the use of
abrasives propelled through nozzles or by centrifugal wheels. All oil, grease, dirt, rust
scale, and foreign matter shall be completely removed from the surface according to SSPCSP 1. All rust, mill scale, and old paint shall be completely removed except for slight
shadows, streaks, or discolorations caused by rust stain, mill scale oxides or slight, tight
residues of paint or coating that may remain; if the surface is pitted, slight residues of rust
or paint may be found in the bottom of pits; at least two-thirds of each square inch of
surface areas shall be free of all visible residues and the remainder shall be limited to the
light discoloration, slight staining or tight residues mentioned above.
Brush-Off Blast Cleaning
Procedure for removal of loose mill scale, loose rust and loose paint by the impact of
abrasives propelled through nozzles or by centrifugal wheels. All oil, grease, dirt, rust
scale, loose mill scale, loose rust and loose paint or coatings shall be removed completely,
but tight mill scale and tightly-adhered rust, paint, and coatings are permitted to remain
provided that all mill scale and rust have been exposed to the abrasive blast pattern
sufficiently to expose numerous flecks of the underlying metal fairly uniformly distributed
over the entire surface.
2
1442-0036
COATING CALCULATIONS
Percent Solids (By Volume)
Volume
Total Volume
Solids
Dry Film Thickness (D.F.T.)

Solids
Wet Film Thickness X % Volume

(W.F.T.)
Wet Film Thickness
D.F.T.
% Volume Solids
Spread Rate
Theoretical Coverage
Effects of Thinning:
Volume Solids
New
Cost/Mil Sq. Ft
1604
W.F.T
Sq.
Ft.
% Volume Solids X 1604 Sq. Ft.
Total
Solids
New Total Volume

=
Cost/Gal.
Coverage
Example:
What is the cost/mil sq. ft. of a coating having 45% volume solids and a cost of $17.50 per gallon?
(Volume Solids) 45% X 1604
721.80 (Coverage)
(Cost/Gal) 17.50
(Coverage) 721.80
2.42
cents
(Cost/Mil
sq.
Ft.)
1
1442-0023

PIPELINE
PIPELINE ESTIMATING
IS PERFORMED BY
KELLOGG BROWN & ROOT TECHNICAL
SERVICES
PIPELINE ENGINEERING GROUP
1
1442-0024

QUALIFICATIONS & BACKUP
STANDARD BACK-UP ORGANIZATION

Please organize back-up books in the following order with tabs for each section.
GENERAL INFORMATION
=
Project Assignment Worksheet
=
Scope of Work
=
Specifications (if any, when applicable)
1) Pipe Specs (include CAPS printout)
2) Paint Specs
3) Insulation Specs
=
Core Documents: Equipment List, One-Lines, Line List, All electronic files, etc.
=
General Communications and/or Memos
=
Material Pricing
1) Print Out of CAPS Material Reports
=
Qualifications and General Notes
SPECIFIC INFORMATION (provide these sections for each area of the estimate).
=
Engineering Furnished Information
=
1) Print Out of CAPS Data
2) Print Out of Error Check Output
GENERAL
=
Any unique aspect of your Estimate should be documented on a daily basis.
=
Input qualifications into computer format. Be mindful of spelling and grammar, as a
poorly written qualification is confusing to others and can be easily misinterpreted.
=
Qualifications should address items included as well as excluded from estimate.
=
References to specifications should be by page number, and paragraph.
=
References to drawings should be by drawing and revision numbers.
=
Qualifications should be noted informally on a daily basis, and refined for computer
input prior to the review phase of the estimate.
BASIS OF TAKEOFF
=
State information sources for quantities, orthographic drawings, isometric drawings,
conceptual routings, supplied quantities, etc.
=
List any assumptions and/or exceptions to specifications or drawings by number
and/or paragraphs.
1
1442-0025

QUALIFICATIONS & BACKUP - Continued
=
=
=
List any deviations from specifications by specification number and paragraph.

List any omissions from scope of work and state logic behind this decision.
The following should be included for control estimates:
1. Workhour rates include unloading and storing of materials, handling of piping to
erection point, pipe erection, complete weldout, mechanical connection, and
installation of inline devices, craft support for reporting quantities of daily
production.
2. Testing workhours include such efforts as flushing, filling, and hydrotesting.
3. Test package preparation and system turn over up to, but excluding,
precommissioning.
4. Hanger and support workhours include unload and storing materials, fabrication
and assembly erections of miscellaneous type supports, base ell supports and
hangers.
5. Fabrication of pipe shoes is not included.
6. Tie-in workhours include location of tie-in, marking and tagging, cutting or
unbolting, and the tie-in labor for rewelding or rebolting to existing piping.
7. Other services workhours are for direct labor assistance for support sub-contract
work, such as x-ray, hot tapping, and/or steam blow.
LABOR
=
State adjustments/inclusions to labor such as: firewatch, safety considerations, etc.
=
Do not reflect productivity adjustments unless advised by chief estimator.
MATERIALS
=
State pricing philosophies such as quotations received, in house pricing, domestic or
foreign sourcing, freight, etc.
INSULATION
The following qualification should be included in each estimate:
=
This estimate is based on new construction environment and does not include
inefficiencies for maintenance and turnaround type work, hot work, shift work, or
overtime.
=
Furnishing and applying framework, angles, rings, pins, clips, nuts, blocks, saddles,
etc., for insulation and support of insulation has not been included in this estimate.
=
This estimate is based on the assumption that we will be permitted to insulate
completely all equipment flanges, manways, piping, fittings, flanges and valves,
2
1442-0025

=
=
instruments, etc., (requiring insulation) connecting or adjacent to insulated equipment

while scaffolding is in place and needed for equipment insulation.
This estimate is based upon all piping being tested and released for insulation. Piping
and equipment insulation has been based on remaining at ambient temperature and in
a non-operative condition while insulation is being applied.
All materials are within accordance with the governing specification___ __________.
Materials used as a basis for this estimate are:
and
.
Warehousing of insulation materials are not covered by these direct work hour rates.
On-site fabrication of commercially available fittings is not included in the work hour
rates.
QA/QC
=
Workhours for pipe inspection is excluded from our estimates. This is normally a
construction staff position and these hours are normally allowed in indirect costs.
QUALIFICATIONS FROM A TYPICAL ESTIMATE
Having made a careful review of the bid documents and after visiting the site of the work,
Kellogg Brown & Root submits this proposal based upon the following clarifications and
qualifications:
=
We have made no provisions or allowances in our price for the removal, repair, or
relocation of any underground obstruction not clearly shown on the drawings.
=
All owner-furnished equipment and materials are to be supplied to us at such times
and in such a manor as to assure continuity of work for our labor forces.
=
All existing installations (i.e.) are to be in proper location and elevation and in
accordance with the referenced data provided for this bid, thereby eliminating any
requirements for subsequent modifications repairs, relocation, or any rework of any
kind.
=
We will utilize excavated materials for backfill purposes, and we have included no
purchased or imported backfill materials in our price.
=
We will dispose of all excess excavated and waste materials within the plant limits.
=
We have made no provisions or allowances in our price for any unexpected work
stoppages due to the owner's ongoing operations and/or request.
=
Our price is based on radiographic inspection of piping welds per specifications
and/or ANSI 31.1, 31.3, and 31.8 code requirements.
3
1442-0025

=
=
=
==
=
=
=
=
=
=
=
All existing lines that are to be tied into are to be purged free of product and made safe
by owner prior to our craftsmen beginning the tie in work.
Owner is to provide adequate power for our 8 bank welding machines within 100 feet
of the working area.
We base our price upon being awarded all phases of this project.
We have made no provision for allowances in our price for any piping work not
explicitly shown on the bid drawings.
Our work forces are to be allowed adequate access to the work areas. We have made
no provisions or allowances in our price for any unreasonable interferences that may
occur from other contractors working at this jobsite.
We have made no provisions or allowance in our price to provide spark-proof boxes
for welding. Should you elect to require spark-proof boxes, we will provide nonpressured boxes for $600.00 each or pressurized boxes for $750.00 each.
We base our price upon all excavated materials as being free of contaminants and/or
hazardous waste.
We have made no provision for allowances in our price for unreasonable delays in
obtaining permits (hot work and vessel entry), waiting for fire watch or waiting for
owner's representatives.
We have made no provisions or allowances in our price for asbestos abatement.
All owner furnished piping materials are to be supplied fully fabricated and piecemarked for erection with no repairs, rework, modifications or alterations being
required.
Our price is based upon utilizing local water sources for hydrotest water. Costs are
excluded for treatment of such water.
Our price is based on disposal of such water in existing drainage systems.
4
1442-0025

TYPICAL CREWS
CREWS FOR ABOVEGROUND PIPING
AG Pipe Welded To 12"
1/4
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)
1/2 EQUIPMENT OPERATOR 1 WELDER

AG Pipe Welded Over 12"
1/2
FOREMAN
2
4
PIPEFITTER
PIPELAYERS
(HELPERS)
1 EQUIPMENT OPERATOR 2 WELDER

AG HDPE and PVC Crew to 12"
1/4
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)
1/2 EQUIPMENT OPERATOR

AG HDPE and PVC Crew Over 12"
1/2
FOREMAN
1
4
PIPEFITTER
PIPELAYERS
(HELPERS)
1 EQUIPMENT OPERATOR
AG Ductile Iron to 12"
1/4
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)
1
1442-0028

TYPICAL CREWS - Continued
AG Ductile Iron Over 12"
1/2
FOREMAN
2
4
PIPEFITTER
PIPELAYERS
(HELPERS)
CREWS FOR UNDERGROUND PIPING
UG Ductile Iron and RCP Crew to 12"
1/4
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)

UG Ductile Iron and RCP Crew Over 12"
1/2
FOREMAN
1
4
PIPEFITTER
PIPELAYERS
(HELPERS)
UG HDPE and PVC Crew to 12"
1/4
FOREMAN
1
2
PIPEFITTER
PIPELAYERS
(HELPERS)

UG HDPE and PVC Crew Over 12"
1/2
FOREMAN
1
4
PIPEFITTER
PIPELAYERS
(HELPERS)
2
1442-0028

TYPICAL CREWS - Continued
UG Welded Pipe to 12"

1/4
FOREMAN
1
2
PIPE
PIPELAYERS
FITTER
(HELPERS)
WELDER
UG Welded Pipe Over 12"
1/2
FOREMAN
2
4
PIPE
PIPELAYERS
FITTER
(HELPERS)
WELDERS
CREWS FOR ABOVEGROUND PAINT AND INSULATION
Pipe Painting
1/2
FOREMAN
PAINTERS
HELPERS

Pipe Insulation
1/2
FOREMAN
INSULATORS
HELPERS
3
1442-0028

PROCUREMENT
1.0
GENERAL
=
Upon initial kickoff of piping estimating effort, procurement and sub contract scope
must be identified.
=
If estimating responsibilities include material pricing, a definitive list of procurement
packages should be made.
=
For lump sum estimates, a detail Bill of Materials shall be prepared from piping
takeoff for formal inquiries.
=
For Control Estimates, purchase agreements, existing purchase orders, and/or
pending project inquiries may be used and should be expedited from project.
2.0
VALVES
=
Since valve takeoff is performed early in the Estimating effort, a valve summary
should be prepared for inquiry as early as possible.
=
=
Include the following in preparation of valve inquiry package:
1) Scope delivery & quote requirements
2) Valve List- with tag number, size, type and model
3) Valve specifications
3.0
PIPE FABRICATION
=
If project is lump sum and completed drawings are in scope of work, the fabrication
inquiry should include such drawings to achieve a true lump sum price from
fabricators.
=
If fabrication price is to be worked from our takeoff, a unit price fabrication inquiry
should sent out with approximate quantities anticipated for project.
=
Any fabrication inquiry must be coordinated through chief estimator and/or
fabrication specialist.
=
Pertinent dates are required with these inquiries and must be obtained from project
scope of work and/or construction support personnel.
=
Include the following in preparation of fabrication inquiry package:
1) Scope-delivery and quote date requirements.
2) All pertinent drawings (or representative Bill of Material)
3) Specifications
4.0
PIPING BULK MATERIALS (including underground)
=
After piping takeoff is complete, bulk material inquiries should be issued.
1
1442-0029

PROCUREMENT - Continued
=
Segregate Bill of Materials by types and materials. This will assist expediting inquiries
by targeting type of material to correct supplier.
5.0
INSULATION
=
Since the insulation takeoff is generated from the piping quantities, the insulation
specifications should be reviewed with the Insulation Pricing Technician prior to
completion of takeoff effort.
=
Any special material pricing can then be expedited with adequate lead-time to
complete insulation pricing.
=
If scope of work is based on issued for construction isometric drawings and insulation
work is to be a subcontract, a formal inquiry should be prepared. The subcontracts
department of procurement should be employed to assist in issuance of a formal
inquiry.
=
If a unit rate subcontract is required, a standard format should be followed as
provided by the subcontracts department of procurement.
2
1442-0029
PIPING FLEXIBILITY
Piping flexibility is one of the most important, least understood functions of piping design.
Today flexibility analysis, or stress analysis as it is often called, is delegated to a computer.
Consequently, the piping designer's responsibility is normally limited to a quick check to
determine if the piping layout is within reasonable tolerances. If the quick check shows it is
outside these limits, he turns the problem over to stress specialists. A stress specialist
translates data to an input sheet, turns this over to the computer group and later receives a
computer output sheet. Then if the piping system is too rigid, the stress specialist may
suggest corrective modifications; but the ultimate responsibility rests with the designer.
A computer run, including formulation of input and diagnosis of output, is expensive but
certainly warranted if the quick check method suggests a need for it. However, thousands
of dollars are wasted on computer analysis of lines of visibly adequate flexibility or of lines,
which would be accepted if a quick check method were used. Piping designers who know
nothing about flexibility analysis are quick to request a full stress analysis rather than take
a chance.
Although several books could be written on piping stress analysis, this chapter must be
limited to presenting a quick check method and explaining it so that all readers can
understand and apply it to their problems.
The competent piping designer will make every effort to provide adequate flexibility in his
piping using a minimum number of fittings. When a quick check determines that the
system is not flexible enough, he reviews the system to determine whether or not he can
redesign, maybe adding an elbow or two to increase flexibility. Then he uses the quick
check method again. If his system proves adequate, he has saved the expense of full
analysis. If the system is still slightly rigid and the designer believes that computer analysis
may prove his system to be within flexibility allowances then he should ask for the stress
analysis.
The quick check method has a built-in safety factor; many arrangements, which prove
slightly stiff by the quick check method, actually come out OK when full analysis is made.
Purpose of Analysis
A hot piping system will expand or elongate. A cold piping system will contract or shrink.
Both of these actions create stress problems. A stress analysis determines the forces at
anchor points, stresses in the piping system, and bending moment at any point. For any of
these factors an allowable is known. For any force generated at an anchor point, often an
equipment nozzle, there must be at least an equal resisting force. If a system throws 20,000
1
1142-0037
PIPING FLEXIBILITY - Continued
pounds of force into an anchor designed to withstand 15,000 pounds of force, it will give. If
the anchor happens to be an equipment nozzle this give means a rupture and possibly an
explosion and fire. Before designing piping systems for adequate flexibility, the designer
must know what forces are allowable.
Allowable Forces
Allowable forces and moments are a nightmare to the piping designer responsible for
providing a piping system that will not overstress the equipment to which it attaches. It is
hard, sometimes, to find out just what the allowables are.
Specific equipment allowables must be obtained from equipment manufacturers. If the
forces involved are figured and passed on to the vendor, the nozzle can often be reinforced
to withstand forces greater than normal, but it must be remembered that even the
manufacturer has force tolerance limitations.
Piping Flexibility Design
It is preferable to provide adequate flexibility in piping systems by using loops or other
configurations constructed of pipes and fittings. Sometimes space or cost is prohibitive;
expansion joints such as the bellows, Barco ball or sliding type must absorb movement.
Piping flexibility should always be achieved with the minimum number of anchors and
guides feasible. Axial expansion joints must be guided on each side and anchored at the
end of pipe runs to withstand hydrostatic testing thrust. U-type loops must be anchored on
both sides of the pipe run to work.
=
Lines, which are to be purged by, steam or hot gas must be checked to make sure that
they will be adequately flexible during the purging operation.
=
Closed relief systems and hot blowdown or pumpout system must also be carefully
thought out.
=
Temperatures in start-up lines often surpass operating temperatures.
=
Exchanger bypasses may still be cold while the inlet and outlet lines are already hot,
resulting in excessive stresses.
=
Always review systems at their worst operating conditions such as during start-up
when a hot line will be feeding into a cold tower or vice versa.
Unit systems, such as a steam system having a large diameter header in the unit pipeway
and smaller size branches feeding into equipment, are often provided with unnecessary
and expensive expansion loops and anchors. Before loops are designed, every effort should
be made to make the branches flexible enough to withstand header expansion. An anchor
placed near the center of the run can be used to direct header expansion by forcing 50% of
2
1142-0037
the expansion to either side of and away from the anchor, distributing expansion along the
header and thereby simplifying branch flexibility.
Flexibility must be considered from the beginning in every system designed. During the
original layout - which may be freehand on a scratch pad - flexibility must be uppermost in
the piping designer's mind. A quick check should be made of all lines 8" or larger during
this initial stage. If flexibility appears to be a problem, smaller lines should be reviewed
and quick checked, too. If a line is too stiff and must be rerouted, the time to find out is
early in the design. Many dollars and man-hours can be wasted making finished drawings
of piping systems, which are too stiff. When this happens and is finally discovered, the
designer must start over completely.
One of the many differences between a draftsman and a designer is that while the
draftsman can only draw the pipe, the designer knows flexibility, process, instrumentation,
flow of fluids and many other specifics which must be considered during the piping layout
and design stage.
The Quick Check Method
The purpose of the quick check method is to determine whether or not a piping system is
adequately flexible without the formal calculations required for a full stress analysis.
Ordinarily if a system is within the quick check guidelines, no further flexibility analysis is
required.
To make use of this method the piping designer must establish some basic facts.
=
Anchor points must be known or assumed.
=
Design pressures and temperatures, expansion coefficients for the metal involved and
any branch or equipment restraints must be included.
=
Special design conditions such as start-up, cydic operation, steam tracing, etc. must be
known.
The lengths of pipe solved for are based on standard weight carbon steel pipe. Alloy
piping, other than austenitic stainless steel and aluminum, may be laid out on the same
basis.
When pipe wall thickness differs from standard weight, a correction factor of ratioing
moment of inertias must be applied. In this case:
Minimum h (adjusted)
= moment
of
inertia,
pipe
specified
moment of inertia, std. wt. pipe
3
1142-0037
minimum h in the formula
When anchor expansion adds to the thrust from the L leg, a correction ratio of linear
expansion must be applied. In this case:
Minimum h (adjusted)
= anchor
movement
+
leg
L
movement
leg L movement
x
minimum h in the formula
The minimum length of h leg required to provide an adequately flexible member must be
tested by applying a factor A which corrects for design temperature. (See Table S-1 for
definitions) The formula is:
Minimum h = A x Do
For the A coefficient of carbon steel pipe, see Table 5-2.
For L-shaped configurations (see Figure S-1) the following formulas apply:
h2 = 0.025 DoLT
Minimum
Maximum L
=
400
(h)2
DoT
Test h = A x
Formula for
Do
Expansion Loop
Figure 5-7, Typical

depicts a typical loop
Anchor Point
piping systems which
expansion
to
be
Figure 5-1. L-Shaped Configuration
straight line. For this
Minimum h
Minimum h2 = 0.0004 x Do x L x T
Maximum
DoT
expansion
loop,
found in most hot
have
too
much
absorbed
by
a
configuration:
= 0.02 DoLT or
(h)2
2500
Minimum W = 0.5 h
Preferred W= 1.5 h
To
test
for
minimum
h:
Do
125
4
1142-0037
Expansion Loop
Force
As an expansion loop
transmitted to the
calculate the anchor
pipe stress of the
8 and the following
This
example
elbows
and
is
of 4" through 14".
For
expands, forces are

two anchor points. To
force and maximum
loop, refer to Figure 5
example.
force at each
F=CxE x
Stress and Anchor
assumes use of LR
restricted to line sizes
L
Distance in Feet
Between Anchors
anchor:
Ip
Figure 5-7. Typical Expansion Loop

Maximum stress:
S=KxExD
C = Constant to be obtained from Table S-2
E = Expansion to be absorbed by the loop, in inches (should be limited to 10")
Ip = Moment of inertia, inches4
D = Outside diameter of pipe in inches
K = Constant to be obtained from Table S-3
Need for Formal Stress Analysis

Designers with extensive flexibility experience should determine the need for formal stress
analysis. Hot piping connecting to strain sensitive equipment such as pumps, compressors
and turbines shall be closely reviewed for possible full analysis.
5
1142-0037
H
GUIDE
X
40 PIPE DIA. MIN.
L
Figure 5-8. Guided Expansion Loop
6
1142-0037
Computer
Aided
Piping
Summary
pCAPS USER GUIDE.doc
TABLE OF CONTENTS
SUBJECT
PAGE
I. INTRODUCTION
II. MENU SELECTION GUIDE
III. DETAIL CODING INSTRUCTIONS
11
A. ANALYZE PROJECT SCOPE

B. SET UP SPECS - INPUT & UPDATE
C. ACTUAL TAKEOFF - DETAIL CODING
D. CHECK DATA FOR ERRORS
E. SUMMARIZING DATA & APPLY UNITS.
F. THE PIPING SUMMARY REPORT
G. PAINT SUMMARY
H. INSULATION SUMMARY
I. VALVE SUMMARY
J. COMBINE FILES & RUN INORDER
K. TRANSFER ESTIMATE ONTO PROJECT DISK
11
12
16
18
21
22
23
25
26
26
26
IV. OTHER REPORTS

A. SPEC SUMMARY (TO BE ISSUED LATER)
B. LINE BY LINE SUMMARY (TO BE ISSUED LATER)
V.
APPENDIX
A.
FORMATS
B.
ENCODERS
XVI.
FORMATS
XVII. ENCODERS
I. INTRODUCTION
A. THE PRODUCT
CAPS is a series of programs which aid the piping estimator by eliminating the manual tasks of
summarizing and sorting data into the various like items, accounts, areas, etc. "CAPS" also is a data
transfer system. The mundane process of typing in page after page of "greensheets" in the program
estimate format is eliminated. The CAPS program writes the greensheets for you directly in ESP format.
The code of accounts, 'S' & 'T' cards, comments, and units are automatically filled in with this process.
B. THE REPORTS 1. PIPING SUMMARY REPORT Summaries by like material is sorted into the aboveground, underground, and demolition accounts by
areas, bid item, and work packages.
2. PAINT SUMMARY REPORT Summaries of the surface area of pipe are generated by area, bid item, and work packages. Quantities are
also sorted into shop fab and field run amounts and the output is written in PC ESTIMATE format once
again.
3. INSULATION SUMMARY REPORT A summary of insulated pipe, fittings, flanges, and valves is generated. Like the previous reports, this is
transferred directly onto your diskette by areas, types of insulation, bid items, and work packages.
4. VALVE SUMMARY - A printed report summarizing all valves from take-offs by tag number.
This report is used as a Bill of Material to be turned over to purchasing for inquiring valve prices.
C. THE PROCESS
1. MATCH TAKEOFF TO SPECS specification information.
Material and labor is merged with detail
2.
SUMMARIZE INTO LIKE MATERIALS~LABOR FOR PRICING & LABOR.
3.
SORTING INTO DESIRED AREAS, BID ITEMS, and ACCOUNTS.
4.
TRANSFER OF DATA INTO ESP FORMAT.
D. CODE OF ACCOUNTS OPTIONS:

A. Generic
B. Petro 84
C. PAPER 85
CAPS FLOWCHART
I.
ANALYZE PROJECT
SCOPE
II.
SET UP PIPING SPECS
III.
ACTUAL TAKEOFF (BATCHLOAD)
IV.
ERRORCHK
V.
SUMMARIES DAT
OPTIONS
PAINT SUMMARY ~
VALVE SUMMARY
INSULATION SUMMARY ~
SPEC SUMMARY
LINE BY LINE SUMMARY
APPLY PRICING & MH'S (CRATES.PRT)
PIPING ESTIMATE
INORDER ~
TRANSFER TO PC ESTIMATE & EXECUTE RUNS
II.
MENU SELECTION GUIDE-
STEP 1 - Open program by clicking CAPS icon

Select
SETUP
The following drop down menu will appear:

JOBNAME
SPECS
INSULATION
PAINT
BIDITEMS
AREAS
SCHEDULEID
NEWJOB
Select
JOB NAME
SPECS
To input project information

To list piping specifications for the project.
INSULATION
To list insulation types and thickness. Normally, this window

contains the insulation ranges listed in the manual. Any
additional insulation requirements can be added in this window.
NOTE: The program will automatically price the insulation
denomination listed in the manual, such as HCAP or HCAR.
(Example: 1.00HCAP, 1.5HCAR etc.).
PAINT
List all the paint systems required for the project. The system
will sort quantities accordingly. (Example Paint-1, Paint-2 etc.).
BID ITEMS
List bid items if any.
AREAS
List areas with description.
SCHEDULE ID
List schedule identification numbers if required.
NEW JOB
This option wipes out all the existing files in the CAPS directory
to prepare for the new job. A warning will popup to avoid any
accidental deletion of the residing caps files.
At this stage CAPS.DAT (Caps data input) is required to proceed.

NOTE! Your CAPS INPUT data should always
be named "CAPS.DAT".
Select
INPUT
The following drop down menu will appear:

INPUT SPECS
DOS
SPFPC
IPMS IMPORT
EXCEL IMPORT
Select
INPUT SPECS
Opens the input file for piping specifications. Yellow fields

contain drop down menus for easy selection of valid choices for
each field. Click on any yellow field, the menu will appear.
Select the required option. Closing this file will automatically
create output file SPECS.PRT. Also, a setup button is provided
to go back to specs set up while staying in SPECS.DAT file for
any possible additions
NOTE! Any input on the shaded fields requires user to press the
enter key to allow the system to accept manual input.
DOS
SPFPC
To exit to DOS.
To go to SPFPC program.
IPMS IMPORT
This option imports data transferred from the IPMS program.

Refer to file structure definition.
NOTE! The IPMS data file should always
be named "IPMS.DAT".
EXCEL IMPORT
This option imports data transferred from the EXCEL

Engineering Input Form.
Refer to file structure definition.
CHECKS
Following drop down menu will appear:

ADDPSE
FIXERRORS
CHECK CAPS
ADDPSE
Adds "PSE" (labor) entries to CAPS.DAT file for every

"PIP" material entry. Caution: If CAPS.DAT contains any labor
entries for pipe (PIP) selecting this option will cause to double
labor for those pipe quantities. Labor for entries other than pipe
should be manually entered in CAPS.DAT.
CHECKCAPS
to
The program scans through the CAPS.DAT to get ready

perform fix errors task
FIXERRORS
Identifies the errors. If the setup option is not filled in correctly,

this option will detect all missing information. Additionally, any
quantities in four digits or more will be indicated to avoid major
quantity errors. An online editor is actuated to assist in

correcting errors. Click mouse on error line to view next error.
Select
PRICING

PAPER
PETRO
This function pulls pricing and labor from database source file.
PAPER OR
PETRO
Selecting any one of these options will

create two reports. First report
"ADDRATES.PRT" is a formal bill of material to be sent

to vendors for pricing requirements. Second, an input file,
"CRATES.PRT" is created for pricing pipe materials and
inputting workhour unit rates. Majority of material and
labor rates will be filled-in automatically by the program
using built-in database. Any entries for unusual material
specs or wall thickness will not be priced by the program
and requires pricing current conditions.
NOTE! In most cases, input of all materials and labor items
should be completed prior to moving to next step.
Select
PAINT

PAINT
PAINT SF-SM
PAINT M-SM
PAINT W/DWG
PAINT WISID
PAINT
This selection will generate a file, PAINT.PRT, containing paint

quantities in standard US measure units. Separate line items for
blast, prime, intermediate coat, and final coat will be listed along
with touch-up quantities.
PAINT SF-SM
Generates paint quantities from pipe measured in standard US

measure units(LF) to metric units (SM) for paint.
Generates paint quantities in metric measures from metric
takeoff
Paint quantities with drawing number. This option is rarely used
but includes the drawing numbers in estimate PC format.
PAINT M-SM
PAINT W/DWG
PAINT W/SID
Paint quantities with schedule I.Ds. This option uses the

schedule I.D as included in the input database file
CAPS.DAT.
Select
INSULATION

Price ins
Insulate
Insulate LF-LM
Insulate M-LM
Ins. W/DWG
Ins. WISID
PRICE INS.
File INRATES.PRT will be created. This file contains material

pricing and labor unit rates for insulation and metal covering
using built-in pricing from the pricing tables. Any spec or size
out of the insulation charts (in piping manual) will not be priced.
Missing pricing and labor units should be completed in this file.
Subcontract prices can be entered at this stage if preferred.
INSULATE
This option will generate two files "INSULATE.PRT" and

JACKET.PRT". These two files contain insulation and metalcovering quantities with labor and material prices (or
subcontract prices) automatically pulled from INRATS.PRT file.
Next four selections are same as paint i,e conversion of units to
metric and including drawing numbers and schedule IDs
Select
ESTIMATES
GENERIC.
SATS.PRT

Generic
CSI
Gen. LF-LM
Gen. LM-LM
Gen. W/DWG
Generates the following files in standard US measure unit:

AG.PRT
Aboveground pipe
XRAY.PRT
Xray quantities.
Statistics
UG.PRT
Underground pipe
CSI
All the above files are in estimate PC format and codes of

accounts.
Same as above but in CSI codes of account.
Gen. LF-LM
Gen. LM-LM
Gen. W/DWG
Standard measure units to metric units.

Metric database to Metric units.
US measure quantities with drawing number.
Select
MISC

Line by Line
ACLS to Caps
Caps to ACLS
Valve Summary
Inorder
Direct to Sub
Caps to ESP
Line by Line
Generates a report listing each individual line listed in the caps

data file. This reports includes all the information associated
with the line such as service, line number, material spec,
drawing number, area, bid item, location (aboveground,
underground etc.), paint, and insulation spec. This report is not
critical to perform regular estimating tasks.
ACLS to CAPS
Special report - This file imports data from automated craft

ledgers system. Some minor programming changes are required
to complete this function. Run this option with supervisors
direction.
CAPS to ACLS
Special report - This file exports the piping data to ACLS data
structure. Again, programming changes require supervisors
direction.
Valve Summary
Generate a printed report that summarizes all valves by like tag

numbers in SPFPC format and Excel format. This report is used
to send to vendors for pricing.
Inorder
Combines all the necessary files generated earlier for

estimate PC as shown on chart combine- 1. At this stage two
files are created ESTIMATE.PRT and ESTIMATE.REL .
ESTIMATE.REL is the final product to be used for the ESP
Template.
Direct to Sub
Provides an option to convert Insulation and Paint in to

subcontract.
Caps to ESP
Creates a file in ESP format from the ESTIMATE.REL file for

importing into ESP.
Other three options Log, Print, and Exit perform tasks as named.
INDIVIDUAL FILE
COMBINED FILE
AG. PRT
XPAY. PRT
JACKET. PRT
ESTIMATE . REL
PAINT. PRT
INSULATION. PRT
STAT. PRT
UG. PRT
Chart Combine-1
10
II. DETAIL CODING INSTRUCTIONS

A. ANALYZE PROJECT SCOPE
1. Determine appropriate Code Of Accounts for estimate
2. Determine C/S areas, bid items, & work packages.
3. Determine level of detail required for take-off based on job scope & time frame.
Identify critical materials. Discuss approach with Chief Estimator.
Lump sum bid- details may be needed for actual material & labor takeoff
Budget or conceptual -linear footage pipe takeoff may be sufficient with use often year
average for labor and material (also insulation).
4. Determine fabrication takeoff needs

a. Fabrication method
Field run (P40)
Outside shop fab (P30) for small bore and straight run pipe.
For outside shop fabrication-carbon steel, alloy, and some
fiberglass reinforced pipe.
Field shop fab (P10)- for fabrication at a shop set up at jobsite (verify
with PE or
construction manager that field shop fab is possible).
b. Purchase responsibilities-KB&R or other as defined in job scope.
c Paint requirements - Identify paint classes for outside shop and field
application
d. Insulation class- Identify the possible classes for pipe insulation. Copy
thickness chart, if available, for all estimators on the project.
5.
Pricing needs
a. Pipe fabrication- Advise Fabrication Specialist of materials of pipe, need
date, and when data will be available.
b. Piping bulks- Advise Purchasing what materials require outside pricing and
when data will be available.
c. Specialties- Brief Purchasing on needs & when info will be available.
d. Subcontracts-Insulation, painting, testing, cleaning, etc.
e. Valves-Valves may need to be inquired early.
11
Top priority should be given

to the valve take-off
See optional valve summary section

NOTE! Just as in a manual estimate, certain takeoff & estimate strategy decisions must be made at this
time. This is especially critical in CAPS, since a change in strategy could mean a waste of valuable time
to correct or rearrange data. The CAPS user must understand and follow the strategy to obtain desired
results.
The caps
program can do
certain things
very fast, but it
can not:
"THINK FOR YOU!!!"
B.
SET UP SPECS
1.Study project documents (line lists, P&ID's, drawings, etc.) for all possible specs to be
required for the takeoff.
Prepare a list of specs or reproduce appropriate pages.
2. To minimize input time, seek out existing CAPS specs already coded from previous
projects. Copy onto your diskette under the file name 'SPECS.DAT'.
a. Correct copied specs as necessary to conform to current version of formats,

see paragraph _ for detail instructions.
b. If existing specs are drastically different, delete all spec entries and code new
specs as detailed in paragraph C.
3. If no existing specs are available, new specs may be coded on

"CAPS SPECS CODING FORM" See EXHIBIT
NOTE: For a completed coding form - See EXHIBIT All entries must be left justified
12
unless otherwise noted.

a .Code one spec per page
b .SPEC - cols. 1-6Enter pipe spec numbers or letters.
c. CTG -category- col. 8-This identifies the grouping of materials (i.e. "B" for all
fittings, etc.-see
EXHIBIT 3) NOTE!!!! This format may not be
changed. Each encoder is assigned to a specific category.
d. MIN - cols 14-19 - Enter the lower range of pipe or item sizes to match
project piping specs. Use
decimals for small
sizes.
e. PERCENT X-RAY - cols. 20-22 - Enter the x-ray percentage requirement on
items which require a field weld. This entry will be used to calculate the
number of x- rays later on. Valid entries are:
'.05' for 05% x-ray '.
10' for 10% x-ray '
1.0' for 100% x-ray
f. STRESS RELIEVE - col. 23 -Enter requirements for stress relieving of welds.

Enter on 'PIP' spec entries only. Valid entries are:
'Y'

for Stress relieve

for no stress relieving
g. Detail col. 25 Enter requirements for detailed or fitting mix pricing.

D

Detail price is required.

A fitting mix price is required
Note: A D in col. 25 is only needed for Category A ( PIPING ).
All fittings in takeoff will get a Detail price. The Detail or fitting mix
pricing option is also available for the CAPS.DAT file.
h. MTL CODE- cols. 29-32 Enter material code per ASTM

'FORMATS' together during summary.
i. TAGNUM - cols. 34-49 -
Additional material or ASTM info entered here.
j. SCHEDULE - cols. 51-60 - Pipe wall schedules (i.e. S/40, S/80, STD, XS,
etc.) are valid entries in this field.
k. END COND - cols. 62-63 - Enter the 2 digit code for end conditions per the
'FORMATS' Section.
l. FAC -
cols 64-65-
Enter the 2 digit code for flange facing per the
13
'FORMATS' Section.
m. RATING - cols 67-72 Enter the flange and valve ratings(i.e.150#,300#,etc.).

When MTO is based on centerline to centerline (PIPS'S & PSE'S
ONLY), enter pipe spec. numbers or letters.
n. When you are finished coding all needed specs save the file and submit
SPECS.DAT file in SAS program to run specs. Simply open the SAS program,
select INPUT, then INPUT SPEC. This will open the specs file. Closing this file
will automatically generate SPECS.PRT file. Print this file and check very
carefully or someone else have it manually checked to match the descriptions
exactly with the specifications. Make adjustments if necessary.
Each estimator assigned to the job should have the copy of the SPECS.PRT file. Each estimator
should be aware of what is loaded in the specs to know what fields or override in the take-off.
More on overrides in paragraph IV.D.8.
CAUTION
If a job with different specifications have been executed on your machine, you
must execute your SPECS.DAT file before you execute any of the menu tasks.
14
II SET UP SPECIFICATIONS
ANALYZE JOB INFORMATION FOR SPEC DEVELOPMENT

NEW PROJECT OR REWORK FOR CLIENT
COPY EXISTING SPECS.DAT
FILE IF AVAILABLE
EXISTING SPECS -?
NEW SPECS-?
CORRECT COPIED SPECS AS NEEDED
DELETE ALL SPEC ENTRIES
CODE NEW SPECS

ON "INPUT FORM"
INPUT INTO
SPECS.DAT
RUN UPDATE
PRINT OUT & CORRECT ERRORS
RERUN UPDATE
RECHECK
OF SPECS
ERRORS- ?
COPY SPECS FOR DISTRIBUTION
15
C.
ACTUAL TAKEOFF
1. The pipe estimating input form - see EXHIBIT
Observe coding rules for: OHs, I's, zero's, Zs
Left justify all entries with exceptions as noted.
2. Header lines-Input on header line applies to data that follows it until another header is
encountered. Header lines begin with "1$" in columns 1-2.
a.
PREFIX - Cols. 3-7 - This is an optional use field.

Input numbers as required for piping
work package
breakdown also called schedule ID.
b.
SERVICE - Col 9-13 - Indicate Line service in this
field (example BFW for boiler feed water)
c.
NUMBER - Col 15 - 19 - This field is used to
identify pipeline number.
d.
SPEC
- Col 21 - 26 - Enter pipe specification
identifier in this column. This entry will pull the material definition from
the SPECS.PRT file.
NOTE
Code in service, line sequence number & spec as required to identify the line. The spec
entry must be coded in the same spaces every time. An imbedded or extra space will be
interpreted as a different spec. Also, do not code specs containing OHs with zeroes. To
the CAPS program you would have asked for an entirely different spec.
e.
DRAWING NUMBER - cols 28-39 - Optional entry
- Code in the most useful document to maintain trackability from takeoff to
drawings.
f.
UNIT - col. 42 - Not in use at this time
g.
AREA - cols. 44-47 - Optional entry for jobs with
multiple areas.
h.
BID ITEM - cols 49-52 - optional entry for jobs
requiring bid items to group cost for bid
form. This field will align with
program estimate bid item field when data is transferred into your module.
i.
LOCATION - col. 54 - This field tells CAPS very
important information. The only valid
entries are:
''Above ground (default value) 'P' Underground- pressure flow
'G' Underground- gravity flow
'D' Demolition- for scrap or disposal
This one entry tells the system
'R' Demolition- for relocation
programs to sort the data into
'T' Tie-ins (special use)
the underground, demolition,
'6' Pipe line code
and other accounts, so be careful
to code in the right letter.
16
j.
PAINT - cols 56-60 - Use this field to identify paint

classes per your job requirements. At the onset of the project individual
designations for different types of paint systems according to job
specifications.
k.
INSULATION - cols 62-68 - A class number and
thickness is best used in this field, per job requirements. A good way to keep
the class and thickness aligned is to left justify the thickness with the type
immediately following; for example:
'l.5HCAP'
'2.OCFSP'
'1 .OPP'
Be constant, any inconsistency could result in a new type.
l.
m.
FP - col 70 - not used at this time.

OPER TEMP - cols 72-75 - Use this field when the
temperature is the only information you have to identify insulation
requirements.
2.
REMARKS - Col 3 - 75 Optional but helpful to describe line to's and from's or
any useful information. This line can be inserted anywhere. Usually used under 1$
line
.
3.
DETAIL TAKEOFF INPUT. - Follow coding rules as listed below.
a. Col. 1 - If this is left blank, the caps programs thinks you want a remark line.
Only valid entries are:
'L' for labor
'M' for material
b. SIZE 1 - Col 3-8 - First size is for large ends on reducers and tees.
c. SIZE 2 - Col 10-15 - Size2 must always have a value, use decimals, not
fractions, and left justify each field.
e. DETAIL Col. 16 - Enter requirements for detailed or fitting mix pricing.

D

Detail price is required.

A fitting mix price is required
Note: A D in col. 16 is only needed for PIP short code.

All fittings in takeoff will get a Detail price.
f. P - Col. 17 - For purchase designation - This field defines who is responsible
17
for purchase of material or providing labor. Valid entries are:

'B' for Kellogg Brown & Root
'0' for others
'V' for Vendor
g. P30, P10, P40 - Cols. 18-20 - Entries here define the logic of fabrication.
Once again, what you code defines which code of account the system
sorts the labor and material to.
Valid entries are:
'P40' for field run
'P30' for outside shop fab
'P10' for field shop fab
h. ITEM - Cols. 21-23-Enter the three-digit code for pipe,
90-degree ells, pipe labor, weld, & etc. from the 'FORMATS' section in this
guide. Again, watch those coding rules for OHs and zeroes, I's, and ones.
Updates of the 'FORMATS' section will be periodically distributed.
i. TAG NUMBER - Cols 25-40 - Enter tag nos. for valves, specialties, and any
information to alter normal encoders.
NOTE! It is important to code repetitive items the same way. For example:
'HOSEREEL' and 'HOSE REEL' are read as different tag numbers by CAPS. Likewise, a
tag number left blank will be read as a third, different tag number. Try keeping a list of
these entries. Copy for every estimator on the project whenever changes occur.
j. QUANTITY - Cols 42-48 - Left justify, no decimals for this entry.
k. OVERRIDES
MATL OVERRIDE - Cols 50-53 - Enter ASTM format per the 'FORMATS'
section. This will override the material value that you coded back in Section II.
Care must be used to assure this entry will add to similar material in other specs.
Avoid using this field unless absolutely necessary and you have a good
understanding of the workings of the CAPS programs.
OVERRIDES Cols. 55-78 - Left justify these entries. Once again, we have the
ability to override the pipe spec. If the drawing indicates a different flange
rating, wall thickness of pipe, end condition, or flange facing from what is coded
in the spec, you can account for the difference by adding the information in the
correct field.
All of these overrides are defined in the 'FORMATS' section of

this guide. The estimator must code the bore overrides as
defined in 'FORMATS' or the error checks program will print an
error.
18
D.
CHECK DATA FOR ERRORS

1. Visual on-line error check.
After all combined data files have been downloaded to the PC and combined to a
single data file 'CAPS.DAT', a visual check should be made. This will find
some obvious errors, such as missing spec, miss-aligned entries, etc. The dollar
sign ($) code on the header line is used to speed this process.
a. Using the EXCLUDE' and FIND' commands, display only the header lines.
Use the following command: "X ALL;F $~ ALL" to find all the header lines.
Data entries such as AREA, BIDITEM, SPEC, LOC, INSULATION, AND
PAINT can be easily viewed for misalignment or omitted entries. All data must
be in the appropriate columns to be read correctly.
b. Make sure other data appears on header line as required by take-off (i.e.
AREA, BID ITEM, PAINT, INSULATION, etc.).
2.
ERRORCHECK a. Open CAPS. Across the top of the screen a series of pull down menu screens
will be displayed. Select the CHECK option, next select CHECK CAPS.
This task reads from your diskette data file 'CAPS.DAT'. Some common errors checked
for you are missing SPEC, invalid ITEM, omitted SIZE2, and others. This creates a
report, to be printed out and reviewed for error notations, called 'ERRORS.PRT'.
b. Print out this file (compressed print) and correct data corresponding to the
errors printed in the 'ERRORS.PRT' file or after running the CHECK CAPS
option select CHECK at the top of the screen and then select fix errors.
c.
Look for and correct errors.

Scan the report and markup data file for corrections. Make corrections as
required in your data 'CAPS.DAT' or possibly the spec file
'SPECS.DAT'.
d.
UPDATE SPECS. Reprint SPECS.PRT until no errors are detected on

printout. It is very important to have the data concise and error free. This
19
will assure that pricing requirements will be clear and few questions will
arise.
e. Verify that 'PIP's and 'PSE's quantities balance.
Material and labor quantities have to balance. Take this opportunity to
scan your print out for differences in the 'PIP' and 'PSE' quantities.
3. Sample error check run- see EXHIBIT 8.
This is an example of some errors:
Missing data in SPEC, AREA, and BIDITEM fields.
Unusual quantities - Either no quantity at all or a large number.
Check if item encoders are material or labor entries.
Prints remark entries- If 'L' or 'M' are missing in column 1, ERRORCHK

assumes a remark line follows.
ERRORCHK does not check coding logic!
If you've got field run pipe coded as
'NF' and the corresponding labor, PSE, in 'PF', the
ERRORCHK program will not catch that. Only coding
errors are picked up.
Spec not in data file.

If you have a spec in your data that is not in your
'SPECS.DAT' file, an error message will be printed on
your screen at the end of the error check run. This
message can be viewed by viewing the following file in
the text editor "C:\PIPE\FRRORS.PRT".
20
E. SUMMARIZE DATA and APPLY RATES 1. Now that the take-off is complete and checked for errors it is time to summarize your
data for pricing and applying labor rates. Selecting PRICING allows the user to apply
rates (Paper or PetroCHEM) from the database.
2. Summary Report
a.
A report is created on the C: drive called

'ADDRATES.PRT', that is an overall summary of piping materials and labor
for your data.
b. Print out 'ADDRATES.PRT' for distribution to procurement and/or
fabrication pricing.
d. Look for errors and if necessary correct in your data files and rerun the menu
option PRICING again.
3. Errors on output
LOGIC ERRORS
Small bore pipe in prefab material or labor

Large bore pipe in field run material or labor
Strange material - an unmatched material error may
appear on your print out. Check the 'SPECS.DAT' for incorrect entries.
Correct errors & rerun the pricing menu.
Check to see if PIPs and PSEs balance

Reproduce material pages for pricing and inquiry EXHIBIT
- Sample material and labor summary
- BETWEEN THE ASTERISKS - EIGHT DIGIT FIELD - INCLUDE THE DECIMAL POINT -
WHILE PRICING & FABRICATION IS BEING PROCESSED, COMPLETE

MANUAL TASKS I.E. EXCAVATION, X-RAYS, STRESS RELIEVING, ETC.
21
NOTE: YOU MUST BE AWARE OF THE SORTING/SUMMARIZING LOGIC AND WHAT

ACCOUNTS THE DATA WILL EVENTUALLY BE ASSIGNED TO.
THE SUMMARIZED DATA WILL BE SORTED BY: LABOR/MATERIAL ITEMS,
PURCHASE, FABRICATION, AND LOCATION.
FOR EXAMPLE:
TRY TO FIGURE OUT THE CORRECT ACCOUNT FOR THE FOLLOWING ENTRIES PRINTED
OUT ON A SHOPPING LIST:
LABOR:
PURCHASED:
FAB:
LOCATION:
PSE
BY KELLOGG BROWN & ROOT
FIELD RUN
BLANK
TRY AGAIN: SAME

AS ABOVE EXCEPTLOCATION:
4. Units Report
A file is created on the C: drive, 'CRATES.PRT', that is for input of material and labor
units. Input units between asterisks. All units must contain a decimal. It is very important
to fill in all lines containing asterisks. If left blank, all entries that occur in the final file
'ESTIMATE.PRT' will be blank. Do not change any information in this file other than
data entry between asterisks. When all units are input you are ready to build your
Estimate deck with the appropriate codes option. 'CRATES.PRT' can be rerun if major
changes occur in the data file with out losing pricing or labor units already included.
F.
PIPING SUMMARY REPORT:
Select ESTIMATE from the menu bar.

Selection of this option will sort your piping data into the appropriate codes of account, area, and
bid items as defined in your take-off. Material and labor units will be distributed for you thus
eliminating the task of inputting repetitive units. Standard labor units will be filled in from the
labor database. Excessive weights, material, etc. must be worked up and input. All of this is done
and the output is written in 'Program Estimate' format. Selection of these options produces the
following files on the C: drive:
AG.PRT - (Aboveground codes for piping estimate)

UG.PRT - (Underground codes for piping estimate)
XRAY.PRT - (Account 1773 for x-rays NDB etc)
STATS.PRT - (Statistics to be added in your qualifications)
22
G.
PAINT SUMMARY:
Select PAINT from the menu bar.
The paint summary can be executed any time after all take-off is complete.
However, your time is best utilized if you execute the summarization option first.
While pricing for pipe is being worked up, you can work on the paint estimate.
If paint for 'BPF' or 'VBF' pipe is furnished by the vendor, then blast and prime
entries must be deleted from the data file.
Selection of this option will produce a file on your "C drive called
PAINT.PRT'. This file is the total paint requirements from your pipe take-off in
the 'CAPS.DAT' file sorted by area, bid item and type of paint into the painting
code of account.
Apply labor and material pricing from the Pipe Estimating Manual according to
the paint classification for your project.
When unit input is complete your paint estimate file is ready to be combined
with your pipe estimate. (See the INORDER option under MISC on the menu
bar.)
23
PAINT SUMMARY
MATERIAL & LABOR TAKEOFF INPUT ON

PIPE ESTIMATING INPUT" FORMS
SELECT OPTION PAINT ON THE MAIN MENU BAR

FILE PAINT.PRT IS GENERATED
EDIT C:\PAINT.PRT BY DELETING BLAST

AND PRIME COAT FOR VENDOR FURNISHED
ITEMS, 'BPF' AND VBF' PIPE
INPUT LABOR AND MATERIAL PRICING
SELECT OPTION MISC THEN

INORDER TO COMBINE FILES
24
H.
INSULATION SUMMARY
Select INSULATION from menu bar.
As in the above option, this option is best executed as soon as your take-off is complete so
that your insulation material prices and man-hour units can be worked up based on
specifications and other project criteria. Your insulation requirements will be sorted and
summarized into insulation type and thickness requirements and be written to a file named
'INRATES.PRT'. The material and man-hour units are applied to this file. After the proper
units are input pricing can be executed and the units will then be applied to insulation types
and thickness by area, bid items, and account codes. Select PRICE INS from the pull down
menu or the desired insulation option. You are now ready to combine the insulation portion
of your estimate with the pipe portion. (See the combine option MISC then INORDER on
menu.)
INSULATION SUMMARY
MATERIAL & LABOR TAKEOFF INPUT ON

PIPE ESTIMATING INPUT FORMS
SELECT OPTION INSULATION ON THE

MAIN MENU BAR / SELECT PRICE INS FROM
PULL DOWN MENU. FILE INRATES.PRT
IS CREATED
APPLY LABOR AND MATERIAL PRICING
SELECT OPTION INSULATE

FROM PULL DOWN MENU BAR
OR THE DESIRED OPTION.
SELECT OPTION MISC / INORDER

TO COMBINE THE FILE
I.
VALVE SUMMARY
25
Select MISC from menu bar; next select VALVE SUMMARY from pull down
menu. This task summarizes valves by item or tag number and by size for purchasing.
This task is usually one of the first tasks completed due to the amount of time it takes for
pricing requirements. A completed run of the valve summary along with the valve
specifications should be given to procurement for inquiry.
J.COMBINE ESTIMATE FILES & RUN INORDER Selection of this task combines the pipe, insulation and paint files into one file called
'ESTIMATE.PRT'. This file is then sorted by area by account code. This file is renamed
'ESTIMATE.REL'.
K. TRANSFER ESTIMATE ONTO PROJECT ESP TEMPLATE Transfer the ESTIMATE.REL data to ESP using the CAPS to ESP function. You are
now ready to execute ESP.
Be sure to check your ESP file for percentage cards as required by the project. Some of
the percentage cards you might need for your individual project are as follows:
- P67
- P68
- P69
- P71
- P72
- P73
- P31
- P81
- P97
- P98
26

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KBR

ONSHORE ESTIMATING DEPARTMENT

OWNER: GREG MINICONE

CODE OF ACCOUNT NARRATIVES

PIPING ESTIMATING GUIDELINES

TECHNICAL STANDARDS AND REFERENCES

PIPING ESTIMATING SOFTWARE

Quantities will be Lot (LOT).

Process EQUIPMENT NDT, preheat services or post weld heat treatment is

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - 04X

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

DOPE & WRAP

HEAT SHRINK SLEEVE

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

DOPE & WRAP

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

ALL OTHER ACTIVITIES SEE CARBON STEEL THIS PAGE

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

PIPING ESTIMATING GUIDELINES

PIPING ESTIMATING GUIDELINES

MATERIAL AND LABOR TAKEOFF

PIPING ESTIMATING CHECKLIST

PIPING ESTIMATING CHECKLIST - Continued

11. Liquid conveying trenches and open ditches.

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

ALL OTHER ACTIVITIES SEE CARBON STEEL THIS PAGE

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

KELLOGG BROWN & ROOT ESTIMATING

UNDERGROUND PIPING - U4X

PIPING ESTIMATING GUIDELINES

PIPING ESTIMATING GUIDELINES

PIPING ESTIMATING GUIDELINES - Continued

Mechanical polishing of internal surfaces of piping is always required on the approach

PIPING ESTIMATING GUIDELINES - Continued

There seems to be several methods to calculate firewatch on estimates. Again, in order

PIPING ESTIMATING GUIDELINES - Continued

PIPING ESTIMATING GUIDELINES - Continued

PIPING DESIGN WORK GROUP LEADER

PROJECT XXXX - PROJECT NAME

MTO from preliminary underground (U/G) planning drawings.

Piping Specifications as of DDMMMYY.

per Company standards.

Steam tracing has been included in this estimate.

ABOVEGROUND AND UNDERGROUND:

SUMMARY - MTO COST RISK